2004 SUBARU FORESTER ignition

AC-40
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
Diagnostic Procedure for Sensors
Step Check Yes No
1 CHECK POWER SUPPLY VOLTAGE FOR
SUNLOAD SENSOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from sunload
sensor.
3) Turn the ignition switch to ON.
4) Measure the power supply voltage for sun-
load sensor.
Connector & terminal
(i51) No. 2 (+) — Chassis ground (
−):Is the voltage approx. 5 V? Go to step 4.Go to step 2.
2 CHECK AUTO A/C CONTROL MODULE
OUTPUT SIGNAL.
1) Turn the ignition switch to OFF.
2) Remove the auto A/C control module.
3) Turn the ignition switch to ON.
4) Measure the voltage between connector
terminals of auto A/C control module.
Connector & terminal
(i49) No. 3 (+) — (i48) No. 16 (
−):Is the voltage approx. 5 V? Go to step 3.Go to step 6.
3 CHECK HARNESS CONNECTOR BETWEEN
AUTO A/C CONTROL MODULE AND SUN-
LOAD SENSOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from auto A/C
control module.
3) Measure the resistance in harness
between auto A/C control module and sunload
sensor.
Connector & terminal
(i51) No. 2 — (i49) No. 3:Is the resistance less than 1
Ω?Go to step 4.Repair the har-
ness between auto
A/C control mod-
ule and sunload
sensor.
4 CHECK HARNESS CONNECTOR BETWEEN
AUTO A/C CONTROL MODULE AND SUN-
LOAD SENSOR.
Measure the resistance in harness between
auto A/C control module and sunload sensor.
Connector & terminal
(i51) No. 1 — (i48) No. 16:Is the resistance less than 1
Ω?Go to step 5.Repair the har-
ness between auto
A/C control mod-
ule and sunload
sensor.
5 CHECK INPUT VOLTAGE FOR AUTO A/C
CONTROL MODULE.
1) Connect the connector of auto A/C control
module.
2) Turn the ignition switch to ON.
3) Measure the voltage between connector
terminals of auto A/C control module.
Connector & terminal
(i49) No. 3 (+) — (i48) No. 16 (
−):Is the voltage approx. 2.5 V? Go to step 6.Replace the sun-
load sensor.
6 CHECK POOR CONTACT.
Check poor contact in auto A/C control module
connector.Is there poor contact in con-
nector?Repair the con-
nector.Replace the auto
A/C control mod-
ule.

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-15
AIRBAG SYSTEM
Passenger’s Airbag Module
5. Passenger’s Airbag Module
A: REMOVAL
CAUTION:
Refer to “CAUTION” in General Description be-
fore handing the airbag module. CAUTION, General Description.>
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 glove box. AL, Glove Box.>
4) Detach the airbag connector from support beam
bracket, and then disconnect the airbag connector.
5) Remove the three bolts, and then carefully re-
move the airbag module.
6) Refer to “CAUTION” for handling of removed air-
bag module. Description.>
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. GER’S AIRBAG MODULE, INSPECTION, Inspec-
tion Locations After a Collision.>
AB-00117

AB-16
AIRBAG SYSTEM
Side Airbag Module
6. Side Airbag Module
A: REMOVAL
CAUTION:
Before working on the airbag module, refer to
the “CAUTION” in General Description. AB-3, CAUTION, General Description.>
NOTE:
Remove the passenger’s side by referring to driv-
er’s side.
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 front seat from the vehicle. SE-6, REMOVAL, Front Seat.>
4) Remove the clip from slide rail IN (A) and re-
verse side of seat cushion assembly, and then re-
move the side airbag harness.
5) Remove the backrest cover. ASSEMBLY, Front Seat.>
6) Remove the side airbag harness from backrest
frame assembly.7) Remove the side airbag module (A) from back-
rest frame assembly.
B: INSTALLATION
1) Ensure there are no foreign particles on side air-
bag module.
2) Install the side airbag module (A) to backrest
frame assembly.
Tightening torque:
5.9 N·m (0.59 kgf-m, 4.4 ft-lb)
AB-00474
(A)
AB-00475
AB-00476
(A)
AB-00477
(A)

AB-18
AIRBAG SYSTEM
Airbag Control Module
7. Airbag Control Module
A: REMOVAL
CAUTION:
 Do not disassemble the airbag control mod-
ule.
 If the airbag control module is deformed or if
water damage is suspected, replace the airbag
control module with a new part.
 Do not drop the airbag control module.
 After removal, keep the airbag control mod-
ule on a dry, clean surface away from moisture,
heat, and dust.
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 console cover. MOVAL, Console Box.>
4) Remove the center console panel. 40, REMOVAL, Instrument Panel Assembly.>
5) Disconnect the connector from airbag control
module.
6) Remove the four bolts, and then remove the air-
bag control module.
B: INSTALLATION
CAUTION:
Use new bolts (for airbag control module only)
during reassembly.
Install in the reverse order of removal.
Tightening torque:
Refer to “COMPONENT” in “General Descrip-
tion” NENT, General Description.>
C: INSPECTION
Check for the following, and replace damaged
parts with new ones.
 Control module, connector, and mounting brack-
et are damaged.
 Airbag is deployed.
 Side airbag is deployed.
AB-00035

AB-19
AIRBAG SYSTEM
Side Airbag Sensor
8. Side Airbag Sensor
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 outer belt (FRONT). 10, FRONT OUTER BELT, REMOVAL, Front Seat
Belt.>
4) Detach the side airbag sensor, and then discon-
nect the airbag connector.
B: INSTALLATION
CAUTION:
Use new TORX® bolts T30 when reassembling.
Install in the reverse order of removal.
Tightening torque:
Refer to “COMPONENT” in “General Descrip-
tion” NENT, General Description.>
C: INSPECTION
Check for the following, and replace damaged
parts with new parts.
 Bracket connector for side airbag sensor is dam-
aged.
 Side airbag is deployed.
AB-00036

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-21
AIRBAG SYSTEM
Front Sub Sensor
10.Front Sub Sensor
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 front grille and front grille side.

4) Disconnect the connector from front sub sensor.
5) Loosen the nut, and then detach the front sub
sensor.
B: INSTALLATION
CAUTION:
Use new nuts when reassembling.
Install in the reverse order of removal.
Tightening torque:
Refer to “COMPONENT” in “General Descrip-
tion” NENT, General Description.>
C: INSPECTION
Check for the following, and replace damaged parts
with new parts.
 Front sub sensor, mounting bracket, and con-
nector are damaged.
 Airbag is deployed.
AB-00040
AB-00116