bleed clutch or brake.txt USE DOT4 Brake/Clutch fluid CAUTION brake fluid is corrosive, wash off hands and rinse off any spills IMMEDIATELY with lots of clean water --- Brake fluid will strip paint if left. DO NOT ALLOW any water near the reservoir or new fluid YOU NEED 2 PEOPLE Hydraulic Brakes and clutch on cars, vans, motorbikes etc work the same --------- Attach tube (pvc clear tube or rubber) to bleed nipple. Place free end of tube into container (jam jar) with enough fluid to ensure tube end is below surface remove reservoir lid top up reservoir 1) get person2 ( it needs 2 people) to slowly press pedal til it stops 2) slacken nipple WHILST PERSON2 IS PRESSING THE PEDAL 3) allow any air etc to come out WHILST person2 is holding the pedal down AT FULL TRAVEL 4) tighten nipple lightly 5) get person2 to allow pedal back up SLOWLY... it should return because of the spring ON THE PEDAL pulls it up 6) top up reservoir repeat 1 to 6 as many times as needed until air stops coming out into jar AND you have good pedal pressure AND pedal doesn't go too far down (use your judgement) tighten nipple fully remove tubing check level and replace reservoir lid ---------- carefully remove tube etc and dispose of sensibly Page 1
AR25.20-S-0070A Bleeding the clutch actuation 10.8.99 ENGINE 111.948 /978, 601.942 /970 in MODEL 638 except CODE (G40) Automatic transmission 1 Expansion reservoir 3 Bleed valve N42.50-2326-01 N25.20-2043-01 Bleeding a Danger! Risk of poisoning from swallowing brake Store brake fluid in original container only. AS42.50-Z-0001-01A fluid. Risk of injury resulting from brake fluid Wear protective clothing and eye protection. coming into contact with skin and eyes. i Notes on handling brake fluid All models AH42.50-P-0001-01A 1 Unscrew cap of expansion reservoir (1) 2 Connect vent hose (arrow) to expansion i Observe notes on use supplied by reservoir (1) manufacturer. 3 Remove dust excluder and connect hose of brake fluid receptacle to bleed valve (3) k (pneumatic) k (electric) 4 At clutch slave cylinder, open bleed valve (3) i This procedure can be supported by until new brake fluid is discharged free of sharply depressing and then slightly bubbles at bleed valve releasing the clutch pedal every 2 to 3 seconds. *WH58.30-Z-1001-24A *WH58.30-Z-1002-24A 5 Close bleed valve (3) n *BA25.20-N-1004-01A 6 Disconnect bleeder unit i Observe notes on use supplied by manufacturer. n *BA25.20-N-1004-01C 7 Correct fluid level in expansion reservoir (1) *BF42.00-N-1001-01A and attach cap g Inspecting 8 Check that clutch functions correctly 9 Test bleed valve (3) for leaks and attach dust excluder n Clutch mechanism Number Designation Engine 601.942/ 970 BA25.20-N-1004-01A Bleed screw to clutch slave cylinder Nm 16 n Clutch mechanism Number Designation Engine 111.948/ 978 BA25.20-N-1004-01C Bleed screw to clutch slave cylinder Nm 16 j Brake system Number Designation Model 638
BF42.00-N-1001-01A Brake fluid TT brake circuit configuration Liter - X brake circuit configuration with ABS/ABD or ABS/ETS Liter Liter v0.4 v0.8 Specifications for service products Shee t BB00.40-P-0331-00 A Commercially available tools Number WH58.30-Z-1001-24A WH58.30-Z-1002-24A Designation Bleeder unit, pneumatic Bleeder unit, electric Copyright Daimler AG 11/8/11 G/06/08. This WIS printout will not be recorded by the update service. Page 2
BB00.40-P-0331-00A Brake fluids (DOT 4 plus) For all vehicle models from Mercedes- Sheet 331.0 Benz and smart The item number "000 989 08 07" is decisive for release. The supplementary codes printed on the container (11th and 12th digits of number) essentially have logistic functions. This does not affect the product release. Product name MB 331.0 brake fluid 000 989 08 07 Customer, town/country Daimler AG, Stuttgart/Germany
AF25.20-S-4042AU Hydraulic clutch master cylinder leaking 8.2.99 ENGINE 111 in MODEL 638.### ## up to 188184 ENGINE 601 in MODEL 638.### ## up to 188184 Damage code Cause Remedy 29 021 04 Clutch master cylinder leakage at gasket 1 Remove/install/replace clutch master AR25.20-S-0100A tappet cylinder Parts ordering notes Part no. Designation Quantity 000 290 32 12 Clutch master cylinder 1
AR83.25-S-1401A Removing and installing air inlet 23.4.96 MODEL 638.0 /1 /2 1 Distributor S32.25-0015-01 S32.25-0016-01 ed Removal, installation 1 Disconnect the hose which comes from the windscreen wiper tank from the distributor (1) 2 Unscrew the screws which secure it to the body (arrows) 3 Pull air duct forward until it unhooks from its mount 4 Reinstall in opposite order i Installation: The shock absorber obstructs installation of the air inlet.
AR25.20-S-0100A Removing and installing master cylinder 23.2.96 MODEL 638 with ENGINE 111.948 /950 /978 /980, 601.942 /970, 611.980 except CODE (G40) Automatic transmission Illustration shows LHD vehicle 1 Clip 2 Master cylinder 3 Supporting axle 4 Supply line (from fluid reservoir) 5 Clamp 6 Hydraulic line 7 Bolt 8 Pedal bracket 9 Clutch pedal 10 Stop Illustration shows RHD vehicle S25.20-2500-06 1 Clip 2 Master cylinder 3 Supporting axle 4 Supply line 5 Clamp 6 Hydraulic line 7 Bolt 8 Pedal bracket 9 Clutch pedal 10 Stop S25.20-2501-06 e d Removal, installation 1.1 Remove trim cover under dashboard i Model 638.2, LHD left-hand side, RHD right and left. 2 Remove clip (1) of master cylinder (2) from supporting axle (3) 3 Remove air inlet AR83.25-S-1401A a Danger! Risk of poisoning from swallowing brake Store brake fluid in original container only. AS42.50-Z-0001-01A fluid. Risk of injury resulting from brake fluid Wear protective clothing and goggles. coming into contact with skin or eyes. p Notes on brake fluid All models AH42.50-P-0001-01A 4 Detach brake fluid supply line (4) connected p Avoid any fouling resulting from *BF42.00-N-1001-01A to brake fluid reservoir discharged brake fluid! Seal supply line (4) to prevent brake fluid from being discharged.
5 Remove clamp (5) of hydraulic line (6) from i Installation: Insert clamp (5) in master master cylinder (2) and then disconnect cylinder (2) and then connect hydraulic hydraulic line (6) line (6). 6 Unscrew bolts (7) of master cylinder (2) from n Engine 601.942/970 *BA25.20-N-1001-01A pedal bracket (8) n Engine 111.948/950/978/980 *BA25.20-N-1001-01C n Engine 611.980 *BA25.20-N-1004-01D 7 Pull out master cylinder (2) 8 Install in the reverse order g Inspecting 9 Check condition of lines and dust boots i Replace if necessary 10 Bleeding the clutch actuation AR25.20-S-0070A n Clutch mechanism Number Designation Engine 601.942/ 970 BA25.20-N-1001-01A Bolt securing clutch master cylinder to pedal Nm 7 bearing bracket n Clutch mechanism Number Designation Engine Engine 111.948/ 111.950/ 978 980 BA25.20-N-1001-01C Bolt securing clutch master cylinder to pedal bearing Nm 7 7 bracket n Clutch mechanism Number Designation Engine 611.980 BA25.20-N-1004-01D Clutch master cylinder to pedal bearing bracket Nm 7 j Brake system Number Designation Model 638 BF42.00-N-1001-01A Brake fluid TT brake circuit configuration Liter - X brake circuit configuration with ABS/ABD or ABS/ETS Liter Liter v0.4 v0.8 Specifications for service products Shee t BB00.40-P-0331-00 A Copyright Daimler AG 11/8/11 G/06/08. This WIS printout will not be recorded by the update service. Page 2
AR25.20-S-0150A Removing and installing slave cylinder 12.7.96 ENGINE 111.948 /978, 601.942 /970 in MODEL 638 except CODE (G40) Automatic transmission 1 Hydraulic line 2 Slave cylinder 3 Bolt Modification notes S25.20-3001-06 13.8.99 Value changed to 20 Nm Value in BA25.20-N-1001-01A changed for *BA25.20-N-1001-01A engine 601.942/970 e Removing 1 Take off front left wheel AR40.10-S-1100A 2 Remove noise encapsulation panels AR94.30-S-5300A 3 Unclip hydraulic line (1) from holders a Danger! Risk of poisoning from swallowing brake Store brake fluid in original container only. AS42.50-Z-0001-01A fluid. Risk of injury resulting from brake fluid Wear protective clothing and eye protection. coming into contact with skin or eyes. 4 Disconnect hydraulic line (1) from slave i Collect the brake fluid which flows out. cylinder (2) i Notes on brake fluid All models AH42.50-P-0001-01A 5 Remove slave cylinder (2) and unscrew hydraulic line (1) d Installing 6 Screw hydraulic line (1) into slave cylinder n Engine 601.942/970 *BA25.20-N-1001-01A (2) and install slave cylinder n Engine 111.948/978 *BA25.20-N-1002-01C i Coat the threads of the bolts (3) with *BR00.45-Z-1011-02A locking agent. 7 Screw hydraulic line (1) onto slave n Engine 601.942/970 *BA25.20-N-1003-01A cylinder (2) n Engine 111.948/978 8 Clip hydraulic line (1) into holders p The hydraulic line (1) must not be twisted and must not chafe against other components. *BA25.20-N-1003-01C 9 Bleed clutch actuation AR25.20-S-0070A g Checking 10 Perform function test n Clutch actuation Number Designation Engine 601.942/ 970
BA25.20-N-1001-01A Bolt, clutch slave cylinder to clutch housing Nm 20 BA25.20-N-1003-01A Hydraulic line to clutch slave cylinder Nm 16 n Clutch actuation Number Designation Engine 111.948/ 978 BA25.20-N-1002-01C Bolt, clutch slave cylinder to transmission Nm 20 BA25.20-N-1003-01C Hydraulic line to clutch slave cylinder Nm 16 Repair materials Number Designation Order number BR00.45-Z-1011-02A Quick glue A 003 989 31 71 Copyright Daimler AG 11/8/11 G/06/08. This WIS printout will not be recorded by the update service. Page 2