Removal SUBARU FORESTER 2004 Service Service Manual

SB-16
SEAT BELT SYSTEM
Disposal of Pretensioner
2. DEPLOYING OF RETRACTOR PRETEN-
SIONER AFTER REMOVAL FROM VEHICLE
1) Fold backrest all the way forward, 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 front outer belt. MOVAL, Front Seat Belt.>
4) Cut off the seat belt as close to retractor as pos-
sible.
5) Short the terminal to alligator clip furnished as a
deployment tool.
6) Connect the deployment tool (A) and deploy-
ment 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) Install the pretensioner on a wheel with tire.
Then, bundle three wire automotive harness [each
with a sectional area of 1.25 mm
2 (0.00194 sq in) or
more], and bind them twofold around the preten-
sioner bracket and wheel.
9) Put three tires without a wheel on the tire in-
stalled with pretensioner. 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 the
vehicle, and secure the nearby area. Connect the
deployment tool alligator clip to the battery negative
(−) terminal.
(A) Deployment tool: (Tool No. 98299PA030)
(B) Deployment adapter D: (Tool No. 98299SA010)
SB-00130
SB-00021
(A)
(B)
(1) 5 m (16 ft) or more
SB-00024
SB-00025
SB-00065
(1)

SB-17
SEAT BELT SYSTEM
Disposal of Pretensioner
11) 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.
12) Wrap the deployed pretensioner in an airtight
vinyl bag, and discard it.
3. DEPLOYING LAP PRETENSIONER AF-
TER REMOVAL FROM VEHICLE
1) Fold backrest all the way forward, 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 fornt outer belt. MOVAL, Front Seat Belt.>
4) Cut off the seat belt as close to lap seat belt pre-
tensioner as possible.5) Short the terminal to alligator clip furnished as a
deployment tool (A).
6) Connect the deployment tool and deployment
adapter F (B).
CAUTION:
The deployment tool terminals should be kept
shorted until just before deployment of the pre-
tensioner.
7) Connect the deployment adapter F connector to
pretensioner yellow connector.
8) Install the pretensioner on a wheel with tire.
Then, bundle three wire automotive harness [each
with a sectional area of 1.25 mm
2 (0.00194 sq in) or
more], and bind them twofold around the preten-
sioner bracket and wheel.
9) Put three tires without a wheel on the tire in-
stalled with pretensioner. Put on an additional tire
with a wheel on top, and then fasten them tight with
a rope.
SB-00018
SB-00131
SB-00027
(A) Deployment tool: (Tool No. 98299PA030)
(B) Deployment adapter F: (Tool No. 98299SA050)
SB-00021
(A)
(B)
SB-00028
SB-00025

LI-11
LIGHTING SYSTEM
Combination Switch (Light)
10.Combination Switch (Light)
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the instrument panel lower cover. to EI-40, REMOVAL, Instrument Panel Assembly.>
3) Remove the screw which secure upper column
cover to lower column cover.
4) Disconnect the connector from combination switch.
5) Remove the screws which secure switch, and
then remove the switch.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
Measure the combination switch resistance.
1. LIGHTING SWITCH
LHD and RHD model with rear fog light:
RHD model without rear fog light:
LI-00009
LI-00068
(A) Lighting & turn signal switch connector (LHD
and RHD model with rear fog light)
(B) Lighting & turn signal switch connector (RHD
model without rear fog light)
(C) Parking switch connector
Switch position Terminal No. Standard
OFF — More than 1 MΩ
Tail 14 and 16 Less than 1 Ω
Head 13, 14 and 16 Less than 1 Ω
Switch position Terminal No. Standard
OFF — More than 1 MΩ
Tail 9 and 15 Less than 1 Ω
Head 9, 14 and 15 Less than 1 Ω
LI-00066
1514131211109171665432187
1514
2143
131211109171665432187
(A)
(B)
(C)

LI-13
LIGHTING SYSTEM
Headlight Assembly
11.Headlight Assembly
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the air intake duct (when removing the
headlight RH). Air Intake Duct.>
3) Remove the front grille and headlight side cover.
EI-23, REMOVAL, Front Bumper.>
4) Disconnect the headlight bulb connector.
5) Remove the three bolts, and disconnect the con-
nectors, and then detach the headlight assembly.
B: INSTALLATION
Install in the reverse order of removal.
C: DISASSEMBLY
CAUTION:
 Do not touch the bulb glass portion.
 Do not touch inside the lens (extension por-
tion) or reflector portion.
 Replace the packing with a new one.
1) Remove the headlight assembly. REMOVAL, Headlight Assembly.>2) Remove the five screws.
3) Remove the two clips.
4) Remove the rubber cap, and then detach the
bulb.
5) Heat the seal portion using a dryer through the
bulb mounting hole.
CAUTION:
Avoid heating one specific point of the seal por-
tion and heating the headlight assembly to
120°C (248°F) or more.
6) Unhook the hook, and then take the lens off the
headlight assembly.
LI-00012
LI-00013
LI-00045
LI-00046
LI-00059
LI-00047

LI-16
LIGHTING SYSTEM
Headlight Bulb
12.Headlight Bulb
A: REMOVAL
CAUTION:
 Because the halogen bulb operates at a high
temperature, dirt and oil on the bulb surface re-
duces the bulb’s service life. Hold the flange
portion when replacing the bulb. Never touch
the glass portion.
 Do not leave the headlight without a bulb for
a long time. Dust, moisture, etc. entering the
headlight may affect its performance.
1) Disconnect the ground cable from battery.
2) Remove the air intake duct (when removing the
headlight RH).
3) Disconnect the harness connector.
4) Remove the rubber cap.
5) Remove the light bulb retaining spring to remove
the bulb.
B: INSTALLATION
Install in the reverse order of removal.
CAUTION:
Attach the rubber cap with letters TOP on the
top so the drain hole will be on the lower side.
C: INSPECTION
1) Visually check the bulb for blow out.
2) Check the bulb specification. SPECIFICATION, General Description.>
3) If NG, replace the bulb with a new one.
LI-00017
LI-00018

LI-17
LIGHTING SYSTEM
Front Turn Signal Light Bulb
13.Front Turn Signal Light Bulb
A: REMOVAL
1) Remove the headlight assembly. REMOVAL, Headlight Assembly.>
2) Turn the socket and remove the bulb.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
1) Visually check the bulb for blow out.
2) Check the bulb specification. SPECIFICATION, General Description.>
3) If NG, replace the bulb with a new one.
LI-00021

LI-18
LIGHTING SYSTEM
Clearance Light Bulb
14.Clearance Light Bulb
A: REMOVAL
1) Remove the headlight assembly. REMOVAL, Headlight Assembly.>
2) Turn the socket and remove the bulb.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
1) Visually check the bulb for blow out.
2) Check the bulb specification. SPECIFICATION, General Description.>
3) If NG, replace the bulb with a new one.
LI-00022

LI-19
LIGHTING SYSTEM
Front Fog Light Assembly
15.Front Fog Light Assembly
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the two clips and lower mudguard.
3) Disconnect the harness connector.
4) Remove the lower bolts.
5) Remove the mounting bolts and clip, and then
detach the fog light assembly.
B: INSTALLATION
Install in the reverse order of removal.
LI-00023
LI-00024
LI-00025

LI-20
LIGHTING SYSTEM
Front Fog Light Bulb
16.Front Fog Light Bulb
A: REMOVAL
1) Remove the front fog light assembly. 19, REMOVAL, Front Fog Light Assembly.>
2) Remove the back cover.
3) Remove the spring retainer, and then detach the
fog light bulb.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
1) Visually check the bulb for blow out.
2) Check the bulb specification. SPECIFICATION, General Description.>
3) If NG, replace the bulb with a new one.
LI-00026
LI-00027

LI-21
LIGHTING SYSTEM
Rear Combination Light Assembly
17.Rear Combination Light As-
sembly
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the two bolts, and then turn the socket
and disconnect cord assembly to remove rear com-
bination light.
B: INSTALLATION
Install in the reverse order of removal.
LI-00028
LI-00029