Removal SUBARU FORESTER 2004 Service Owner's Guide

AB-30
AIRBAG SYSTEM
Disposal of Airbag Module (Deploying After Removal from Vehicle)
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 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.
SB-00018
AB-00043

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-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). to SB-10, FRONT
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. 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.
Airbag Control
Module.>Replace the side
airbag harness
with body harness.

AB-100
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 the connec-
tor (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). to SB-10, FRONT
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 connector (AB20) from seat
belt pretensioner.
5) Disconnect the connectors (AB7) and
(AB8) from the airbag control module. AB-18, Airbag Control Module.>
6) Connect the connector (1R) in test harness
R to the connector (AB7).
7) Connect the battery ground cable and turn
the ignition switch to ON.
8) Measure the voltage between connector
(3R) in test harness R and the chassis ground.
Connector & terminal
(3R) No. 2 (+) — Chassis ground (
−):
(3R) No. 4 (+) — Chassis ground (
−): Is the voltage less than 1 V? Replace the airbag
control module.
Airbag Control
Module.>Replace the side
airbag harness
with body harness.

SB-10
SEAT BELT SYSTEM
Front Seat Belt
4. Front Seat Belt
A: REMOVAL
1. FRONT OUTER BELT
1) Fold backrest all the way forward, and then move
front seat all the way forward.
2) Turn the ignition switch to OFF, disconnect the
ground cable from battery, and wait for more than
20 seconds before starting work.
3) Remove the center pillar lower trim. 44, REMOVAL, Lower Inner Trim.>
4) Remove the anchor cover. Loosen the shoulder
anchor bolt, and then detach the shoulder anchor
from center pillar.
5) Turn over the floor mat to remove the bolts.
6) Disconnect the yellow connector of pretensioner
harness, and remove the front outer belt.
7) Remove the center pillar upper trim. 43, REMOVAL, Upper Inner Trim.>
8) Remove the two bolts and adjustable anchor as-
sembly.CAUTION:
 Do not drop or apply any impact to the pre-
tensioner.
 Pretensioner and bracket should be treated as
an assembly. Do not attempt to disassemble it.2. FRONT OUTER SEAT BELT WITH LAP
SEAT BELT PRETENSIONER
1) Fold backrest forward, and then move front seat
forward.
2) Turn the ignition switch to OFF, disconnect the
ground cable from battery, and wait for more than
20 seconds before starting work.
3) Remove the center pillar lower trim. 44, REMOVAL, Lower Inner Trim.>
4) Remove the anchor cover. Loosen the shoulder
anchor bolt, and then detach the shoulder anchor
from center pillar.
5) Turn over the floor mat to remove the bolts.
6) Disconnect the yellow connector of pretensioner
harness and orange connector of lap pretensioner
harness, and remove the front outer belt.
7) Remove the center pillar upper trim. 43, REMOVAL, Upper Inner Trim.>
SB-00003
SB-00004
SB-00005
SB-00003
SB-00007

SB-11
SEAT BELT SYSTEM
Front Seat Belt
8) Remove the two bolts and adjustable anchor as-
sembly.
CAUTION:
 Do not drop or apply any impact to the pre-
tensioner.
 Pretensioner and bracket should be treated
as an assembly. Do not attempt to disassemble
it.
3. FRONT INNER BELT
1) Disconnect the connector.
2) Remove the anchor bolt, and then detach the in-
ner belt.
B: INSTALLATION
1. FRONT OUTER BELT
Install in the reverse order of removal.
CAUTION:
 The parts on right and left are not identical.
Before installation, make sure that the correct
part is used.
 Be careful not to twist the belts during instal-
lation.
Tightening torque:
NENT, General Description.>
2. FRONT OUTER BELT WITH LAP SEAT
BELT PRETENSIONER
Install in the reverse order of removal.
CAUTION:
 The parts on right and left are not identical.
Before installation, make sure that the correct
part is used.
 Be careful not to twist the belts during instal-
lation.
Tightening torque:
NENT, General Description.>
3. FRONT INNER BELT
Install in the reverse order of removal.
Tightening torque:
NENT, General Description.>
C: INSPECTION
1. FRONT OUTER BELT
Check for the following, and replace with new parts
if necessary.
 Pretensioner is cracked or deformed.
 Seat belt is slackened, bent or frayed. Seat belt
is abnormally wound or extended.
2. FRONT INNER BELT
Check for the following, and replace with new parts
if necessary.
 Inner belt is deformed or damaged.
 Seat belt buckle is engaged improperly.
SB-00005
SB-00006

SB-12
SEAT BELT SYSTEM
Rear Seat Belt
5. Rear Seat Belt
A: REMOVAL
1. OUTER BELT SIDE
1) Remove the luggage floor mat. MOVAL, Luggage Floor Mat.>
2) Remove the rear seat. AL, Rear Seat.>
3) Remove the rear quarter trim. MOVAL, Rear Quarter Trim.>
4) Remove the seat belt lower anchor bolt.
5) Remove the anchor cover. Remove the bolt and
shoulder anchor from pillar.
6) Remove the rear quarter trim. MOVAL, Rear Quarter Trim.>
7) Remove the bolts, and then detach the outer belt
side.8) Remove the two bolts and adjustable anchor as-
sembly.
2. OUTER BELT CENTER
1) Remove the anchor cover. Remove the bolt and
then detach the shoulder anchor from pillar.
2) Remove the strut cap. AL, Rear Quarter Trim.>
3) Remove the rear rail trim. MOVAL, Rear Quarter Trim.>
4) Remove the rear pillar upper trim. REMOVAL, Rear Quarter Trim.>
5) Remove the rear skirt trim. MOVAL, Rear Quarter Trim.>
6) Remove the rear quarter lower trim. 45, REMOVAL, Rear Quarter Trim.>
7) Remove the cover (B) while detaching snap lock
carefully. Put the outer belt center tongue (A) out to
the other side of the trim through the hole.
8) Remove the clips and hang down rear end of
roof trim.
SB-00008
SB-00009
SB-00010
SB-00011
SB-00009
SB-00012

SB-13
SEAT BELT SYSTEM
Rear Seat Belt
9) Disconnect the harness and connector, and then
remove the outer belt center assembly.
3. INNER BELT
1) Remove the rear cushion.
2) Remove the bolt, and then detach the inner belt.
B: INSTALLATION
1. OUTER BELT SIDE
Install in the reverse order of removal.
CAUTION:
 During installation, make sure that the seat
belts are not twisted.
 After installation, make sure that the seat
belts can be smoothly extended and wound.
Tightening torque:
NENT, General Description.>
2. OUTER BELT CENTER
Install in the reverse order of removal.
CAUTION:
 During installation, make sure that the seat
belts are not twisted.
 After installation, make sure that the seat
belts are smoothly extended and wound.
Tightening torque:
NENT, General Description.>
3. INNER BELT
Install in the reverse order of removal.
CAUTION:
During installation, make sure that the seat
belts are not twisted.
Tightening torque:
NENT, General Description.>
C: INSPECTION
1. OUTER BELT SIDE
Check for the following, and replace with new parts
if necessary.
 Seat belt is slackened, bent, or frayed. Seat belt
is abnormally wound or extended.
2. OUTER BELT CENTER
Check for the following, and replace with new parts
if necessary.
 Seat belt is slackened, bent, or frayed. Seat belt
is abnormally wound or extended.
3. INNER BELT
Check for the following, and replace with new parts
if necessary.
 Inner belt is deformed or damaged.
 Seat belt buckle is engaged improperly.
SB-00036
SB-00014

SB-14
SEAT BELT SYSTEM
Disposal of Pretensioner
6. Disposal of Pretensioner
A: CAUTION
 Do not discard undeployed pretensioners, because
they may cause serious personal injury when acci-
dentally deployed.
 Deployment of the pretensioners should be done
on a flat place free from any possible danger. Avoid
deploying outdoors during heavy rainy or strong
windy weather.
 Do not drop or damage the pretensioner.
 Because deploying the pretensioners 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 after deployment of
the pretensioners. Therefore, it must be deployed
in a well-ventilated area with no smoke alarms
nearby.
 Wear gloves, goggles, and earplugs during this
operation. Wash your hands afterwards.
 After deployment, the pretensioner is especially
hot. Leave it unattended for 40 minutes or longer,
and then discard it.
 Do not let water get on the deployed pretension-
er.
 Wrap the deployed pretensioner in an airtight vi-
nyl bag, and then discard it.
 If circumstances do not permit pretensioner de-
ployment, contact a SUBARU dealer.
B: OPERATION
1. DEPLOYING OF PRETENSIONER WHILE
INSTALLED IN VEHICLE
1) Fold backrest all the way forward, and then
move front seat all the way forward.
2) Turn the ignition switch to OFF, disconnect the
ground cable from battery, and wait for more than
20 seconds before starting work.
3) Remove the center pillar lower trim. 44, REMOVAL, Lower Inner Trim.>
4) Disconnect the connector (A) of pretensioner.
5) Short the terminal to alligator clip furnished as
deployment tool (A).6) Connect the deployment tool and deployment
adapter D (B).
CAUTION:
The deployment tool terminals should be kept
shorted until just before deployment of the pre-
tensioner.
7) Connect the deployment adapter D connector and
pretensioner yellow connector.
8) Extend the deployment tool to the limit, and
make sure that the vehicle is empty. Close all win-
dows, sunroof, and rear gate completely.
9) Move the battery at least 5 m (16 ft) from the ve-
hicle, and secure the nearby area. Connect the de-
ployment tool alligator clip to the battery negative (−
) terminal.
10) Connect the other cable of deployment tool to
the battery positive (+) terminal. Then deploy the
pretensioner.
SB-00129
(A)
(A) Deployment tool: (Tool No. 98299PA030)
(B) Deployment adapter D: (Tool No. 98299SA010)
SB-00021
(A)
(B)
SB-00017
SB-00018

SEAT BELT SYSTEM
Disposal of Pretensioner
CAUTION:
 After deployment, pretensioner is especially
hot. Leave it unattended for 40 minutes or long-
er.
 Do not let water get on the deployed preten-
sioner.
11) Perform the following steps 12) through 17) for
the vehicle with lap pretensioner.
12) Disconnect the orange connector (a) from lap
pretensioner.
13) Connect the deployment tool (A) and deploy-
ment adapter F (B).
CAUTION:
The deployment tool terminals should be kept
shorted until just before deployment of the pre-
tensioner.
14) Connect the deployment adapter F connector
and lap seat belt pretensioner orange connector.15) Extened the deployment tool to the limit, and
make sure that the vehicle is empty. Close all win-
dows, sunroof and rear gate completely.
16) Move the battery at least 5 m (16 ft) from the
vehicle, and secure the nearby area. Connect the
deployment tool alligator clip to the battery negative
(
− ) terminal.
17) Connect the other cable of deployment tool to
the battery positive (+) terminal. Then deploy the
pretensioner.
CAUTION:
 After deployment, pretensioner is especially
hot. Leave it unattended for 40 minutes or long-
er.
 Do not let water get on the deployed preten-
sioner.
18) Remove the front outer belt. REMOVAL, Front Seat Belt.>
19) Wrap the deployed pretensioner in an airtight
vinyl bag, and discard it.
(A) Deployment tool: (Tool No. 98299PA030)
(B) Deployment adapter F: (Tool No. 98299SA050)
SB-00020
(a)
SB-00021
(A)
(B)
SB-00017
SB-00018
SB-00131
SB-15