ECU SUBARU FORESTER 2004 Service User Guide

AB-24
AIRBAG SYSTEM
Airbag Module Disposal (Deployment Processing On Vehicle)
8) Extend the wiring of deployment tool to the limit,
and make sure that the vehicle is empty. Close all
the windows, sunroof and rear gate completely.
9) Move the battery at least 5 m (16 ft) from vehicle,
and secure the nearby area. Connect the deploy-
ment tool alligator clip to the battery negative (−)
terminal.
10) Connect the other cable of deployment tool to
the battery positive (+) terminal, and deploy the air-
bag module.
CAUTION:
 After deployment, the airbag module will be
especially hot, leave it unattended for 40 min-
utes, and then discard it.
 Do not let water get on the deployed airbag
module.
11) Remove the airbag module. Passenger’s Airbag Module.>
12) Wrap the airbag module in an airtight vinyl bag,
and discard it.3. SIDE AIRBAG MODULE
1) Turn the ignition switch to OFF.
2) Disconnect the ground cable from battery and
wait for at least 20 seconds before starting work.
3) Disconnect the side airbag module connector
(yellow) under the front seat cushion.
4) Set the backrest at most standing position, and
then set the seat position at center of slide rail.
5) Short the terminal to alligator clip furnished as
deployment tool (A)
6) Connect the deployment tool and deployment
adapter A (B).
CAUTION:
The deployment tool should be kept shorted
terminals until just before deployment of airbag
module.
7) Connect the deployment adapter A (1) to the
side airbag module connector (yellow).
CAUTION:
 Do not place any object on front seat.
 Deploy the side airbag one by one to discard
it.
SB-00017
SB-00018
AB-00043
(A) Deployment tool:
(Tool number 98299PA030)
(B) Deployment adapter A:
(Tool number 98299FC030)
SB-00016
(1)
AB-00652

AB-25
AIRBAG SYSTEM
Airbag Module Disposal (Deployment Processing On Vehicle)
8) Extend the wiring of deployment tool to the limit,
and make sure that the vehicle is empty. Close all
the windows, sunroof and rear gate completely.
9) Move the battery at least 5 m (16 ft) from vehicle,
and secure the nearby area. Connect the deploy-
ment tool alligator clip to the battery negative (−)
terminal.
10) Connect the other cable of deployment tool to
the battery positive (+) terminal, and deploy the air-
bag module.
CAUTION:
 After deployment, the airbag module will be
especially hot, leave it unattended for 40 min-
utes, and then discard it.
 Do not let water get on the deployed airbag
module.
11) Remove the side airbag module. 16, REMOVAL, Side Airbag Module.>
12) Wrap the deployed airbag module in airtight vi-
nyl bag, and discard it.
SB-00017
SB-00018
AB-00043

AB-27
AIRBAG SYSTEM
Disposal of Airbag Module (Deploying After Removal from Vehicle)
9) Install the airbag module with pad side facing up-
ward on a wheel with tire.
10) Put three tires without wheels on the tire in-
stalled with the airbag module. Put on an additional
tire with a wheel, and then fasten them tight with a
rope.
11) Move the battery at least 5 m (16 ft) from vehi-
cle, and secure the nearby area. Connect the de-
ployment tool alligator clip to the battery negative (−
) terminal.12) Connect the other cable of deployment tool to
the battery positive (+) terminal, and deploy the air-
bag module.
CAUTION:
 After deployment, the airbag module will be
especially hot, leave it unattended for 40 min-
utes, and then discard it.
 Do not let water get on the deployed airbag
module.
13) Wrap the deployed airbag module in airtight vi-
nyl bag, and discard it.
2. PASSENGER’S AIRBAG MODULE
1) Turn the ignition switch to OFF.
2) Disconnect the ground cable from battery and
wait for at least 20 seconds before starting work.
3) Remove the passenger airbag module. AB-15, Passenger’s Airbag Module.>
4) Bundle three automotive wire harnesses [each
with a sectional area of 1.25 mm
2 (0.00194 sq in) or
more], route them through airbag module bracket
(A). Then, twist them to add strength.
(1) 5 m (16 ft) or more
AB-00050
SB-00025
SB-00065
(1)
SB-00018
AB-00043
AB-00051
(A)

AB-28
AIRBAG SYSTEM
Disposal of Airbag Module (Deploying After Removal from Vehicle)
5) Short the terminal to alligator clip furnished as
deployment tool (A)
6) Connect the deployment tool and deployment
adapter E (B).
CAUTION:
The deployment tool should be kept shorted
terminals until just before deployment of airbag
module.
7) Connect the deployment adapter E connector to
the airbag module.
8) Install the airbag module with opening side fac-
ing upward on 14-inch or greater size wheel with
tire.
9) Put three tires without wheels on the tire in-
stalled with the airbag module. Put on an additional
tire with a wheel on top, and then fasten them tight
with a rope.10) Move the battery at least 5 m (16 ft) from vehi-
cle, and secure the nearby area. Connect the de-
ployment tool alligator clip to the battery negative (−
) terminal.
11) Connect the other cable of deployment tool to
the battery positive (+) terminal, and deploy the air-
bag module.
CAUTION:
 After deployment, the airbag module will be
especially hot, leave it unattended for 40 min-
utes, and then discard it.
 Do not let water get on the deployed airbag
module.
12) Wrap the deployed airbag module in airtight vi-
nyl bag, and discard it.
(A) Deployment tool:
(Tool number 98299PA030)
(B) Deployment adapter E:
(Tool number 98299SA030)
SB-00016
AB-00052
SB-00025
(1) 5 m (16 ft) or more
SB-00065
(1)
SB-00018
AB-00043

AB-29
AIRBAG SYSTEM
Disposal of Airbag Module (Deploying After Removal from Vehicle)
3. SIDE AIRBAG MODULE
1) Turn the ignition switch to OFF.
2) Disconnect the ground cable from battery and
wait for at least 20 seconds before starting work.
3) Remove the front seats. AL, Front Seat.>
4) Remove the side airbag module. REMOVAL, Side Airbag Module.>
5) Bundle three automotive wire harnesses [each
with a sectional area of 1.25 mm
2 (0.00194 sq in) or
more], and then bind them through the holes in air-
bag module bracket.
6) Short the terminal to alligator clip furnished as
deployment tool (A)
7) Connect the deployment tool and deployment
adapter A (B).
CAUTION:
The deployment tool should be kept shorted
terminals until just before deployment of airbag
module.
8) Connect the deployment adapter A connector to
the airbag module.9) Install the airbag module on 14-inch or greater
size tire without wheel.
10) Put two tires without wheels (A) under the tire
installed with the side airbag module (B). Put on an
additional tire without a wheel (C), and then put a
tire with a wheel (D) on top. Fasten them tight with
a rope.
11) Move the battery at least 5 m (16 ft) from vehi-
cle, and secure the nearby area. Connect the de-
ployment tool alligator clip to the battery negative (−
) terminal.
(A) Airbag module bracket
(B) Side airbag module
(A) Deployment tool:
(Tool number 98299PA030)
(B) Deployment adapter A:
(Tool number 98299FC030)
AB-00144
(A)(B)
SB-00016
(A) Pad
(B) Airbag module bracket
(1) 5 m (16 ft) or more
AB-00145
(A)
(B)
AB-00146
(A)
(B)
(C)
(D)
SB-00065
(1)

FUJI HEAVY INDUSTRIES LTD. G8080GE7
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
BODY SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.HVAC SYSTEM
(HEATER, VENTILATOR AND A/C)AC
HVAC SYSTEM (AUTO A/C)
(DIAGNOSTIC)AC
AIRBAG SYSTEM AB
AIRBAG SYSTEM (DIAGNOSTIC) AB
SEAT BELT SYSTEM SB
LIGHTING SYSTEM LI
WIPER AND WASHER SYSTEM WW
ENTERTAINMENT ET
COMMUNICATION SYSTEM COM
GLASS/WINDOW/MIRROR GW
BODY STRUCTURE BS
INSTRUMENTATION/DRIVER INFO IDI
SEAT SE
SECURITY AND LOCK SL
SUNROOF/T-TOP/CONVERTIBLE TOP
(SUNROOF)SR
EXTERIOR/INTERIOR TRIM EI
EXTERIOR BODY PANEL EB

AB-5
AIRBAG SYSTEM (DIAGNOSTIC)
General Description
 If any damage, opening, or rust is found on the
airbag system wiring harness, do not attempt to re-
pair using soldering equipment. Be sure to replace
the faulty harness with a new genuine part.
 Install the wiring harness securely with the spec-
ified clips to avoid interference or tangled up with
other parts.
 Do not allow water or oil to come in contact with
the connector terminals. Do not touch the connec-
tor terminals. Either of the airbag modules for driver, passen-
ger or side, or pretensioner must not be disassem-
bled.
 The airbag module cannot be used again once
inflated.
 After removal, keep the airbag module with the
pad facing upward on a dry, clean, and flat surface
away from heat and light sources, and moisture
and dust.
 Do not check continuity of either of the airbag
modules for driver, passenger or side, or preten-
sioner.
AB-00124
AB-00125
AB-00126
AB-00127
AB-00056
AB-00006

AB-35
AIRBAG SYSTEM (DIAGNOSTIC)
Airbag Warning Light Failure
1. LHD MODEL
WIRING DIAGRAM:
Step Check Yes No
1 CHECK POOR CONTACT IN CONNECTORS
(AB1) AND (B31).
1) Turn the ignition switch to OFF, disconnect
the battery ground cable, and wait more than
20 seconds.
2) Remove the side sill cover. (Driver’s side)
3) Confirm that firm contact is secured
between connectors (AB1) and (B31).Is the poor contact in connec-
tors (AB1) and (B31)?Repair the body
harness or replace
the airbag main
harness with body
harness.Go to step 2.
AB-00739
12
34561
2345678910123456789101112131415161718192021222324252627282930
B31 i11AB3
i10
B:
C: i10
i11
AIRBAG
WARNING
LIGHTCOMBINATION
METERB9
B8
B10
NO.14
i3B38 28
i2B37 19
5
AIRBAG CONTROL MODULEAB3
B31
AB1
3
3
AIRBAG
CIRCUIT
E
BATTERY
1234567891011121314151617
1819202122232425262728
IGNITION
SWITCH
B: C:

AB-36
AIRBAG SYSTEM (DIAGNOSTIC)
Airbag Warning Light Failure
2 CHECK AIRBAG WARNING LIGHT.
1) Turn the ignition switch to OFF, disconnect
the battery ground cable, and wait more than
20 seconds.
2) Connect the connector (1T) in test harness
T to body harness connector (B31).
3) Connect the connector (1M) in test harness
M to connector (2T) in test harness T.
4) Connect the battery ground cable and turn
the ignition switch to ON.
5) Connect the connectors, (3M) and (4M) in
test harness M.Is the airbag warning light
turned off?Go to step 4.Go to step 3.
3 CHECK BODY HARNESS.
Check the body harness.
N
OTE:
After problem has been eliminated, disconnect
the connectors (3M) and (4M).Is the anything unusual to body
harness? Repair the body
harness.Replace the com-
bination meter
printed circuit.
Combination
Meter Assembly.>
4 CHECK POOR CONTACT.
Confirm that firm contact is secured between
the airbag control module and the connector
(AB3). ule.>Is the poor contact in connec-
tor (AB3)?Replace the airbag
main harness with
body harness or
replace the airbag
control module.
Airbag Control
Module.>Go to step 5.
5 CHECK AIRBAG MAIN HARNESS.
1) Turn the ignition switch to OFF, disconnect
the battery ground cable, and wait more than
20 seconds.
2) Connect the connector (AB1) to (B31).
3) Disconnect the connectors (AB2) and
(AB30).
4) Remove the glove box and disconnect the
connectors (AB4).
5) Disconnect the connector (AB3) from the
airbag control module, and connect the con-
nector (1R) in test harness R. Airbag Control Module.>
6) Connect the battery ground cable and turn
the ignition switch to ON.
7) Connect the connectors (5R) and (6R) in
test harness R.
N
OTE:
After problem has been eliminated, disconnect
the connectors (5R) and (6R).Is the airbag warning light
turned off?Go to step 6.Replace the airbag
main harness with
body harness.
6 CHECK GROUNDING CIRCUIT.
1) Turn the ignition switch to OFF, disconnect
the battery ground cable, and wait more than
20 seconds.
2) Disconnect the connector (AB3) from the
airbag control module.
3) Connect the connector (1R) in test harness
R to body harness connector (AB3).
4) Measure the resistance between connector
(2R) in test harness R and the chassis ground.
Connector & terminal
(2R) No. 10 — Chassis ground:
(2R) No. 11 — Chassis ground: Is the resistance less than 10
Ω?Replace the airbag
control module.
Airbag Control
Module.>Repair the body-
grounding circuit. Step Check Yes No

AB-37
AIRBAG SYSTEM (DIAGNOSTIC)
Airbag Warning Light Failure
2. RHD MODEL
WIRING DIAGRAM:
Step Check Yes No
1 CHECK POOR CONTACT IN CONNECTORS
(AB1) AND (B31).
1) Turn the ignition switch to OFF, disconnect
the battery ground cable, and wait more than
20 seconds.
2) Remove the side sill cover. (Driver’s side)
3) Confirm that firm contact is secured
between connectors (AB1) and (B31).Is the poor contact in connec-
tors (AB1) and (B31)?Repair the body
harness or replace
the airbag main
harness with body
harness.Go to step 2.
AB-00740
12
34561
2345678910123456789101112131415161718192021222324252627282930
B31 i11AB3
i10
B:
C: i10
i11
AIRBAG
WARNING
LIGHTCOMBINATION
METERB9
B8
B10
NO.14
i3B38 20
10
16
AIRBAG CONTROL MODULEAB3
B31
AB1
1
3
AIRBAG
CIRCUIT
E
BATTERY
1234567891011121314151617
1819202122232425262728
IGNITION
SWITCH