Bleeding the iB5 Clutch System

Special tool

Vacuum/pressure hand pump 416-D001 (23-036A)

Name	Specification
Super DOT 4 Brake Fluid	ESD-M6C57-A

WARNING: Avoid contact with skin or eyes with brake fluid. If brake fluid contacts skin or eyes, rinse immediately with water. Failure to follow these instructions may result in injury.

CAUTION: If brake fluid comes into contact with paintwork, immediately wash the affected areas with water.

NOTE: Absolute cleanliness must be maintained when adding brake fluid.

NOTE: Do not reuse brake fluid.

NOTE: If the proper brake bleeding equipment is available, it can be used to bleed the clutch hydraulic system.

1. General notes:

• The hydraulic clutch drive is a self-ventilating system. The elements are arranged in such a way that even the smallest amount of air that gets into the system is removed automatically.

2. Remove the air filter.

• 1. Disconnect the inlet hose.
• 2. Disconnect the mass air flow (MAF) sensor connector.
• 3. Disconnect the crankcase ventilation hose.

3. Remove the air intake pipe.




4. Pump out the brake fluid from the brake fluid reservoir by suction until the level drops to the MIN mark.



5. Add approximately 100 ml of Super DOT 4 brake fluid to the reservoir using special tool 416-D001.

6.

NOTE: The special tool reservoir must be positioned below the air bleed nipple and the lift pipe hose connection must face the air bleed nipple.

Install the special tool, open the bleed nipple and use the special tool to fill approximately 80 ml of Super DOT 4 brake fluid into the clutch system.

• Tighten the bleed nipple to 10 Nm.
• Detach the special tool.
• To remove any small amount of air remaining in the system, pump the clutch pedal several times (4 - 5 times maximum), depressing the pedal to its full travel.

7. Install the air intake pipe.




8. Install the air filter.

• 1. Connect the inlet hose.
• 2. Connect the mass air flow (MAF) sensor connector.
• 3. Connect the PCV hose.

9.

NOTE: Absolute cleanliness must be maintained when adding brake fluid.

Check the brake fluid level.

• The brake fluid level should be between the MIN and MAX marks. If the fluid level falls below the MIN mark, the brake warning light comes on.
• If necessary, refill the reservoir. The reservoir should be filled with Super DOT 4 brake fluid.

10.

NOTE: Carefully engage reverse gear.

Check that the clutch is working properly.

• Start the engine, depress the clutch pedal and wait approximately 2 seconds before engaging reverse. If the engagement is particularly noisy during this operation, remove the small amount of air remaining in the system by repeatedly operating the clutch pedal (4 to 5 times, maximum), depressing the pedal to its full travel.
• After a pause of approximately 30 seconds, check the clutch operation again. If engaging the gear is still accompanied by excessive noise, repeat the above operations.