sensor SUBARU FORESTER 2004 Service Owner's Guide

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-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-13
AIRBAG SYSTEM
Inspection Locations After a Collision
5. FRONT SUB SENSOR
If the front section of vehicle as shown in the figure
is damaged:
Check for the following, and replace damaged
parts with new ones.
 Front sub sensor is cracked or deformed.
 Mounting bracket is cracked or deformed.
 Connector is scratched or cracked.
 Airbag is deployed.
6. SIDE AIRBAG SENSOR
If the side section of vehicle as shown in the figure
is damaged:
Check for the following, and replace damaged
parts with new ones.
 Side airbag sensor is cracked or deformed.
 Mounting bracket is cracked or deformed.
 Connector is scratched or cracked.
 Side airbag is deployed. (operating side)
7. ROLL CONNECTOR
Check for the following, and replace damaged
parts with new ones.
 Combination switch or steering roll connector is
cracked or deformed.
8. STEERING SHAFT
Check for the following, and replace damaged
parts with new ones.
 Overall length of steering column should be with-
in specifications.
Specifications:
Overall length L
815.6
±1.5 mm (32.1±0.06 in)
If necessary, replace it with a new part.
AB-00029
AB-00030
AB-00717
L

AB-19
AIRBAG SYSTEM
Side Airbag Sensor
8. Side Airbag Sensor
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 outer belt (FRONT). 10, FRONT OUTER BELT, REMOVAL, Front Seat
Belt.>
4) Detach the side airbag sensor, and then discon-
nect the airbag connector.
B: INSTALLATION
CAUTION:
Use new TORX® bolts T30 when reassembling.
Install in the reverse order of removal.
Tightening torque:
Refer to “COMPONENT” in “General Descrip-
tion” NENT, General Description.>
C: INSPECTION
Check for the following, and replace damaged
parts with new parts.
 Bracket connector for side airbag sensor is dam-
aged.
 Side airbag is deployed.
AB-00036

AB-21
AIRBAG SYSTEM
Front Sub Sensor
10.Front Sub Sensor
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 front grille and front grille side.

4) Disconnect the connector from front sub sensor.
5) Loosen the nut, and then detach the front sub
sensor.
B: INSTALLATION
CAUTION:
Use new nuts when reassembling.
Install in the reverse order of removal.
Tightening torque:
Refer to “COMPONENT” in “General Descrip-
tion” NENT, General Description.>
C: INSPECTION
Check for the following, and replace damaged parts
with new parts.
 Front sub sensor, mounting bracket, and con-
nector are damaged.
 Airbag is deployed.
AB-00040
AB-00116

AB-4
AIRBAG SYSTEM (DIAGNOSTIC)
General Description
3. General Description
A: CAUTION
 When servicing a vehicle, be sure to turn the ig-
nition switch to OFF, disconnect the ground cable
from battery, and wait for more than 20 seconds
before starting work.
 The airbag system is fitted with a backup power
source. If the airbag system is serviced within 20
seconds after the ground cable is disconnected, it
may inflate.
 If sensors, airbag module, airbag control module,
pretensioner, and harness are deformed or dam-
aged, replace them with new genuine parts.
 Do not use the airbag system and pretensioners
on other vehicles. When replacing parts, be sure to
replace them with new parts.
 When checking the system, be sure to use a dig-
ital circuit tester. Use of an analog circuit tester may
cause the airbag to activate erroneously. When checking, use a test harness. Do not di-
rectly apply the tester probe to any connector termi-
nal of the airbag.
 Do not drop the airbag modulator parts, subject
them to high temperature over 93°C (199°F), or let
water, oil, or grease get on them; otherwise, the in-
ternal parts may be damaged and reliability greatly
lowered.
AB-00002
AB-00120
AB-00121
(1) Test harness
AB-00122
(1)
AB-00123

AB-6
AIRBAG SYSTEM (DIAGNOSTIC)
General Description
 The removed front seat with the airbag module
must be kept at least 200 mm (8 in) away from walls
and other objects.
 When painting or performing sheet metal work
on the front part of the vehicle, including the front
wheel apron, front fender, and front side frame, re-
move the front sub sensors and wire harness of the
airbag system.
 When painting or performing sheet metal work
on the side of the vehicle, including the side sill,
center pillar, and front and rear doors, remove the
side airbag sensors and wiring harness of the air-
bag system.
 Do not discard undeployed airbag modules.
They could easily cause a serious accident if acci-
dentally deployed.
(1) More than 200 mm (8 in)
AB-00128
(1)
AB-00129

AB-10
AIRBAG SYSTEM (DIAGNOSTIC)
General Description
 TEST HARNESS G
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
98299FC020 TEST HARNESS G Used when measuring voltage, resistance of
side airbag sensor.
3G
2G
1G
ST98299FC020
AB-00428
3G 2G 1G2G
1G 3G
4 3 7
8 6
5
1
23
4 1
2
2
1 4
3
12 3
4567812
341 2
3 4

AB-11
AIRBAG SYSTEM (DIAGNOSTIC)
General Description
 TEST HARNESS H
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
98299FA030 TEST HARNESS H Used when measuring voltage, resistance of
front sub-sensor.
3H2H
1H
ST98299FA030
AB-00720
3H
3H 2H 1H2H
1H 4 3
6 5
1
345621
1 2
2
2 121

AB-19
AIRBAG SYSTEM (DIAGNOSTIC)
Electrical Components Location
4. Electrical Components Location
A: LOCATION
1. LHD MODEL
(a) To body harness (b) To seat belt pretensioner (LH) (c) To seat belt pretensioner (RH)
(1) Front sub sensor (LH) (6) Passenger’s airbag inflator (12) Side airbag sensor (LH)
(2) Front sub sensor (RH) (7) Roll connector (13) Side airbag sensor (RH)
(3) Front sub sensor harness (LH) (8) Airbag main harness (14) Side airbag inflator (LH)
(4) Front sub sensor harness (RH) (9) Driver’s airbag inflator (15) Side airbag inflator (RH)
(5)
Airbag control module with built-in
safety and electric sensor(10) Side airbag harness (LH)
(11) Side airbag harness (RH)
Connector
No.(AB1) (AB2) (AB3) (AB4) (AB7) (AB8) (AB9) (AB10) (AB11) (AB12) (AB13) (AB14)
Pole 622841212242422
Color Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow
Male/Female Male Female Female Female Female Female Female Female Female Female Female Male
Connector
No.(AB15) (AB18) (AB19) (AB20) (AB21) (AB26)
Pole 222222
Color Yellow Yellow Yellow Yellow Yellow Yellow
Male/Female Female Female Female Female Female Male
AB-00737
(1)
(2)
(3)
(7) (a)
(9)
(14)
(15)
(13) (11)
(c) (6)
(5)
(8)
(10)
(b)
(12)(4)
AB18
B31
AB1
AB12
AB20AB19
AB10
AB3
AB8
AB15
AB7
AB9
AB4
AB26
AB2
AB21
AB14
AB13
AB11