2004 SUBARU FORESTER air bleeding

CL-31
CLUTCH SYSTEM
Clutch Fluid
8. Clutch Fluid
A: INSPECTION
1) Park the vehicle on a level surface.
2) Inspect the fluid level using scale on the outside
of the reservoir tank. If the level is below “MIN”, add
fluid to bring it up to “MAX”, and also inspect for
leakage.
B: REPLACEMENT
CAUTION:
 The FMVSS No. 116, fresh DOT3 or DOT4
brake fluid must be used.
 Cover the bleeder with waste cloth, when
loosening it, to prevent brake fluid from being
splashed over surrounding parts.
 Avoid mixing different brands of brake fluid
to prevent degrading the quality of the fluid.
 Be careful not to allow dirt or dust to get into
the reservoir tank.
NOTE:
 For convenience and safety, it is advisable to
have two men working.
1) Remove the air cleaner case and air chamber.
2) Either jack-up the vehicle and place a rigid rack
under it, or lift-up the vehicle.
3) Draw out the brake fluid from reservoir tank with
syringe.
4) Refill the reservoir tank with new recommended
brake fluid.
Recommended brake fluid:
FMVSS No. 116, fresh DOT3 or DOT4 brake
fluid
5) Drain fluid in the same method as air bleeding.
6) Refill the brake fluid before reservoir tank be-
comes empty, and drain contaminated fluid again.
7) Repeat the above procedure until the contami-
nated fluid is completely drained.
(A) Reservoir tank
(B) MIN level
(C) MAX level
PM-00076
(A)
(B) (C)

CL-32
CLUTCH SYSTEM
Clutch Fluid Air Bleeding
9. Clutch Fluid Air Bleeding
A: PROCEDURE
1. 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.
Case.> take Duct.>
2) Fit one end of a vinyl tube into the air bleeder of
operating cylinder and put the other end into a
brake fluid container.
3) Slowly depress the clutch pedal and keep it de-
pressed. 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.
4) Repeat these steps until there are no more air
bubbles in the vinyl tube.
CAUTION:
Cover the bleeder with waste cloth when loos-
ening it, to prevent brake fluid from being
splashed over surrounding parts.5) Tighten the air bleeder.
Tightening torque:
T: 8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
6) After depressing the clutch pedal, make sure
that there are no leaks evident in the entire system.
7) After bleeding air from the system, ensure that
clutch operates properly.
2. TURBO MODEL
NOTE:
Bleed air from the oil line with help of co-worker.
1) Remove the intercooler. 11, INSTALLATION, Intercooler.>
2) Fit one end of a vinyl tube into the air bleeder of
master cylinder and put the air bleeder of other end
into a brake fluid container. (RHD turbo model)
3) Slowly depress the clutch pedal and keep it de-
pressed. 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. (RHD turbo model)
4) Repeat these steps until there are no more air
bubbles in the vinyl tube.
CAUTION:
Cover the bleeder with waste cloth when loos-
ening to prevent brake fluid from being
splashed over surrounding parts.
(A) Clutch hose
(B) Air bleeder
(A) Operating cylinder
(B) Vinyl tube
CL-00063
(B)(A)
CL-00064
(B)
(A)
(A) Vinyl tube
CL-00065
T
(A)
CL-00066

CL-33
CLUTCH SYSTEM
Clutch Fluid Air Bleeding
5) Tighten the air bleeder. (RHD turbo model)
Tightening torque:
T: 8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
6) Remove the operating cylinder.
NOTE:
Do not remove the clutch hose.
7) Fix the piston with clamp to avoid the piston from
jumping out.
8) Fit one end of a vinyl tube into the air bleeder of
operating cylinder and put the other end into a
brake fluid container.9) Slowly depress the clutch pedal and keep it de-
pressed. 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 screw part higher than tip of op-
erating cylinder when performing this procedure.
10) Repeat these steps until there are no more air
bubbles in the vinyl tube.
CAUTION:
Cover the bleeder with waste cloth when loos-
ening it, to prevent brake fluid from being
splashed over surrounding parts.
11) Tighten the air bleeder.
Tightening torque:
T: 8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
12) Install the operating cylinder.
Tightening torque:
T: 37 N
⋅m (3.8 kgf-m, 27.5 ft-lb)
13) After depressing the clutch pedal, make sure
that there are no leaks evident in the entire system.
14) After bleeding air from the system, ensure that
clutch operates properly.
15) Install the intercooler. 11, INSTALLATION, Intercooler.>
CL-00067
T
CL-00068
CL-00069
(A) Operating cylinder
(B) Vinyl tube
CL-00070
(B) (A)
CL-00068