1999 SUBARU FORESTER Service Repair Manual

1. General
A: PRECAUTION
IIf any of the airbag system parts such as
sensors, airbag module, airbag control module and
harness are damaged or deformed, replace with
new genuine parts.
G5M0291
IWhen servicing, be sure to turn the ignition
switch off, disconnect the negative (þ) battery ter-
minal then the positive (+) terminal in advance, and
wait for more than 20 seconds before starting
work.
G5M0292
IWhen checking the system, be sure to use a
digital circuit tester. Use of an analog circuit tester
may cause the airbag to activate erroneously. Do
not directly apply the tester probe to any connec-
tor terminal of the airbag. When checking, use a
test harness.
G5M0293
G5M0294
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1. General

IDo not drop the airbag modulator parts, subject
it to high temperatures over 90ÉC (194ÉF), or apply
oil, grease, or water to it; otherwise, the internal
parts may be damaged and its reliability greatly
lowered.
G5M0295
IIf any damage or open is found on the SRS air-
bag system wire harness, do not attempt to repair
using soldering, etc. Be sure to replace the faulty
harness with a new genuine part.
G5M0296
IInstall the wire harness securely with the speci-
fied clips so as to avoid interference or jamming
with other parts.
G5M0297
IBefore connecting the airbag system to ground,
make sure that the grounding terminal is free from
paint and contamination.
IDo not allow water or oil to come in contact with
the connector terminals. Do not touch the connec-
tor terminals.
G5M0298
IWhen connecting or disconnecting airbag
connector, make sure ignition switch is OFF.
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1. General

2. Inspection and Replacement
Standards
A: VEHICLES WHICH BECOME
INVOLVED IN A COLLISION
If the vehicle equipped with an SRS airbag system
is damaged in a collision, the airbag system parts
must be checked and replaced in accordance with
the following standards:
IAfter faulty parts are replaced, the warning light
operation must be checked.
IWhen the ignition switch is turned ON, it lights
up for about 7 seconds and then it goes out for at
least 30 seconds.
IThe trouble code stored in memory must be
erased after the check.
B: AIRBAG MODULE (DRIVER AND
PASSENGER)
1. INSPECTION STANDARD
IThe vehicle damaged in a collision (regardless
of whether or not airbag is deployed).
IThe designated trouble code is output during
self-diagnosis.
2. REPLACEMENT STANDARD
IAirbag is deployed.
IThe pad surface is scratched or cracked.
IHarness and/or connector is deformed or
cracked, their circuits are broken, lead wire is
exposed, etc.
IMounting bracket is cracked or deformed.
IThe module surface is fouled with foreign mat-
ter. (grease, oil, water, cleaning solvent, etc.)
IAirbag module dropped to the floor/ground.
IAirbag module determined as faulty during self-
diagnosis.
C: AIRBAG MODULE (SIDE)
1. INSPECTION STANDARD
IThe vehicle damaged in a side collision (regard-
less of whether or not airbag is deployed).
IThe designated trouble code is output during
self-diagnosis.
2. REPLACEMENT STANDARD
ISide airbag is deployed.
IThe front seat assembly is damaged or
deformed.
IHarness and/or connector is deformed or
cracked, their circuits are broken, lead wire is
exposed, etc.
IMounting bracket is cracked or deformed.ISide airbag module determined as faulty during
self-diagnosis.
D: MAIN HARNESS
1. INSPECTION STANDARD
IA vehicle damaged in a collision (regardless of
whether or not airbag is deployed).
IThe designated trouble code is output during
self-diagnosis.
2. REPLACEMENT STANDARD
IHarness circuit is broken, lead wire is exposed,
corrugated tube is cracked, etc.
IConnector is scratched or cracked.
IThe designated trouble code is output during
self-diagnosis.
E: AIRBAG CONTROL MODULE
1. INSPECTION STANDARD
IA vehicle damaged in a collision (regardless of
whether or not airbag is deployed).
IThe designated trouble code is output during
self-diagnosis.
2. REPLACEMENT STANDARD
IControl module is cracked or deformed.
IMounting bracket is cracked or deformed.
IConnector is scratched or cracked.
IControl module dropped to the floor/ground.
IControl module determined as faulty during
diagnostics.
IFront or side airbag is deployed.
F: ROLL CONNECTOR
1. INSPECTION STANDARD
IA vehicle damaged in a collision (regardless of
whether or not airbag is deployed).
IThe designated trouble code is output during
self-diagnosis.
2. REPLACEMENT STANDARD
ICombination switch or steering roll connector is
deformed or cracked.
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2. Inspection and Replacement Standards

G: STEERING WHEEL
1. INSPECTION STANDARD
IA vehicle damaged in a collision (regardless of
whether or not airbag is deployed).
2. REPLACEMENT STANDARD
ICheck steering wheel insert for cracks or defor-
mities.
ICheck to ensure that new airbag module is prop-
erly installed in steering wheel.
IAfter installing airbag module, check to ensure
that it is free of interference with steering wheel
and that clearance between the two is equal at all
points.
B5M0095
ICheck steering wheel distortion in axial and
radial directions.
Specifications:
Axial free play A
Less than
±6mm(±0.24 in)
Radial free play L
Less than
±7mm(±0.28 in)
B5M0096A
H: STEERING COLUMN ASSEMBLY
1. INSPECTION STANDARD
IA vehicle damaged in a collision (regardless of
whether or not airbag is deployed).
2. REPLACEMENT STANDARD
ICheck to ensure that clearance of expand plate
on steering column under side is within specifica-
tions.
Clearance of expand plate: L
More than 15 mm (0.59 in)
S5M0213B
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2. Inspection and Replacement Standards

I: FRONT SUB SENSOR
1. INSPECTION STANDARD
ICheck the front section (Refer to shaded area of
vehicle in figure) for damage, regardless of
whether or not airbag is deployed.
G5M0311
IThe designated trouble code is output during
self-diagnosis.
2. REPLACEMENT STANDARD
IBracket is deformed.
IHousing is cracked or deformed.
IThe label (that identifies the manufacturing num-
ber) is peeled or deteriorated.
IHarness circuit is broken, lead wire is exposed,
corrugated tube is cracked, etc.
IFront sub sensor determined as faulty as a
result of Diagnostics.
IAirbag is deployed (replace all front sub sen-
sors).
IFront sub sensor dropped to the floor/ground.
J: SIDE AIRBAG SENSOR
1. INSPECTION STANDARD
ICheck the side section (Refer to shaded area of
vehicle in figure) for damage, regardless of
whether or not airbag is deployed.
B5M0514
IThe designated trouble code is output during
self-diagnosis.
2. REPLACEMENT STANDARD
IBracket is deformed.
IHousing is cracked or deformed.
IThe label (that identifies the manufacturing num-
ber) is peeled or deteriorated.
IHarness circuit is broken, lead wire is exposed,
corrugated tube is cracked, etc.
ISide airbag sensor determined as faulty as a
result of Diagnostics.
ISide airbag is deployed (replace side airbag
sensor on the deployed side).
ISide airbag sensor dropped to the floor/ground.
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2. Inspection and Replacement Standards

3. Airbag Module
A: REMOVAL AND INSTALLATION
CAUTION:
IThe airbag module (driver, passenger and
side) must not be disassembled. The airbag
module cannot be used again once inflated.
G5M0299
IWhen removing and installing the airbag
module (driver, passenger and side), the opera-
tor should stand, as much as possible, on the
side of the airbag module.
G5M0300
IAfter removal, the airbag module (driver,
passenger and side) should be kept away from
heat and light sources, and stored on a clean,
flat surface to prevent from any damage to its
lower structure.
G5M0301
IDo not check airbag module (driver, passen-
ger and side) continuity with airbag removed
from the vehicle body.
G5M0302
IReplace airbag module (driver, passenger
and side) with a new one, should any of the
following conditions develop:
IPad surface is scratched or cracked.
IConnector harness is damaged.
IInflator side structure of module is
cracked or deformed.
IModule is excessively stained with water,
oil, etc.
IModule was accidentally dropped.
IThe front seat assembly is damaged or
deformed.
IThe removed front seat with the airbag mod-
ule must be kept on its back. At this time, keep
the module side at least 200 mm (7.87 in) away
from walls or other objects.
B5M0515A
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5-5[W3A0]SERVICE PROCEDURE
3. Airbag Module

IWhen storing a removed airbag module
(driver and passenger), be sure to place it in
parallel with floor with the pad facing up. Do
not place it against a wall, or place anything on
the pad; otherwise, a dangerous condition may
be created if the module malfunctions.
G5M0604
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[W3A0]5-5SERVICE PROCEDURE
3. Airbag Module

1. DRIVER'S AIRBAG MODULE
1) Set front wheels in straight ahead position.
2) Turn ignition switch off.
3) Disconnect ground cable from battery and wait
for at least 20 seconds before starting work.
4) Using TORXTBIT T30, remove the two TORXT
bolts.
H5M0662
5) Disconnect airbag connector on back of airbag
module.
H5M0664
6) Refer toªCAUTIONºfor handling of a removed
airbag module.
7) Install in the reverse order of removal.
CAUTION:
Do not allow harness and connectors to inter-
fere or get caught with other parts.
2. PASSENGER'S AIRBAG MODULE
1) Turn ignition switch off.
2) Disconnect ground cable from battery and wait
for at least 20 seconds before starting work.
3) Remove glove box.
4) Disconnect airbag connector. [M2F2].>
S5M0214
5) Remove the seven bolts and then carefully
remove airbag module.
S5M0215
6) Refer to ªCAUTIONº for handling of a removed
airbag module.
7) Install in the reverse order of removal.
CAUTION:
Do not allow harness and connectors to inter-
fere or get caught with other parts.
3. SIDE AIRBAG MODULE
The side airbag module cannot be detached from
the front seat assembly. When replacing side air-
bag module, replace front seat assembly. 5-3 [W100].>
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5-5[W3A1]SERVICE PROCEDURE
3. Airbag Module