2004 SUBARU FORESTER ECU

AB-5
AIRBAG SYSTEM (DIAGNOSTIC)
General Description
 If any damage, opening, or rust is found on the
airbag system wiring harness, do not attempt to re-
pair using soldering equipment. Be sure to replace
the faulty harness with a new genuine part.
 Install the wiring harness securely with the spec-
ified 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 airbag module cannot be used again once
inflated.
 After removal, keep the airbag module with the
pad facing upward on a dry, clean, and flat surface
away from heat and light sources, and moisture
and dust.
 Do not check continuity of either of the airbag
modules for driver, passenger or side, or preten-
sioner.
AB-00124
AB-00125
AB-00126
AB-00127
AB-00056
AB-00006

AB-35
AIRBAG SYSTEM (DIAGNOSTIC)
Airbag Warning Light Failure
1. LHD MODEL
WIRING DIAGRAM:
Step Check Yes No
1 CHECK POOR CONTACT IN CONNECTORS
(AB1) AND (B31).
1) Turn the ignition switch to OFF, disconnect
the battery ground cable, and wait more than
20 seconds.
2) Remove the side sill cover. (Driver’s side)
3) Confirm that firm contact is secured
between connectors (AB1) and (B31).Is the poor contact in connec-
tors (AB1) and (B31)?Repair the body
harness or replace
the airbag main
harness with body
harness.Go to step 2.
AB-00739
12
34561
2345678910123456789101112131415161718192021222324252627282930
B31 i11AB3
i10
B:
C: i10
i11
AIRBAG
WARNING
LIGHTCOMBINATION
METERB9
B8
B10
NO.14
i3B38 28
i2B37 19
5
AIRBAG CONTROL MODULEAB3
B31
AB1
3
3
AIRBAG
CIRCUIT
E
BATTERY
1234567891011121314151617
1819202122232425262728
IGNITION
SWITCH
B: C:

AB-36
AIRBAG SYSTEM (DIAGNOSTIC)
Airbag Warning Light Failure
2 CHECK AIRBAG WARNING LIGHT.
1) Turn the ignition switch to OFF, disconnect
the battery ground cable, and wait more than
20 seconds.
2) Connect the connector (1T) in test harness
T to body harness connector (B31).
3) Connect the connector (1M) in test harness
M to connector (2T) in test harness T.
4) Connect the battery ground cable and turn
the ignition switch to ON.
5) Connect the connectors, (3M) and (4M) in
test harness M.Is the airbag warning light
turned off?Go to step 4.Go to step 3.
3 CHECK BODY HARNESS.
Check the body harness.
N
OTE:
After problem has been eliminated, disconnect
the connectors (3M) and (4M).Is the anything unusual to body
harness? Repair the body
harness.Replace the com-
bination meter
printed circuit.
Combination
Meter Assembly.>
4 CHECK POOR CONTACT.
Confirm that firm contact is secured between
the airbag control module and the connector
(AB3). ule.>Is the poor contact in connec-
tor (AB3)?Replace the airbag
main harness with
body harness or
replace the airbag
control module.
Airbag Control
Module.>Go to step 5.
5 CHECK AIRBAG MAIN HARNESS.
1) Turn the ignition switch to OFF, disconnect
the battery ground cable, and wait more than
20 seconds.
2) Connect the connector (AB1) to (B31).
3) Disconnect the connectors (AB2) and
(AB30).
4) Remove the glove box and disconnect the
connectors (AB4).
5) Disconnect the connector (AB3) from the
airbag control module, and connect the con-
nector (1R) in test harness R. Airbag Control Module.>
6) Connect the battery ground cable and turn
the ignition switch to ON.
7) Connect the connectors (5R) and (6R) in
test harness R.
N
OTE:
After problem has been eliminated, disconnect
the connectors (5R) and (6R).Is the airbag warning light
turned off?Go to step 6.Replace the airbag
main harness with
body harness.
6 CHECK GROUNDING CIRCUIT.
1) Turn the ignition switch to OFF, disconnect
the battery ground cable, and wait more than
20 seconds.
2) Disconnect the connector (AB3) from the
airbag control module.
3) Connect the connector (1R) in test harness
R to body harness connector (AB3).
4) Measure the resistance between connector
(2R) in test harness R and the chassis ground.
Connector & terminal
(2R) No. 10 — Chassis ground:
(2R) No. 11 — Chassis ground: Is the resistance less than 10
Ω?Replace the airbag
control module.
Airbag Control
Module.>Repair the body-
grounding circuit. Step Check Yes No

AB-37
AIRBAG SYSTEM (DIAGNOSTIC)
Airbag Warning Light Failure
2. RHD MODEL
WIRING DIAGRAM:
Step Check Yes No
1 CHECK POOR CONTACT IN CONNECTORS
(AB1) AND (B31).
1) Turn the ignition switch to OFF, disconnect
the battery ground cable, and wait more than
20 seconds.
2) Remove the side sill cover. (Driver’s side)
3) Confirm that firm contact is secured
between connectors (AB1) and (B31).Is the poor contact in connec-
tors (AB1) and (B31)?Repair the body
harness or replace
the airbag main
harness with body
harness.Go to step 2.
AB-00740
12
34561
2345678910123456789101112131415161718192021222324252627282930
B31 i11AB3
i10
B:
C: i10
i11
AIRBAG
WARNING
LIGHTCOMBINATION
METERB9
B8
B10
NO.14
i3B38 20
10
16
AIRBAG CONTROL MODULEAB3
B31
AB1
1
3
AIRBAG
CIRCUIT
E
BATTERY
1234567891011121314151617
1819202122232425262728
IGNITION
SWITCH

AB-38
AIRBAG SYSTEM (DIAGNOSTIC)
Airbag Warning Light Failure
2 CHECK AIRBAG WARNING LIGHT.
1) Turn the ignition switch to OFF, disconnect
the battery ground cable, and wait more than
20 seconds.
2) Connect the connector (1M) in test harness
M to body harness connector (B31).
3) Connect the battery ground cable and turn
the ignition switch to ON.
4) Connect the connectors, (3M) and (4M) in
test harness M.Is the airbag warning light
turned off?Go to step 4.Go to step 3.
3 CHECK BODY HARNESS.
Check the body harness.
N
OTE:
After problem has been eliminated, disconnect
the connectors (3M) and (4M).Is the anything unusual to body
harness?Repair the body
harness.Replace the com-
bination meter
printed circuit.
Combination
Meter Assembly.>
4 CHECK POOR CONTACT.
Confirm that firm contact is secured between
the airbag control module and the connector
(AB3). ule.>Is the poor contact in connec-
tor (AB3)? Replace the airbag
main harness with
body harness or
replace the airbag
control module.
Airbag Control
Module.>Go to step 5.
5 CHECK AIRBAG MAIN HARNESS.
1) Turn the ignition switch to OFF, disconnect
the battery ground cable, and wait more than
20 seconds.
2) Connect the connector (AB1) to (B31).
3) Disconnect the connectors (AB21) and
(AB26).
4) Remove the glove box and disconnect the
connectors (AB4).
5) Disconnect the connector (AB3) from the
airbag control module, and connect the con-
nector (1R) in test harness R. Airbag Control Module.>
6) Connect the battery ground cable and turn
the ignition switch to ON.
7) Connect the connectors (5R) and (6R) in
test harness R.
N
OTE:
After problem has been eliminated, disconnect
the connectors (5R) and (6R).Is the airbag warning light
turned off? Go to step 6.Replace the airbag
main harness with
body harness.
6 CHECK GROUNDING CIRCUIT.
1) Turn the ignition switch to OFF, disconnect
the battery ground cable, and wait more than
20 seconds.
2) Disconnect the connector (AB3) from the
airbag control module.
3) Connect the connector (1R) in test harness
R to body harness connector (AB3).
4) Measure the resistance between connector
(2R) in test harness R and the chassis ground.
Connector & terminal
(2R) No. 10 — Chassis ground:
(2R) No. 11 — Chassis ground: Is the resistance less than 10
Ω?Replace the airbag
control module.
Airbag Control
Module.>Repair the body-
grounding circuit. Step Check Yes No

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

SB-14
SEAT BELT SYSTEM
Disposal of Pretensioner
6. Disposal of Pretensioner
A: CAUTION
 Do not discard undeployed pretensioners, because
they may cause serious personal injury when acci-
dentally deployed.
 Deployment of the pretensioners should be done
on a flat place free from any possible danger. Avoid
deploying outdoors during heavy rainy or strong
windy weather.
 Do not drop or damage the pretensioner.
 Because deploying the pretensioners 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 after deployment of
the pretensioners. Therefore, it must be deployed
in a well-ventilated area with no smoke alarms
nearby.
 Wear gloves, goggles, and earplugs during this
operation. Wash your hands afterwards.
 After deployment, the pretensioner is especially
hot. Leave it unattended for 40 minutes or longer,
and then discard it.
 Do not let water get on the deployed pretension-
er.
 Wrap the deployed pretensioner in an airtight vi-
nyl bag, and then discard it.
 If circumstances do not permit pretensioner de-
ployment, contact a SUBARU dealer.
B: OPERATION
1. DEPLOYING OF PRETENSIONER WHILE
INSTALLED IN VEHICLE
1) Fold backrest all the way forward, and 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 center pillar lower trim. 44, REMOVAL, Lower Inner Trim.>
4) Disconnect the connector (A) of pretensioner.
5) Short the terminal to alligator clip furnished as
deployment tool (A).6) Connect the deployment tool and deployment
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) Extend the deployment tool to the limit, and
make sure that the vehicle is empty. Close all win-
dows, sunroof, and rear gate completely.
9) Move the battery at least 5 m (16 ft) from the ve-
hicle, and secure the nearby area. Connect the de-
ployment tool alligator clip to the battery negative (−
) terminal.
10) Connect the other cable of deployment tool to
the battery positive (+) terminal. Then deploy the
pretensioner.
SB-00129
(A)
(A) Deployment tool: (Tool No. 98299PA030)
(B) Deployment adapter D: (Tool No. 98299SA010)
SB-00021
(A)
(B)
SB-00017
SB-00018

SEAT BELT SYSTEM
Disposal of 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.
11) Perform the following steps 12) through 17) for
the vehicle with lap pretensioner.
12) Disconnect the orange connector (a) from lap
pretensioner.
13) Connect the deployment tool (A) and deploy-
ment adapter F (B).
CAUTION:
The deployment tool terminals should be kept
shorted until just before deployment of the pre-
tensioner.
14) Connect the deployment adapter F connector
and lap seat belt pretensioner orange connector.15) Extened the deployment tool to the limit, and
make sure that the vehicle is empty. Close all win-
dows, sunroof and rear gate completely.
16) 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.
17) 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.
18) Remove the front outer belt. REMOVAL, Front Seat Belt.>
19) Wrap the deployed pretensioner in an airtight
vinyl bag, and discard it.
(A) Deployment tool: (Tool No. 98299PA030)
(B) Deployment adapter F: (Tool No. 98299SA050)
SB-00020
(a)
SB-00021
(A)
(B)
SB-00017
SB-00018
SB-00131
SB-15