AB-5
General Description
AIRBAG SYSTEM
•When checking, use a test harness (1). Damage
to connector terminal cause malfunction. Do not di-
rectly apply the tester probe to connector terminal
of airbag.
•Do not allow water or oil to come in contact with
the connector terminals. Also do not touch the con-
nector terminals.
•Do not check continuity of the airbag modules for
driver’s side, passenger’s side and curtain, or the
pretensioner.
•If damage, open circuit or rust is found on airbag
system wire harness, do not use a soldering equip-
ment to repair. Replace the faulty harness with a
new genuine part.
•Install the wire harness securely with the speci-
fied clips to avoid interference or tangled with other
parts.
•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 air-
bag system.
•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.
•Do not use the airbag or pretensioner parts from
other vehicles. Always replace the defective parts
with new parts.
•Never reuse a deployed airbag module and pre-
tensioner.
AB-00122
(1)
AB-00126
AB-00006
AB-00124
AB-00125
AB-00129
AB-12
Inspection Locations After a Collision
AIRBAG SYSTEM
3. Inspection Locations After a
Collision
A: REPLACEMENT
Replace the following parts when the airbag is de-
ployed.
1. FRONT COLLISION
1) Driver’s airbag module
2) Passenger’s airbag module
3) Driver’s seat belt (Pretensioner)
4) Passenger’s seat belt (Pretensioner)
5) Airbag control module
6) Front sub sensor (L/R)
7) Roll connector
8) Instrument panel (for integrating with passen-
ger’s airbag module)
9) Passenger side seat cushion pad and frame as-
sembly
2. SIDE COLLISION
1) Airbag control module
2) Side airbag module (operating side seat back-
rest)
3) Side airbag sensor (operating side)
4) Curtain airbag module (operating side)
5) Curtain airbag sensor (operating side)
3. INSPECTION OF OTHER PARTS
Check for the following parts, and replace the dam-
aged parts with new parts.
1) Steering wheel and steering shaft
Check the steering shaft for mounting conditions
and deflection of front and rear, upward and down-
ward directions, and deflection of front and rear di-
rection with tilt lever released. (After a collision,
there is a good chance that the shock absorbing
part of steering shaft may have operated.)
2) Check the connectors of airbag module, preten-
sioner, etc. for damage, and also check each har-
ness for pinch and connector damage. Replace the
harness as a unit if damage is found.
3) Check the seat cushion frame, backrest, seat rail
and headrest for deformation, distortion, crack, and
installing condition and play.
4) For passengers seat, replace the seat cushion
frame assembly with new one if the seat cushion
frame is deformed or cracked.
5) If there are tears or loosening in the passenger
side seat cushion cover, it may interfere with the
proper operation of the passenger detection sys-
tem. Replace with a new cushion cover.
6) Be sure to perform the system calibration for the
occupant detection system after removing or re-
placing the passenger seat cushion cover. Failure
to do so may cause improper operation of the pas-
senger detection system.
TION, Subaru Select Monitor.>
7) Use the Subaru Select Monitor to check whether
the drivers seat position sensor and the drivers and
the front left/right seat belt buckle switches are op-
erating normally.
B: INSPECTION
If the vehicle is involved in a collision, even if it is a
slight collision, be sure to check the following sys-
tems.
1. DRIVER’S AIRBAG MODULE
1) Check for the following, and replace the dam-
aged parts with new parts.
•Airbag module is cracked or deformed.
•Harness and/or connector is cracked, deformed
or open. Harness 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 for the following, and replace the damaged
parts with new parts.
•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.
•When steering wheel deformation in axial and
vertical directions exceed limits.
Specification:
Axial deflection A
Less than 6 mm (0.24 in)
Vertical deflection L
Less than 7 mm (0.28 in)
AB-00028
L
A
AB(diag)-4
General Description
AIRBAG SYSTEM (DIAGNOSTICS)
3. General Description
A: 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. After disconnecting the battery ground ca-
ble, the airbag may deploy if you do not wait for
more than 20 seconds before starting the service of
airbag system.
•If sensors, airbag module, airbag control module,
pretensioner or harness is deformed or damaged,
replace with new part.
•Do not use the airbag system and pretensioners
on other vehicles. When replacing parts, be sure to
replace them with new ones.
•When checking the airbag system, be sure to
use a digital circuit tester. Use of an analog circuit
tester may cause the airbag to activate erroneously
due to a minimal current inside tester.
•When checking, use a test harness (1). Damage
to connector terminal causes malfunction. Do not
directly put the tester probe on airbag connector
terminal.
•Do not drop the airbag system parts, or keep
them at high temperature over 93°C (199°F), or let
water, oil or grease get on them; the internal parts
may be damaged and reliability greatly lowered.
IN-00203
AB-00120
AB-00121
AB-00122
(1)
AB-00123
AB(diag)-5
General Description
AIRBAG SYSTEM (DIAGNOSTICS)
•If damage, open circuit or rust is found on airbag
system wire harness, do not use a soldering equip-
ment to repair. Replace the faulty harness with a
new genuine part.
•Install the wire harness securely with the speci-
fied clips to avoid interference or tangled with other
parts.
•Do not allow water or oil to come in contact with
the connector terminals. Also do not touch the con-
nector terminals.
•Either of the airbag modules for driver’s, passen-
ger’s, side or curtain, or the pretensioner must not
be disassembled.
•The airbag module cannot be used again if de-
ployed once.
•After removal, keep the airbag module with the
pad side facing upward on a dry, clean and flat sur-
face away from heat, light sources, moisture and
dust.
•Do not check continuity of the airbag modules for
driver’s side, passenger’s side and curtain, or the
pretensioner.
AB-00124
AB-00125
AB-00126
AB-00779
AB-00056
AB-00006
ET-3
Audio System
ENTERTAINMENT
2. Audio System
A: WIRING DIAGRAM
B: INSPECTION
Symptom Repair order
No power coming in. (No display and no sound from speakers) 1. Check the fuse and power supply for audio.
2. Check the audio ground.
3. Remove the audio and repair them.
A specific speaker does not operate. 1. Check the speaker.
2. Check the output circuit between audio and speaker.
Audio generates noise with engine is r unning. 1. C heck the audio ground.
2. Check the generator.
3. Check the ignition coil.
4. Remove the audio and repair them.
Vo l u m e i s l o w i n A M a n d F M m o d e s o r i n t e r f e r e n c e n o i s e
occurs.
1. Check the antenna.
2. Check the antenna amplifier.
3. Check the noise suppressor.
4. Check the audio ground.
5. Remove the audio and repair them.
ET-19
Antenna
ENTERTAINMENT
14.Antenna
A: INSPECTION
Measure the resistance between the antenna ter-
minal and each antenna wire.
If an antenna wire is OK, resistance will be less
than 1 Ω. If an antenna wire is broken, resistance
will be more than 1 MΩ.
NOTE:
When checking the continuity, wind a piece of alu-
minum foil around the tip of tester probe and press
foil against the antenna wire with your finger.
To locate the broken point, move the probe along
antenna wire.
B: REPAIR
1) Clean the antenna wire and surrounding area
with a cloth dampened by alcohol.
2) Paste a thin masking film on the glass along bro-
ken wire.
3) Apply the conductive silver composition (DU-
PONT No. 4817) on the broken portion with a draw-
ing pen.
4) Dry out the deposited portion.
5) After repair has been completed, measure the
resistance in repaired wire.
(A) Tester probe
(B) Aluminum foil
(C) Antenna wire
ET-00007
(B)
(C)
(A)
ET-00008
(A) Broken portion
(B) Masking film
(C) Conductive silver composition
ET-00009
(B)
(C)
(A)
EI-23
Front Bumper
EXTERIOR/INTERIOR TRIM
C: REPAIR
1. COATING METHOD FOR PP BUMPER
Process
No.Process name Job contents
1Bumper installation
Place the bumper on a paint worktable as
required. Use the paint worktable conforming
to inner shape of bumper if possible.
(1) Bumper
(2) Set bumper section
2MaskingMask specified part (black base) with masking tape. Use masking tape for PP (example,
Nichiban No. 533, etc. ).
3Degreasing/cleaningClean all parts to be painted with white gasoline, normal alcohol, etc. to remove dirt, oil, fat, etc.
4Primer paint Apply primer to all parts to be painted, using spray gun. Use primer (clear).
5Drying
Dry at normal temperature [10 — 15 min. at 20°C (68°F)].
In half-dried condition, PP primer paint is dissolved by solvent, e.g. thinner, etc.
Therefore, if dust or dirt must be removed, use ordinary alcohol etc.
6Top coat paint (I)
Non-colored Metallic paint
Use section (block) paint for top coat.
•Paint to be used (for each color):
Solid paint
Hardener PB
Thinner T-301
•Mixture ratio:
Main agent vs. hardener = 4:1
• Viscosity: 10 — 13 sec./20°C (68°F)
•Film thickness: 35 — 45 µ
•Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi)
Use section (block) paint for top coat.
•Paint to be used (for each color):
Metallic paint
Hardener PB
Thinner T-306
•Mixture ratio:
Main agent vs. hardener = 10:1
•Viscosity: 10 — 13 sec./20°C (68°F)
•Film thickness: 15 — 20 µ
•Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi)
7Drying Not required.
Dry at normal temperature [at least 10 min. at
20°C (68°F)].
In half-dried condition, avoid dust, dirt.
8Top coat paint (II)Not required.
Apply a clear coat to parts with top coat paint
(I), three times at 5 — 7 minutes intervals.
•Paint to be used:
Metallic paint
Hardener PB
Thinner T-301
•Mixture ratio:
Clear coat vs. hardener = 6:1
•Viscosity: 14 — 16 sec./20°C (68°F)
•Film thickness: 25 — 30 µ
•Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi)
9Drying
60°C (140°F), 60 min. or 80°C (176°F), 30 min.
If higher than 80°C (176°F), PP may become be deformed. Keep maximum temperature below
80°C (176°F).
10 Inspection Check paint.
11 Removal of masking Remove the masking tape applied in procedure 2.
EI-00234(2)
(1)
GW-25
Rear Window Defogger
GLASS/WINDOWS/MIRRORS
17.Rear Window Defogger
A: INSPECTION
1. CHECK WITH SUBARU SELECT MONITOR
CAUTION:
Check that the rear window defogger timer is in initial setting or customize setting before performing
inspection.
2. HEAT WIRE INSPECTION
CAUTION:
Use a dry and soft cloth when wiping dirt off the
glass. Move the cloth along the heat wire to
avoid damaging it.
1) Turn the ignition switch to ON.
2) Turn the defogger switch to ON.
3) Wrap the tips of tester probe with aluminum foil
to avoid damage to heat wire.
4) Measure the voltage at heat wire center with DC
voltmeter.
Standard voltage:
Approx. 6 V
NOTE:
•If the measured value is 12 volts, heat wire is
open between heat wire center and positive (+) ter-
minal of tester probe.
•If it is 0 V, the circuit is open between heat wire
center and ground.
Step Check Yes No
1CHECK INPUT SIGNAL TO THE BODY INTE-
GRATED UNIT.
Check the input signal when the rear window
defogger switch is operated using Subaru
Select Monitor.
1) Connect the Subaru Select Monitor to data
link connector.
2) Turn the ignition switch to ON.
3) Select {Integ. unit} from the «main menu».
4) Select the {Current Data Display & Save}.
5) Check the input signal when the rear win-
dow defogger switch is set to ON.
After rear defogger switch is
set to ON, does it turn to OFF
in 15 minutes? Or does it
repeat 15 minutes operation
and 2 minutes stop?
END. Replace the body
integrated unit.
Integrated Unit.>
(1) Tester probe
(2) Aluminum foil
(3) Heat wire
(4) Press
GW-00076
(2)
(3)
(4)
(1)
(1) Center of heat wire
Vo l t a g e C r i t e r i a
Approx. 6 V Normal
Approx. 12 V or 0 V Open
GW-00077
(1)