airbag SUBARU FORESTER 2004 Service Repair Manual

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

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

AC-3
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
General Description
2. General Description
A: CAUTION
1) Never connect the battery in reverse polarity.
Auto A/C control module may be destroyed instant-
ly.
2) Do not disconnect the battery terminals while the
engine is running.
A large counter electromotive force will be generat-
ed in the generator, and this voltage may damage
electronic parts such as auto A/C control module,
etc.
3) Before disconnecting the connectors of each
sensor and the auto A/C control module, be sure to
turn off the ignition switch.
Auto A/C control module may be damaged.
4) Every A/C-related part is a precision part. Do not
drop them.
5) Airbag system wiring harness is routed near the
A/C control panel (auto A/C control module) and
junction box.
CAUTION:
 For airbag system, yellow-colored wiring har-
ness and connectors are all used. Do not use
the electrical test equipment on these circuits.
 Be careful not to damage the airbag system
wiring harness when servicing the A/C control
panel (auto A/C control module) and junction
box.
B: INSPECTION
Before performing the diagnosis, check the follow-
ing items which might affect A/C system problems.
1. BATTERY
1) Measure battery voltage and specific gravity of
electrolyte.
Standard voltage: 12 V
Specific gravity: More than 1.260
2) Check the condition of the fuses for A/C system
power supply and other fuses.
3) Check the condition of harness and harness
connector connections.
2. ASPIRATOR HOSE
1) Turn the ignition switch to ON, and press the A/
C switch.
2) Turn the temperature control dial at maximum
hot position.
3) Press the defroster switch.
4) Turn the fan speed control dial to 4th position.5) Approach a strip of paper (b) in front of the in-ve-
hicle sensor suction port (a) located in the instru-
ment lower cover, and check that air is being
sucked into the port by seeing the paper moving to-
wards port.
NOTE:
Be careful not to let the paper get sucked into port.
6) If the paper does not move at all, remove the in-
strument panel lower cover MOVAL, Instrument Panel Assembly.> and check
for improper connection of the aspirator hose (a),
in-vehicle sensor and heater unit, and repair them if
necessary.
3. A/C LINE
Check the connection for A/C line (A) and lower
side high-pressure pipe.
4. CONTROL LINKAGE
1) Check the state of mode door linkage.
2) Check the state of air mix door linkage.
3) Check the state of intake door linkage.
AC-00094
(a)
(a)
(b)
AC-00065
(a)
AC-00096
(A)

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

AIRBAG SYSTEM
AB
Page
1. General Description ....................................................................................2
2. Airbag Connector ........................................................................................9
3. Inspection Locations After a Collision .......................................................12
4. Driver’s Airbag Module ..............................................................................14
5. Passenger’s Airbag Module ......................................................................15
6. Side Airbag Module ...................................................................................16
7. Airbag Control Module ..............................................................................18
8. Side Airbag Sensor ...................................................................................19
9. Roll Connector ..........................................................................................20
10. Front Sub Sensor ......................................................................................21
11. Airbag Module Disposal (Deployment Processing On Vehicle) ................22
12. Disposal of Airbag Module (Deploying After Removal from Vehicle) ........26

AB-2
AIRBAG SYSTEM
General Description
1. General Description
A: COMPONENT
1. SRS AIRBAG
(1) Combination switch ASSY with roll
connector(5) Airbag control moduleTightening torque: N·m (kgf-m, ft-lb)
(6) Side airbag sensorT1: 5.9 (0.59, 4.4)
(2)
TORX
® bolt T30(7) Wiring harness rear
T2: 7.4 (0.75, 5.4)
(3) Airbag module ASSY (Driver’s
side)(8) Side airbag moduleT3: 10 (1.0, 7.2)
(9) Wiring harness CTRT4: 20 (2.0, 14.5)
(4) Airbag module ASSY (Passen-
ger’s side)(10) Wiring harness frontT5: 25 (2.5, 18.1)
(11) Front sub sensor
AB-00685
T3
T2
T5
T3
T4(2)(4)
(3) (1)
(2)
(10)
(11)
(9)
(7)(6) (5)
(8)T2
T1

AB-3
AIRBAG SYSTEM
General Description
B: 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 the airbag warning light illuminates, repair the
vehicle immediately. Airbag or pretensioner may in-
flate incorrectly, or not inflate in collision.
 If sensors, airbag module, airbag control module,
pretensioner or harness are deformed or damaged,
replace them with new parts.
 When checking the airbag system, be sure to
use a digital circuit tester.
Infinitesimal electric current in an analog circuit
tester may cause the airbag to activate erroneous-
ly. When checking, use a test harness (1). Do not
directly apply the tester probe to any connector ter-
minal of the airbag. Damage to the connector termi-
nal may cause the airbag to activate erroneously.
 Do not check continuity of either of the airbag
modules for driver, passenger or side, or preten-
sioner.
FU-00009
AB-00120
AB-00121
AB-00122
(1)
AB-00006

AB-4
AIRBAG SYSTEM
General Description
 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.
 If any damage, opening, or rust is found on the
airbag system wire harness, do not attempt to re-
pair using soldering equipment. Be sure to replace
the faulty harness with a new genuine part.
 Install the wire harness securely with the speci-
fied 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 removed front seat with the airbag module
must be kept at least 200 mm (8 in) away from walls
and other objects.
 Do not use the airbag or pretensioner parts from
other vehicles. Always replace defective parts with
new ones.
 Never reuse a deployed airbag or pretensioner.
 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.
AB-00123
AB-00124
AB-00125
(1) More than 200 mm (8 in)
AB-00126
AB-00779
AB-00128
(1)

AB-5
AIRBAG SYSTEM
General Description
 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 wire harness of the airbag
system.
AB-00129

AB-6
AIRBAG SYSTEM
General Description
 When storing a removed airbag module, do not place any objects on it or pile airbag modules on top of
each other. If the airbag inflates for some reason when it is placed with its pad side facing downward or under
any object, a serious accident may result.
(1) Driver’s airbag module (2) Passenger’s airbag module
AB-00130
(2) (1)