driver SUBARU FORESTER 2004 Service User Guide

AB-7
AIRBAG SYSTEM
General Description
C: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
98299FC030 DEPLOYMENT
ADAPTER A Used for deploying the side airbag module.
 Used with DEPLOYMENT TOOL
(98299PA030).
98299SA010 TEST HARNESS
ADAPTER D Used for deploying the driver’s airbag module
and seat belt pretensioner.
 Used with DEPLOYMENT TOOL
(98299PA030).
 Can not reuse.
98299SA030 TEST HARNESS
ADAPTER E Used for deploying the passenger’s airbag
module.
 Used with DEPLOYMENT TOOL
(98299PA030).
98299SA050 TEST HARNESS
ADAPTER F Used for deploying lap seat belt pretensioner.
 Used with DEPLOYMENT TOOL
(98299PA030).
ST98299FC030
ST98299SA010
ST98299SA030
ST98299SA050

AB-8
AIRBAG SYSTEM
General Description
2. GENERAL TOOL
98299PA030 DEPLOYMENT
TOOL Used for deploying the airbag module.
 Used with DEPLOYMENT ADAPTER A
(98299FC030).
TOOL NAME REMARKS
TO RX
® T30Used for removal/installation of driver’s airbag module. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST98299PA030

AB-9
AIRBAG SYSTEM
Airbag Connector
2. Airbag Connector
A: OPERATION
1. POWER SUPPLY
1) How to disconnect:
(1) Move the slide lock (A) in the direction of ar-
row.
(2) Pull the female connector in the direction of
arrow with slide lock (A) moved.
CAUTION:
When pulling, be sure to hold onto the connec-
tor and not the wire.
2) How to connect:
Holding the connector (A), push it in carefully until a
connecting sound is heard.
CAUTION:
Be sure to insert the connector in until it locks.
Then pull on it gently to make sure that it is
locked.
2. DRIVER’S AIRBAG (BETWEEN AIRBAG
HARNESS AND ROLL CONNECTOR), PAS-
SENGER’S AIRBAG AND SIDE AIRBAG
1) How to disconnect:
(1) Push the lock arm (A).
(2) With the lock arm (A) pushed in, move the
slide lock (B) in the direction of arrow.
(3) With the slide lock pulled, remove the lock
arm to its original position, and then pull in the
direction of arrow to separate connector.
CAUTION:
When pulling, be sure to hold onto the connec-
tor and not the wire.
2) How to connect:
Holding the connector, and push it in carefully until
a connecting sound is heard.
CAUTION:
Be sure to insert the connector in until it locks.
Then pull on it gently to make sure that it is
locked.
AB-00015
AB-00016
AB-00017
(A) (B)
AB-00018
AB-00019

AB-10
AIRBAG SYSTEM
Airbag Connector
3. DRIVER’S AIRBAG MODULE AND PRE-
TENSIONER
1) How to disconnect:
(1) Using a flat tip screwdriver, pry the push
lock upward to unlock.
(2) Pull the connector to disconnect from driv-
er’s side airbag module assembly or retractor
assembly.
2) How to connect:
Connect the connector in reverse order of discon-
necting. At this time, be sure to insert the connector
in until a connecting sound is heard.
CAUTION:
 Be sure to insert the connector in until it
locks. Then pull it gently to make sure that it is
locked.
 Be sure to insert the push lock in.
4. FRONT SUB-SENSOR AND SIDE AIR-
BAG SENSOR
1) How to disconnect:
Holding outer part (A), pull it in the direction of ar-
row.
CAUTION:
When pulling, be sure to hold onto the connec-
tor and not the wire.
2) How to connect:
Holding the connector, and push it in carefully until
a connecting sound is heard.
CAUTION:
 Do not put your hand on the outer part, since
outer (A) moves back.
 Be sure to insert the connector in until it
locks. Then pull it gently to make sure that it is
locked.
5. PASSENGER’S AIRBAG
1) How to disconnect:
(1) Move the slide lock (A) in the direction of ar-
row.
AB-00478
AB-00479
AB-00480
AB-00024
AB-00025
AB-00021
(A)

AB-11
AIRBAG SYSTEM
Airbag Connector
(2) With the slide lock pushed, pull the connec-
tor in the direction of arrow and disconnect it.
CAUTION:
When pulling, be sure to hold onto the connec-
tor and not the wire.
2) How to connect:
Holding the connector, and push it in carefully until
a connecting sound is heard.
CAUTION:
Be sure to insert the connector in until it locks.
Then pull on it gently to make sure that it is
locked.
6. LAP SEAT BELT PRETENSIONER
1) How to disconnect:
(1) Using a flat tip screwdriver, pry the push
lock (A) upward to unlock.(2) Pull the connector to disconnect from lap
seat belt pretensioner.
CAUTION:
When pulling, be sure to hold onto the connec-
tor and not the wire.
2) How to connect:
Connect the connector in reverse order of discon-
necting. At this time, be sure to insert the connector
in until a connecting sound is heard.
CAUTION:
 Be sure to insert the connector in until it
locks.
Then pull it gently to make sure that it is locked.
 Be sure to lock the push lock securely.
AB-00022
AB-00023
AB-00115
(A)
AB-00026
AB-00027

AB-12
AIRBAG SYSTEM
Inspection Locations After a Collision
3. Inspection Locations After a
Collision
A: REPLACEMENT
When airbag system is deployed, replace the fol-
lowing parts.
1. FRONT COLLISION
1) Driver’s airbag module
2) Passenger’s airbag module
3) Driver’s seat belt (pretensioner, lap seat belt pre-
tensioner)
4) Passenger’s seat belt (pretensioner)
5) Airbag control module
6) Front sub-sensor
7) Roll connector
2. SIDE COLLISION
1) Airbag control module
2) Side airbag module (operating side seat bag)
3) Side airbag sensor (operating side)
3. INSPECTION OF OTHER PARTS
Check for the following parts, replace the damaged
parts with new ones.
1) Steering wheel and steering shaft
Check the steering wheel and steering shaft for
mounting condition and deflection of axial and radi-
al direction. Check the steering shaft for deflection
of axial direction with tilt lever released. (After a col-
lision, absorbing part of steering shaft may inflate.)
2) Check the direct type connector of driver’s air-
bag module, pretensioner, etc. for damage, and
also check each harness for pinch and connector
damage. If damage is found, replace the harness
as a unit.
B: INSPECTION
If the vehicle is involved in a collision on any side,
even if it is a slight collision, be sure to check the
following system parts.
1. DRIVER’S AIRBAG MODULE
1) Check for the following, and replace damaged
parts with new ones.
 Airbag module is cracked or deformed.
 Harness and/or connector is cracked, deformed
or open. Lead wire is exposed.
 The module surface is fouled with grease, oil,
water or cleaning solvent.
2) When installing a new driver’s airbag module,
check the following. If necessary, install a new air-
bag module and steering wheel.
 The steering wheel is in the way, making it diffi-
cult to install the airbag module. The clearance between the driver’s airbag mod-
ule and steering wheel is not constant.
 The steering wheel deformation in axial and radi-
al directions exceed limits.
Specifications:
Height deflection A
Less than 6 mm (0.24 in)
O.D. deflection L
Less than 17 mm (0.67 in)
2. PASSENGER’S AIRBAG MODULE
Check for the following, and replace damaged
parts with new ones.
 Airbag module is cracked or deformed.
 Harness and/or connector is cracked, deformed
or open. Lead wire is exposed.
 Mounting bracket is cracked or deformed.
3. SIDE AIRBAG MODULE
Check for the following, and replace damaged
parts with new ones.
 Front seat is damaged or deformed.
 Harness and/or connector is cracked, deformed
or open.
 Lead wire is exposed.
4. AIRBAG CONTROL MODULE
Check for the following, and replace damaged
parts with new ones.
 Control module is cracked or deformed.
 Mounting bracket is cracked or deformed.
 Connector is scratched or deformed.
 Airbag is deployed.
 Side airbag is deployed.
AB-00028
L
A

AB-14
AIRBAG SYSTEM
Driver’s Airbag Module
4. Driver’s Airbag Module
A: REMOVAL
CAUTION:
Refer to “CAUTION” in General Description be-
fore handing the airbag module. CAUTION, General Description.>
1) Position the front wheels straight ahead. (After
moving the vehicle more than 5 m (16 ft) with front
wheels positioned straight ahead, make sure that
the vehicle moves straight ahead).
2) Turn the ignition switch to OFF.
3) Disconnect the ground cable from battery, and
wait for at least 20 seconds before starting work.
4) Using the TORX
® BIT T30, remove the two
TORX® bolts on side of steering wheel.
5) Disconnect the airbag connector on the back of
airbag module, and then remove the airbag mod-
ule.
6) Refer to “CAUTION” for handling of removed air-
bag module. scription.>
B: INSTALLATION
Install in the reverse order of removal.
CAUTION:
Do not allow harness and connectors to inter-
fere or get tangled up with other parts.
Tightening torque:
Refer to “COMPONENT” in “General Descrip-
tion” NENT, General Description.>
C: INSPECTION
CAUTION:
Refer to “CAUTION” in General Description be-
fore handing the airbag module. CAUTION, General Description.>
Check for the following, and replace damaged
parts with new ones.
 Airbag module, harness, connector, and mounting
bracket are damaged. AIRBAG MODULE, INSPECTION, Inspection Lo-
cations After a Collision.>
(1)
TORX® BIT T30
CC-00018
(1)
AB-00033

AB-20
AIRBAG SYSTEM
Roll Connector
9. Roll Connector
A: REMOVAL
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 driver’s airbag module. 14, Driver’s Airbag Module.>
4) Remove the steering wheel. MOVAL, Steering Wheel.>
5) Remove the steering column cover.
6) Remove the screws, and then remove the roll
connector.
B: INSTALLATION
1) Install in the reverse order of removal.
2) Before installing the steering wheel, be sure the
direction of roll connector is adjusted with steering.

C: INSPECTION
Check for the following, and replace damaged parts
with new parts.
 Combination switch and roll connector are cracked
or deformed.
D: ADJUSTMENT
1) Check that the front wheels are positioned in
straight ahead direction.
2) Turn the roll connector pin (A) clockwise until it
stops.
3) Turn the roll connector pin (A) counterclockwise
approx. 2.65 turns until “▲” marks are aligned.
AB-00593
AB-00594
(A)

AB-22
AIRBAG SYSTEM
Airbag Module Disposal (Deployment Processing On Vehicle)
11.Airbag Module Disposal (De-
ployment Processing On Ve-
hicle)
A: OPERATION
CAUTION:
 Do not discard an undeployed airbag mod-
ules because it may cause a serious personal
injury when accidentally deployed.
 As a rule, the airbag module should be de-
ployed while still installed in the vehicle. Do not
remove the airbag modules unless necessary.
 Deployment of the airbag module should be
done on a flat place free from any possible dan-
ger. Avoid deploying outdoors during rainy or
windy weather.
 Deploying the airbag module causes a high
explosive noise, be sure to warn people in the
area, and do not allow anyone within a 5 m (16
ft) radius of the disposal site.
 Some smoke will be emitted from deployment
of the airbag module. Therefore, it must be de-
ployed in a well-ventilated place with no smoke
detector nearby.
 Wear protective gloves, safety goggles and
earplugs during this operation. Wash your hands
afterwards.
 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.
 Wrap the deployed airbag module in an air-
tight vinyl bag, and discard it.
 If circumstances do not permit the airbag
module deployment, contact the SUBARU deal-
er.
1. DRIVER’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 lower cover. MOVAL, Instrument Panel Assembly.>4) Disconnect the airbag connector (AB30) and
(AB2) below steering column.
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 to airbag
connector (AB30).
(A) Deployment tool:
(Tool number 98299PA030)
(B) Deployment adapter A:
(Tool number 98299SA030)
(1) Deployment adapter A:
(Tool number 98299SA030)
AB-00197
AB30
AB2
SB-00016
AB-00198
AB30
(1)

AB-23
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. Driver’s Airbag Module.>
12) 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 glove box.
4) Disconnect the airbag connectors (AB4) and
(AB27).
5) Short the terminal to alligator clip furnished as
deployment tool (A)
6) Connect the deployment tool (A) and deploy-
ment 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 to the airbag
connector (AB27).
SB-00017
SB-00018
AB-00043
(A) Deployment tool:
(Tool number 98299PA030)
(B) Deployment adapter E:
(Tool number 98299SA030)
(1) Deployment adapter E:
(Tool number 98299SA030)
SB-00016
AB-00199
AB27
(1)