2004 SUBARU FORESTER sensor

AC-41
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
General Diagnostic Table
9. General Diagnostic Table
A: INSPECTION
Symptom Problem parts
A/C system fails to operate.Fuse
 Connector (Poor contact)
Ground
 Auto A/C control module
 Blower fan motor
 Blower fan relay
 A/C Relay
 Compressor (Magnet clutch)
 Evaporator sensor
Fuse is blown out.Fuse
 Connector (Poor contact)
Illumination cannot dim.Fuse
 Connector (Poor contact)
 Auto A/C control module
Blower fan does not rotate or fan speed cannot be controlled.Fuse
 Connector (Poor contact)
Ground
 Auto A/C control module
 Blower fan motor
 Blower fan relay
Unable to switch suction vents. Connector (Poor contact)
 Auto A/C control module
 Intake door actuator
Unable to switch blow vents. Connector (Poor contact)
 Auto A/C control module
 Mode door actuator
Compartment temperature does not increase. (No hot air is dis-
charged.) Connector (Poor contact)
 Auto A/C control module
 Air mix door actuator
 In-vehicle sensor, ambient sensor, evaporator sensor and
sunload sensor
 In-vehicle sensor aspirator hose
Compartment temperature does not decrease. (No cool air is
discharged.) Connector (Poor contact)
 Auto A/C control module
 Air mix door actuator
 A/C Relay
 Compressor (Magnet clutch)
 Radiator fan motor
 Radiator fan relay
 In-vehicle sensor, ambient sensor, evaporator sensor and
sunload sensor
 In-vehicle sensor aspirator hose
Compartment temperature is higher or lower than setting tem-
perature. Auto A/C control module
 Air mix door actuator
 In-vehicle sensor, ambient sensor, evaporator sensor and
sunload sensor
 In-vehicle sensor aspirator hose
Compartment temperature does not quickly respond to setting
temperature. Air mix door actuator
 In-vehicle sensor, ambient sensor, evaporator sensor and
sunload sensor
 In-vehicle sensor aspirator hose
Radiator fan does not rotate during A/C operation. Radiator fan motor
 Radiator fan relay

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-10
AIRBAG SYSTEM
Airbag Connector
3. DRIVER’S AIRBAG MODULE AND PRE-
TENSIONER
1) How to disconnect:
(1) Using a flat tip screwdriver, pry the push
lock upward to unlock.
(2) Pull the connector to disconnect from driv-
er’s side airbag module assembly or retractor
assembly.
2) How to connect:
Connect the connector in reverse order of discon-
necting. At this time, be sure to insert the connector
in until a connecting sound is heard.
CAUTION:
 Be sure to insert the connector in until it
locks. Then pull it gently to make sure that it is
locked.
 Be sure to insert the push lock in.
4. FRONT SUB-SENSOR AND SIDE AIR-
BAG SENSOR
1) How to disconnect:
Holding outer part (A), pull it in the direction of ar-
row.
CAUTION:
When pulling, be sure to hold onto the connec-
tor and not the wire.
2) How to connect:
Holding the connector, and push it in carefully until
a connecting sound is heard.
CAUTION:
 Do not put your hand on the outer part, since
outer (A) moves back.
 Be sure to insert the connector in until it
locks. Then pull it gently to make sure that it is
locked.
5. PASSENGER’S AIRBAG
1) How to disconnect:
(1) Move the slide lock (A) in the direction of ar-
row.
AB-00478
AB-00479
AB-00480
AB-00024
AB-00025
AB-00021
(A)

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