Brake & Clutch Flush

[markmooch]

I’ve just replaced the ABS pump and want to flush the brake & clutch system entirely as it won’t have been done for years. Do I need a pressure bleeder and VAGCOM or can it be done by one person manually (pipe on the nipples, plastic bottle to collect fluid) with the engine running (to power the brake & clutch system)? The car is a 1.6 FSI.


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[Crasher]

You need to do what we call a basic settings bleed. Yes you will need a diagnostic system capable of output tests and basic setting, a pressure bleeder certainly makes life easier as it becomes a three person job. The way we do it is to run the bleeder at 1.5Bar and bleed the master cylinder first IF it has nipples and then conventionally bleed all four corners so you have something of a pedal. Then you go into basic settings and as you will have a Mk60 system you only need to do the bleed a couple of times. When you click on go it will tell you to push down and hold the pedal and I MEAN HOLD as the ABS pump will then force the pedal back at you so hard it can lift your bum out of the seat... the first time will make you swear! Then it will say release and open both front nipples at the same time so you in the car, an assistant underneath and when you click go the ABS pump will run for about ten seconds purging air out then it will ask you to pump the pedal 10 times and do this smoothly . When done wait for the pressure bleeder to catch up filling the system. You need to go through this step a few times, on the Golf 4 Mk20 system it was a seventeen step process that if not completed left the ABS light on with a permanent code. Optionally you can then run output tests on each corner and following the screen press and release instructions it will operate the ABS and ESP function and at the front also the EDL function, then we run fluid through all four corners again and usually se a few bubbles. If you find it is being stubborn in that with the engine running the pedal is squiggy, you can also run the ABS pump in output tests and pedal pump pressure bleed each corner and that usually gets any stubborn bubbles out. Importantly you will also need to have the battery on charge doing this as the ABS pump running takes a huge current and can cause problems. An odd thing you may experience is the pedal feels great with the engine off but drops to the floor engine running and that means there is still air in there.