replace SUBARU FORESTER 2004 Service Manual Online
[x] Cancel search | Manufacturer: SUBARU, Model Year: 2004, Model line: FORESTER, Model: SUBARU FORESTER 2004Pages: 2870, PDF Size: 38.67 MB
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 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.
Page 232 of 2870
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).
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.
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.
Module.>Replace the side
airbag harness
with body harness.
Page 233 of 2870
FUJI HEAVY INDUSTRIES LTD. G8080GE7
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
BODY SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.HVAC SYSTEM
(HEATER, VENTILATOR AND A/C)AC
HVAC SYSTEM (AUTO A/C)
(DIAGNOSTIC)AC
AIRBAG SYSTEM AB
AIRBAG SYSTEM (DIAGNOSTIC) AB
SEAT BELT SYSTEM SB
LIGHTING SYSTEM LI
WIPER AND WASHER SYSTEM WW
ENTERTAINMENT ET
COMMUNICATION SYSTEM COM
GLASS/WINDOW/MIRROR GW
BODY STRUCTURE BS
INSTRUMENTATION/DRIVER INFO IDI
SEAT SE
SECURITY AND LOCK SL
SUNROOF/T-TOP/CONVERTIBLE TOP
(SUNROOF)SR
EXTERIOR/INTERIOR TRIM EI
EXTERIOR BODY PANEL EB
Page 238 of 2870
SB-4
SEAT BELT SYSTEM
General Description
B: CAUTION
Before starting, turn the ignition switch to OFF,
disconnect the battery ground cable and wait for 20
seconds or more.
The pretension system has a backup power source.
The pretensioner might deploy if you do not wait for 20
seconds or more before starting work.
Do not drop or apply any impact to the preten-
sioner.
If oil, grease, or water gets on the pretensioner,
wipe it off immediately with a dry cloth.
Do not expose the pretensioner to high tempera-
ture or flame.
Do not allow current to flow through or voltage to
reach the pretensioner. Do not use a circuit tester
to check resistance of the pretensioner.
Do not disassemble or attempt to repair the pre-
tensioner. If it is dented, cracked, or deformed, re-
place it with a new one.
Do not use the airbag or pretensioner parts from
other vehicles. Always replace parts with new
parts.
When handling a seat belt with a deployed pre-
tensioner, wear gloves and goggles. Wash your
hands afterwards.
Do not re-use a seat belt with a deployed preten-
sioner again.
Be sure to deploy pretensioner before disposal.
If the material gets in your eyes or on your skin
during deployment, wash it away with clean water,
and then consult a doctor.
Page 240 of 2870
SB-6
SEAT BELT SYSTEM
Inspection Locations After a Collision
2. Inspection Locations After a
Collision
A: INSPECTION
Check for the following, and then replace with new
parts if necessary.
Center pillar lower garnish is discolored or cracked.
Wiring harness and/or connector is damaged.
Page 242 of 2870
SB-8
SEAT BELT SYSTEM
Seat Belt Warning System
6 CHECK HARNESS BETWEEN SEAT BELT
SWITCH AND CHASSIS GROUND.
Measure the resistance of harness between
seat belt switch and chassis ground.
Connector & terminal
(R8) No. 1 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 7.Repair the open
circuit of harness
between seat belt
switch and chas-
sis ground.
7 CHECK SEAT BELT SWITCH.
1) Hold the tang plate disconnected from seat
belt buckle.
2) Measure the resistance between seat belt
switch terminals.
Te r m i n a l s
(R8) No. 1 — (R8) No. 2:Is the resistance less than 1
Ω?Go to step 8.Replace the inner
belt assembly.
8 CHECK SEAT BELT SWITCH.
1) Insert the tang plate into seat belt buckle.
2) Measure the resistance between seat belt
switch terminals.
Te r m i n a l s
(R8) No. 1 — (R8) No. 2:Is the resistance more than 1
MΩ?Go to step 9.Replace the inner
belt assembly.
9 CHECK OPERATION OF SPEEDOMETER IN
COMBINATION METER.
Check the speedometer indicates vehicle
speed correctly.Does the speedometer operate
correctly?Go to step 10.Check the speed-
ometer circuit.
10 CHECK VEHICLE MODEL.
Check the model of vehicle.Is the vehicle MT model? Go to step 11.Go to step 13.
11 CHECK HARNESS BETWEEN VEHICLE
SPEED SENSOR AND SEAT BELT TIMER
MODULE.
1) Turn the ignition switch to OFF.
2) Disconnect the connector of vehicle speed
sensor.
3) Measure the resistance between vehicle
speed sensor harness connector and seat belt
timer module connector.
Connector & terminal
(B17) No. 1 — (B44) No. 7:Is the resistance less than 10
Ω?Go to step 12.Repair the open
harness between
vehicle speed sen-
sor and seat belt
timer module.
12 CHECK HARNESS BETWEEN VEHICLE
SPEED SENSOR AND SEAT BELT TIMER
MODULE.
Measure the resistance between seat belt
timer module harness connector and chassis
ground.
Connector & terminal
(B44) No. 7 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 15.Repair the short of
harness.
13 CHECK HARNESS BETWEEN TCU AND
SEAT BELT TIMER MODULE.
1) Turn the ignition switch to OFF.
2) Disconnect the connector of TCU.
3) Measure the resistance of harness
between TCU harness connector and seat belt
timer module harness connector
Connector & terminal
(B56) No. 17 — (B44) No. 7:Is the resistance less than 10
Ω?Go to step 14.Repair the open
harness between
TCU and seat belt
timer module. Step Check Yes No
Page 243 of 2870
SB-9
SEAT BELT SYSTEM
Seat Belt Warning System
14 CHECK HARNESS BETWEEN TCU AND
SEAT BELT TIMER MODULE.
Measure the resistance between seat belt
timer module harness connector and chassis
ground.
Connector & terminal
(B44) No. 7 — Chassis ground:Is the resistance less than 10
Ω?Go to step 15.Repair the short of
harness.
15 CHECK SEAT BELT TIMER MODULE OUT-
PUT SIGNAL.
1) Turn the ignition switch to ON.
2) Measure the voltage between seat belt
timer module harness connector and chassis
ground.
Connector & terminal
(B44) No. 2 (+) — Chassis ground (–):Is the voltage more than 10 V? Go to step 16.Check the wiring
harness and com-
bination meter,
and then repair or
replace them.
16 CHECK POOR CONTACT.
Check the poor contact of seat belt warning
light circuit.Is there any poor contact
occurs?Repair the poor
contact.Go to step 17.
17 CHECK SEAT BELT TIMER MODULE.
1) Connect all connectors.
2) Lift-up the vehicle and place rigid racks.
NOTE:
Raise all wheels off floor.
3) Hold the tang plate disconnected from seat
belt buckle.
4) Start the engine, and set the vehicle speed
less than 19 km/h (12 MPH)
N
OTE:
The speed difference between front and rear
wheels may light the ABS warning light, but this
indicates no malfunction. When diagnosis is fin-
ished, perform the ABS memory clearance pro-
cedure of OBD system.
Check seat belt warning light comes on.Does the seat belt warning
light come on?Go to step 18.Replace the seat
belt timer module.
18 CHECK SEAT BELT TIMER MODULE.
1) Connect all connectors.
2) Lift-up the vehicle and place rigid racks.
N
OTE:
Raise all wheels off floor.
3) Hold the tang plate disconnected from seat
belt buckle.
4) Start the engine, and set the vehicle speed
more than 25 km/h (16 MPH).
NOTE:
The speed difference between front and rear
wheels may light the ABS warning light, but this
indicates no malfunction. When diagnosis is fin-
ished, perform the ABS memory clearance pro-
cedure of OBD system.
Check seat belt warning light comes on and
buzzer beeps.Does the seat belt warning
light come on and buzzer
beep?Temporary poor
contact of connec-
tor or harness may
be the cause.
Check the poor
contact.Replace the seat
belt timer module. Step Check Yes No
Page 245 of 2870
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:
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:
3. FRONT INNER BELT
Install in the reverse order of removal.
Tightening torque:
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
Page 247 of 2870
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:
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:
3. INNER BELT
Install in the reverse order of removal.
CAUTION:
During installation, make sure that the seat
belts are not twisted.
Tightening torque:
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