Clutch Fluid Air Bleeding: Procedure

WARNING: This page is about a different car, the 2004 Subaru Outback, 2004 Subaru Legacy, and 2004 Subaru Baja. However, it is still accessible from the selected car via links, so may be relevant.

NON-TURBO MODEL
NOTE: Bleed air from the oil line with help of co-worker.
1. Remove the air cleaner case and air intake duct. (Except U5 model) Refer to REMOVAL , Air Cleaner Case and REMOVAL , Air Intake Duct.
2. Remove the air intake chamber and air intake duct. (U5 model) Refer to REMOVAL , Air Intake Chamber and REMOVAL , Air Intake Duct.
3. Attach one end of a vinyl tube into the air bleeder of master cylinder and put the other end into a brake fluid container.
4. Slowly depress the clutch pedal and keep it. Then open the air bleeder to discharge air together with the fluid.
  Release the air bleeder for 1 or 2 seconds. Next, with the bleeder closed, slowly release the brake pedal.
  
  Fig 1: Attaching One End Of Vinyl Tube Into Air Bleeder Of Master Cylinder & Putting Other End Into Brake Fluid Container
  Courtesy of SUBARU OF AMERICA, INC.
5. Repeat the above steps until there are no more air bubbles in the vinyl tube.
  CAUTION: Cover the bleeder with waste cloth when loosening it, to prevent brake fluid from being splashed over surrounding parts.
6. Tighten the air bleeder.
  1. Tightening torque: 8 N.m (0.8 kgf-m, 5.8 ft-lb)
7. Fit one end of a vinyl tube into the air bleeder of operating cylinder and put the other end into a brake fluid container.
  
  Fig 2: Tightening Air Bleeder
  Courtesy of SUBARU OF AMERICA, INC.
8. Slowly depress the clutch pedal and keep it depressed. Then open the air bleeder to discharge air together with the fluid.
  Release the air bleeder for 1 or 2 seconds. Next, with the bleeder closed, slowly release the clutch pedal.
  
  Fig 3: Opening Air Bleeder For Discharging Air Together With Fluid
  Courtesy of SUBARU OF AMERICA, INC.
9. Repeat these steps until there are no more air bubbles in the vinyl tube.
  CAUTION: Cover the bleeder with waste cloth when loosening it, to prevent brake fluid from being splashed over surrounding parts.
10. Tighten the air bleeder.
  1. Tightening torque: T: 8 N.m (0.8 kgf-m, 5.8 ft-lb)
  Fig 4: Tightening Air Bleeder
  Courtesy of SUBARU OF AMERICA, INC.
11. After depressing the clutch pedal, make sure that there are no leaks evident in the entire system.
12. After bleeding air from the system, ensure that clutch operates properly.
TURBO MODEL
NOTE: Bleed air from the oil line with help of a co-worker.
1. Remove the intercooler. Refer to REMOVAL , Intercooler.
2. Remove the operating cylinder.
  NOTE: Do not remove the clutch hose.
  
  Fig 5: Removing Operating Cylinder
  Courtesy of SUBARU OF AMERICA, INC.
3. Fix the piston with clamp to avoid the piston from jumping out of cylinder.
  
  Fig 6: Fixing Piston With Clamp
  Courtesy of SUBARU OF AMERICA, INC.
4. Fit one end of a vinyl tube into the air bleeder of operating cylinder and put the other end into a brake fluid container.
5. Slowly depress the clutch pedal and keep it depressed. Then open the air bleeder to discharge air together with the fluid.
  Release the air bleeder for 1 or 2 seconds. Next, with the bleeder closed, slowly release the clutch pedal.
  
  NOTE: Set the air breather part higher than tip of operating cylinder when performing this procedure.
  
  Fig 7: Fitting Vinyl Tube Into Air Bleeder Of Operating Cylinder
  Courtesy of SUBARU OF AMERICA, INC.
6. Repeat these steps until there are no more air bubbles in the vinyl tube.
  CAUTION: Cover the bleeder with waste cloth when loosening it, to prevent brake fluid from being splashed over surrounding parts.
7. Tighten the air bleeder.
  1. Tightening torque: T: 8 N.m (0.8 kgf-m, 5.8 ft-lb)
8. Install the operation cylinder.
  1. Tightening torque: T: 37 N.m (3.8 kgf-m, 27.5 ft-lb)
  Fig 8: Installing Operation Cylinder
  Courtesy of SUBARU OF AMERICA, INC.
9. After depressing the clutch pedal, make sure that there are no leaks evident in the entire system.
10. After bleeding air from the system, ensure that the clutch operates properly.
11. Install the intercooler. Refer to INSTALLATION , Intercooler.