steering SUBARU FORESTER 2004 Service Repair Manual

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-14
AIRBAG SYSTEM
Driver’s Airbag Module
4. Driver’s Airbag Module
A: REMOVAL
CAUTION:
Refer to “CAUTION” in General Description be-
fore handing the airbag module. CAUTION, General Description.>
1) Position the front wheels straight ahead. (After
moving the vehicle more than 5 m (16 ft) with front
wheels positioned straight ahead, make sure that
the vehicle moves straight ahead).
2) Turn the ignition switch to OFF.
3) Disconnect the ground cable from battery, and
wait for at least 20 seconds before starting work.
4) Using the TORX
® BIT T30, remove the two
TORX® bolts on side of steering wheel.
5) Disconnect the airbag connector on the back of
airbag module, and then remove the airbag mod-
ule.
6) Refer to “CAUTION” for handling of removed air-
bag module. scription.>
B: INSTALLATION
Install in the reverse order of removal.
CAUTION:
Do not allow harness and connectors to inter-
fere or get tangled up with other parts.
Tightening torque:
Refer to “COMPONENT” in “General Descrip-
tion” NENT, General Description.>
C: INSPECTION
CAUTION:
Refer to “CAUTION” in General Description be-
fore handing the airbag module. CAUTION, General Description.>
Check for the following, and replace damaged
parts with new ones.
 Airbag module, harness, connector, and mounting
bracket are damaged. AIRBAG MODULE, INSPECTION, Inspection Lo-
cations After a Collision.>
(1)
TORX® BIT T30
CC-00018
(1)
AB-00033

AB-20
AIRBAG SYSTEM
Roll Connector
9. Roll Connector
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 driver’s airbag module. 14, Driver’s Airbag Module.>
4) Remove the steering wheel. MOVAL, Steering Wheel.>
5) Remove the steering column cover.
6) Remove the screws, and then remove the roll
connector.
B: INSTALLATION
1) Install in the reverse order of removal.
2) Before installing the steering wheel, be sure the
direction of roll connector is adjusted with steering.

C: INSPECTION
Check for the following, and replace damaged parts
with new parts.
 Combination switch and roll connector are cracked
or deformed.
D: ADJUSTMENT
1) Check that the front wheels are positioned in
straight ahead direction.
2) Turn the roll connector pin (A) clockwise until it
stops.
3) Turn the roll connector pin (A) counterclockwise
approx. 2.65 turns until “▲” marks are aligned.
AB-00593
AB-00594
(A)

AB-22
AIRBAG SYSTEM
Airbag Module Disposal (Deployment Processing On Vehicle)
11.Airbag Module Disposal (De-
ployment Processing On Ve-
hicle)
A: OPERATION
CAUTION:
 Do not discard an undeployed airbag mod-
ules because it may cause a serious personal
injury when accidentally deployed.
 As a rule, the airbag module should be de-
ployed while still installed in the vehicle. Do not
remove the airbag modules unless necessary.
 Deployment of the airbag module should be
done on a flat place free from any possible dan-
ger. Avoid deploying outdoors during rainy or
windy weather.
 Deploying the airbag module 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 from deployment
of the airbag module. Therefore, it must be de-
ployed in a well-ventilated place with no smoke
detector nearby.
 Wear protective gloves, safety goggles and
earplugs during this operation. Wash your hands
afterwards.
 After deployment, the airbag module will be
especially hot, leave it unattended for 40 min-
utes, and then discard it.
 Do not let water get on the deployed airbag
module.
 Wrap the deployed airbag module in an air-
tight vinyl bag, and discard it.
 If circumstances do not permit the airbag
module deployment, contact the SUBARU deal-
er.
1. DRIVER’S AIRBAG MODULE
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 lower cover. MOVAL, Instrument Panel Assembly.>4) Disconnect the airbag connector (AB30) and
(AB2) below steering column.
5) Short the terminal to alligator clip furnished as
deployment tool (A).
6) Connect the deployment tool and deployment
adapter A (B).
CAUTION:
The deployment tool should be kept shorted
terminals until just before deployment of airbag
module.
7) Connect the deployment adapter A to airbag
connector (AB30).
(A) Deployment tool:
(Tool number 98299PA030)
(B) Deployment adapter A:
(Tool number 98299SA030)
(1) Deployment adapter A:
(Tool number 98299SA030)
AB-00197
AB30
AB2
SB-00016
AB-00198
AB30
(1)

AB-3
AIRBAG SYSTEM (DIAGNOSTIC)
Check List for Interview
2. Check List for Interview
A: CHECK
Customer’s Name Inspector’s Name
Date Vehicle Brought In / / Registration No.
Odometer Readingkm
milesVIN
Date Problem Occurred / / Registration Year / /
Weather❏ Fine ❏ Cloudy ❏ Rainy ❏ Snowy ❏ Other:
Temperature°C (°F)
Road Condition❏ Level road❏ Uphill ❏ Downhill❏ Rough road ❏ Others:
Vehicle Operation❏ Starting❏ Idling
❏ Driving (❏ Constant speed❏ Acceleration❏ Deceleration
❏ Steering wheel turn❏ Others: )
Details of Problem
Check Airbag Warning Light❏ Normal (After turning the ignition switch to ON, lit for 7 seconds and goes off.)
❏ Remains ON❏ Remains OFF
Check DTC❏ Normal Code❏ DTC: (Code: )

AB-22
AIRBAG SYSTEM (DIAGNOSTIC)
Airbag Control Module I/O Signal
WI-03205
AIRBAG CONTROL MODULE
L1G2YBr 1BR
2
AB13 (YELLOW) (BLACK)
(YELLOW)(YELLOW) INFLATOR (DRIVER SIDE)STEERING
ROLL CONNECTOR FRONT SUB SENSOR LH
FRONT SUB SENSOR RH
INFLATOR (PASSENGER SIDE)
(YELLOW)AB15(YELLOW)AB3
(YELLOW)
AB18
AB2
AB3
AB15AB18
AB4
GA
LWG
YLYWYBY
AB21
AB26YL 2YW1
15 26
YBrBR
9 20
13 147 8
YL 2YW 1Y
2
BW
28
YB
1
YGYR
11 10
YR 4YG
3
1212
AB21
BW
GAB-1
B
27
B
A/B(L)-02
A/B(L)-02
1234567891011121314151617
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AB4
1
234
AB14
AB13
LW 2G1
AB2
21

AB-25
AIRBAG SYSTEM (DIAGNOSTIC)
Airbag Control Module I/O Signal
WI-03207
AIRBAG CONTROL MODULE
L1G2P1Br 2
INFLATOR (DRIVER SIDE)FRONT SUB SENSOR LH
FRONT SUB SENSOR RH
INFLATOR (PASSENGER SIDE)
AB2
AB3
AB15AB18
AB4
GA
LG
YYBYBY
AB14
AB13P2Br
PBr 1
15 26
PBR
9 20
13 147 8
Y 2YB 1Y 2
B
28
YB 1
YGYR
11 10
YR 4YG 3B
A/B(R)-02
A/B(R)-02
STEERING
ROLL CONNECTOR
AB21
AB26Y2YB 1
AB13 (YELLOW) (BLACK)
(YELLOW)(YELLOW) (YELLOW)AB15(YELLOW)AB3
(YELLOW)
AB18
1212
AB211234567891011121314151617
1819202122232425262728
AB4
1
234
AB2
21

AB-46
AIRBAG SYSTEM (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
13.Diagnostic Procedure with Diagnostic Trouble Code (DTC)
A: DTC 11
DIAGNOSIS:
 Airbag main harness circuit is open, shorted or shorted to ground.
 Airbag module harness circuit (Driver) is open, shorted or shorted to ground.
 Roll connector circuit is open, shorted or shorted to ground.
 Driver’s airbag module is faulty.
 Airbag control module is faulty.
CAUTION:
 Before diagnosing the airbag system, be sure to turn the ignition switch to OFF, disconnect the
ground cable from battery, and wait more than 20 seconds before starting to work.
 When replacing the airbag module, seat belt pretensioner, roll connector, control module and sen-
sor, confirm that airbag warning light is turn normally after reconnect the each parts.
 When inspecting the airbag main harness, disconnect the driver’s airbag module and passenger’s
airbag module connectors for safety reasons.
WIRING DIAGRAM:
AB-00741
AB3
AB21
AB26
AB222
11
14
13
AB21AB3AB2
1212
AIRBAG CONTROL MODULE
STEERING
ROLL CONNECTOR
INFLATOR
(DRIVER SIDE)
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1819202122232425262728

AB-50
AIRBAG SYSTEM (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
C: DTC 15
DIAGNOSIS:
 Airbag main harness circuit (Driver) is shorted to the power supply.
 Airbag module harness (Driver) is shorted to the power supply.
 Roll connector is shorted to the power supply.
 Driver’s airbag module is faulty.
 Airbag control module is faulty.
CAUTION:
 Before diagnosing the airbag system, be sure to turn the ignition switch to OFF, disconnect the
ground cable from battery, and wait more than 20 seconds before starting to work.
 After replacing the airbag module, seat belt pretensioner, roll connector, control module or sensor,
reconnect each part and confirm that the airbag warning light operates properly.
 When inspecting the airbag main harness, disconnect the driver’s airbag module and passenger’s
airbag module connectors for safety reasons.
WIRING DIAGRAM:
AB-00741
AB3
AB21
AB26
AB222
11
14
13
AB21AB3AB2
1212
AIRBAG CONTROL MODULE
STEERING
ROLL CONNECTOR
INFLATOR
(DRIVER SIDE)
1234567891011121314151617
1819202122232425262728