SUBARU FORESTER 2004 Service Repair Manual
Manufacturer: SUBARU, Model Year: 2004, Model line: FORESTER, Model: SUBARU FORESTER 2004Pages: 2870, PDF Size: 38.67 MB
Page 221 of 2870
AB-89
AIRBAG SYSTEM (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
W: DTC 65
DIAGNOSIS:
Seat belt pretensioner circuit (RH) is shorted to the power supply.
Pretensioner is faulty.
Pretensioner harness is faulty.
Airbag control module is faulty.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch to OFF, disconnect the
ground cable from battery, and wait more than 20 seconds before starting to work.
After replacing the airbag module, seat belt pretensioner, roll connector, control module or sensor,
reconnect each part and confirm that the airbag warning light operates properly.
When inspecting the side airbag harness, disconnect the side airbag module connector and seat
belt pretensioner connector for the safety reasons.
WIRING DIAGRAM:
AB-00086
12
AIRBAG CONTROL MODULEAB8
PRETENSIONER RH
AB20
AB20
6 1
25
AB8
123456
789101112
Page 222 of 2870
AB-90
AIRBAG SYSTEM (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK SEAT BELT PRETENSIONER.
1) Turn the ignition switch to OFF, disconnect
the battery ground cable, and wait more than
20 seconds.
2) Disconnect the connector (AB20) from the
seat belt pretensioner (RH).
3) Connect the connector (1F) in test harness
F to (AB20).
4) Connect the airbag resistor to connector
(3F) in test harness F.
5) Connect the battery ground cable, and turn
the ignition switch to ON.Is the airbag warning light
turned on normally?Replace the seat
belt pretensioner
(RH).
Belt.>Go to step 2.
2 CHECK SIDE AIRBAG HARNESS (RH).
1) Turn the ignition switch to OFF, disconnect
the battery ground cable, and wait more than
20 seconds.
2) Disconnect the airbag resistor from the test
harness.
3) Disconnect the connector (AB11) from side
airbag module (RH).
4) Disconnect the connectors (AB7) and
(AB8) from the airbag control module.
5) Connect the connector (1R) in test harness
R to the connector (AB8).
6) Connect the battery ground cable and turn
the ignition switch to ON.
7) Measure the voltage between connector
(3R) in test harness R and the chassis ground.
Connector & terminal
(3R) No. 17 (+) — Chassis ground (
−):
(3R) No. 19 (+) — Chassis ground (
−): Is the voltage less than 1 V? Replace the airbag
control module.
Module.>Replace the side
airbag harness
with body harness.
Page 223 of 2870
AB-91
AIRBAG SYSTEM (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
X: DTC 66
DIAGNOSIS:
Seat belt pretensioner circuit (LH) is shorted to the power supply.
Pretensioner is faulty.
Pretensioner harness is faulty.
Airbag control module is faulty.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch to OFF, disconnect the
ground cable from battery, and wait more than 20 seconds before starting to work.
After replacing the airbag module, seat belt pretensioner, roll connector, control module or sensor,
reconnect each part and confirm that the airbag warning light operates properly.
When inspecting the side airbag harness, disconnect the side airbag module connector and seat
belt pretensioner connector for the safety reasons.
WIRING DIAGRAM:
AB-00087
12
AIRBAG CONTROL MODULEAB7
PRETENSIONER LH
AB19
AB19
1 1
22
AB7
123456
789101112
Page 224 of 2870
AB-92
AIRBAG SYSTEM (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK SEAT BELT PRETENSIONER.
1) Turn the ignition switch to OFF, disconnect
the battery ground cable, and wait more than
20 seconds.
2) Disconnect the connector (AB19) from the
seat belt pretensioner (LH).
3) Connect the connector (1F) in test harness
F to (AB19).
4) Connect the airbag resistor to the connec-
tor (3F) in test harness F.
5) Connect the battery ground cable and turn
the ignition switch to ON.Is the airbag warning light
turned on normally?Replace the seat
belt pretensioner
(LH).
Belt.>Go to step 2.
2 CHECK SIDE AIRBAG HARNESS (LH).
1) Turn the ignition switch to OFF, disconnect
the battery ground cable, and wait more than
20 seconds.
2) Disconnect the airbag resistor from the test
harness.
3) Disconnect the connector (AB9) from side
airbag module (LH).
4) Disconnect the connectors (AB7) and
(AB8) from the airbag control module.
5) Connect the connector (1R) in test harness
R to the connector (AB7).
6) Connect the battery ground cable and turn
the ignition switch to ON.
7) Measure the voltage between connector
(3R) in test harness R and the chassis ground.
Connector & terminal
(3R) No. 11 (+) — Chassis ground (
−):
(3R) No. 13 (+) — Chassis ground (
−): Is the voltage less than 1 V? Replace the airbag
control module.
Module.>Replace the side
airbag harness
with body harness.
Page 225 of 2870
AB-93
AIRBAG SYSTEM (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Y: DTC 72
DIAGNOSIS:
Airbag harness is open, shorted or shorted to ground.
Airbag module harness circuit (Passenger) is open, shorted or shorted to ground.
Passenger’s airbag module is faulty.
Airbag control module is faulty.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the
ground cable from the battery, and wait more than 20 seconds before starting to work.
After replacing the airbag module, seat belt pretensioner, roll connector, control module or sensor,
reconnect each part and confirm that the airbag warning light operates properly.
When inspecting the airbag main harness, disconnect the driver’s airbag module and passenger’s
airbag module connectors for safety reasons.
WIRING DIAGRAM:
AB-00621
AB3 INFLATOR
(PASSENGER SIDE)
AB4
AB4
10
11 4
37
8
1
2
AIRBAG CONTROL MODULEAB3
1234567891011121314151617
1819202122232425262728
1234
Page 226 of 2870
AB-94
AIRBAG SYSTEM (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK PASSENGERS AIRBAG MODULE.
1) Turn the ignition switch OFF, disconnect the
battery ground cable, and wait more than 20
seconds.
2) Remove the glove box.
3) Disconnect the connector passenger’s air-
bag module from (AB4).
4) Connect the connector (1P) in test harness
K to connector (AB4).
5) Connect two airbag resistors to connectors
(2P) and (3P) in test harness P.
6) Connect the battery ground cable and turn
the ignition switch ON.Is the airbag warning light
turned on normally?Replace the pas-
senger’s airbag
module.
ger’s Airbag Mod-
ule.>Go to step 2.
2 CHECK AIRBAG MAIN HARNESS.
1) Turn the ignition switch OFF, disconnect the
battery ground cable, and wait more than 20
seconds.
2) Disconnect two airbag resistors from the
connectors (2P) and (3P) in test harness P.
3) Remove the lower cover and disconnect the
connector (AB21) from (AB26).
4) Disconnect the connector (AB3) from the
air bag control module, and connect the con-
nector (1R) in test harness R.
5) Measure the resistance between connector
(2R) in test harness R and the connector (2P)
in test harness P.
Connector & terminal
(2R) No. 9 — (3P) No. 3:
(2R) No. 13 — (3P) No. 4: Is the resistance less than 10
Ω?Go to step 3.Replace the airbag
main harness
together with body
harness as a unit.
3 CHECK AIRBAG MAIN HARNESS.
Measure the resistance of the connector (2R)
in test harness R.
Connector & terminal
(2R) No. 9 — No. 13:
(2R) No. 9 — Chassis ground:
(2R) No. 13 — Chassis ground:Is the resistance more than 1
MΩ?Replace the airbag
control module.
Module.>Replace the airbag
main harness
together with body
harness as a unit.
Page 227 of 2870
AB-95
AIRBAG SYSTEM (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Z: DTC 76
DIAGNOSIS:
Airbag main harness circuit (Passenger) is shorted to the power supply.
Airbag module harness (Passenger) is shorted to the power supply.
Passenger’s airbag module is faulty.
Airbag control module is faulty.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the
ground cable from the battery, and wait more than 20 seconds before starting to work.
After replacing the airbag module, seat belt pretensioner, roll connector, control module or sensor,
reconnect each part and confirm that the airbag warning light operates properly.
When inspecting the airbag main harness, disconnect the driver’s airbag module and passenger’s
airbag module connectors for safety reasons.
WIRING DIAGRAM:
AB-00621
AB3 INFLATOR
(PASSENGER SIDE)
AB4
AB4
10
11 4
37
8
1
2
AIRBAG CONTROL MODULEAB3
1234567891011121314151617
1819202122232425262728
1234
Page 228 of 2870
AB-96
AIRBAG SYSTEM (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK PASSENGERS AIRBAG MODULE.
1) Turn the ignition switch OFF, disconnect the
battery ground cable, and wait more than 20
seconds.
2) Remove the glove box.
3) Disconnect the connector (AB4) from pas-
senger’s airbag module.
4) Connect the connector (1P) in test harness
D to connector (AB4).
5) Connect two airbag resistors to connectors
(2P) and (3P) in test harness P.
6) Connect the battery ground cable and turn
the ignition switch ON. Is the airbag warning light
turned on normally?Replace the pas-
senger’s airbag
module.
ger’s Airbag Mod-
ule.>Go to step 2.
2 CHECK AIRBAG MAIN HARNESS.
1) Turn the ignition switch OFF, disconnect the
battery ground cable, and wait more than 20
seconds.
2) Disconnect two airbag resistors from the
connectors (2P) and (3P) in test harness P.
3) Remove the lower cover and disconnect the
connector (AB21) from (AB26).
4) Disconnect the connector (AB3) from the
airbag control module, and connect the con-
nector (1R) in test harness R.
5) Measure the voltage between connector
(2R) in test harness R and the chassis ground.
Connector & terminal
(2R) No. 9 (+) — Chassis ground (
−):
(2R) No. 13 (+) — Chassis ground (
−): Is the voltage less than 1 V? Replace the airbag
control module.
Module.>Replace the airbag
main harness
together with body
harness as a unit.
Page 229 of 2870
AB-97
AIRBAG SYSTEM (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
AA:DTC 81
DIAGNOSIS:
Lap seat belt pretensioner circuit (RH) is open, shorted or shorted to ground.
Lap pretensioner is faulty.
Lap pretensioner harness is faulty.
Airbag control module is faulty.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch to OFF, disconnect the
ground cable from battery, and wait more than 20 seconds before starting to work.
After replacing the airbag module, seat belt pretensioner, roll connector, control module or sensor,
reconnect each part and confirm that the airbag warning light operates properly.
When inspecting the side airbag harness, disconnect the side airbag module connector and seat
belt pretensioner connector for the safety reasons.
WIRING DIAGRAM:
AB-00749
AB8
AB25
4 1
23
AB8AB25
12
AIRBAG CONTROL MODULE
LAP SEAT BELT PRETENSIONER
FOR AUSTRALIA MODEL
123456
789101112
Page 230 of 2870
AB-98
AIRBAG SYSTEM (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK LAP SEAT BELT PRETENSIONER.
1) Turn the ignition switch to OFF, disconnect
the battery ground cable, and wait more than
20 seconds.
2) Disconnect the connector (AB25) from the
lap seat belt pretensioner (RH).
3) Connect the connector (1Q) in test harness
Q to (AB25).
4) Connect the airbag resistor to connector
(2Q) in test harness Q.
5) Connect the battery ground cable, and turn
the ignition switch to ON.Is the airbag warning light
turned on normally?Replace the lap
seat belt preten-
sioner (RH).
OUTER SEAT
BELT WITH LAP
SEAT BELT PRE-
TENSIONER,
REMOVAL, Front
Seat Belt.>Go to step 2.
2 CHECK SIDE AIRBAG HARNESS (RH).
1) Turn the ignition switch to OFF, disconnect
the battery ground cable, and wait more than
20 seconds.
2) Disconnect the airbag resistor from the test
harness.
3) Disconnect the connector (AB11) from side
airbag module (RH).
4) Disconnect the connectors (AB20) from
seat belt pretensioner.
5) Disconnect the connector (AB8) from air-
bag control module.
6) Connect the connector (1R) in test harness
R to the connector (AB8).
7) Measure the resistance between connector
(3R) in test harness R and connector (2Q) in
test harness Q.
Connector & terminal
(3R) No. 2 — (2Q) No. 2:
(3R) No. 4 — (2Q) No. 1: Is the resistance less than 10
Ω?Go to step 3.Replace the side
airbag harness
with body harness.
3 CHECK SIDE AIRBAG HARNESS.
Measure the resistance between the connector
(3R) in test harness R and the chassis ground.
Connector & terminal
(3R) No. 2 — (3R) No. 4:
(3R) No. 2 — Chassis ground:
(3R) No. 4 — Chassis ground: Is the resistance more than 1
MΩ?Replace the airbag
control module.
Module.>Replace the side
airbag harness
with body harness.