Airbag System: Removal & Installation Subaru Outback BR

REPLACEMENT

Replace the following parts if the airbag has been activated.

REMOVAL

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1. Position the front wheels straight ahead. (After moving a vehicle 5 m (16 ft) or more 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 60 seconds before starting work.
4. Remove the driver's airbag module assembly. Preparation tool: TORX® T30 Loosen the two TORX® bolts on the sides of the steering wheel. Disconnect the airbag connector and remove the airbag module assembly. Ref. to «DRIVER'S AIRBAG MODULE, CURTAIN AIRBAG MODULE & PRETENSIONER»(ref-371944-S37826240752010091900000) , PROCEDURE, Airbag Connector. Disconnect the horn harness.

INSTALLATION

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1. Before installation, inspect the following items and replace any faulty part with a new one. Airbag module is cracked or deformed. Harness and/or connector are cracked, deformed or open. Harness wire is exposed. The steering wheel is in the way, making it difficult to install the airbag module. The clearance between the driver's airbag module and steering wheel is not constant. When steering wheel deformation in axial and vertical directions exceed limits. Standard: Axial deflection A (deflection of steering wheel) Less than 6 mm (0.24 in) Vertical deflection L (runout of steering wheel) Less than 17 mm (0.68 in)
2. Install each part in the reverse order of removal. Tightening torque: 10 N.m (1.0 kgf-m, 7.4 ft-lb)

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1. Turn the ignition switch to OFF.
2. Disconnect the ground cable from battery and wait for at least 60 seconds before starting work.
3. Remove the console front cover assembly. MT model Remove the shift knob. Release the clips and claws, then pull up the console front cover assembly. NOTE: Turn over the front center pocket mat (a) and pull up the console front cover from the slit. Disconnect the harness connector and remove the console front cover assembly. AT model Remove the select lever knob. Lower the cover grip AT. Remove the clamp grip pin, then remove the select lever knob. Release the clips and claws, then pull up the console front cover assembly. NOTE: Turn over the front center pocket mat (a) and pull up the console front cover from the slit. Disconnect the harness connector and remove the console front cover assembly.
4. Remove the left and right console front side cover assembly. Remove the screws and release the clips (A) to (D) in order. Remove the console front side cover assembly by pulling it up.
5. Remove the console box assembly. Move the seat forward, and remove the bolts after detaching the left and right caps. NOTE: For a model with power seat, connect the battery ground cable and move the seat. Then, disconnect the battery ground cable again and wait for 60 seconds at least before restarting the work. Remove the screws, disconnect the harness connector and remove the console box assembly.
6. Remove the clips, and remove the instrument panel side cover LH.
7. Remove the instrument panel lower cover. Remove the clips and data link connector, and remove the instrument panel lower cover under. Remove the screws and clips and release the claws, and remove the instrument panel lower cover while disconnecting the harness connectors.
8. Remove the center panel assembly. CAUTION: Do not put your finger on the fin of the air vent grille. Doing so may damage the fin. Attach the protective tape (a) to the meter visor. Insert a finger into the air vent grille and release the left and right clips at the top of the center panel. (A), (B) Insert a finger into the air vent grille and release the left and right clips at the center of the center panel. (C), (D) Release the clips at the bottom of the center panel and remove the center panel assembly.
9. Remove the combination meter assembly. CAUTION: Be careful not to damage the meter or instrument panel. Pay particular attention to avoid damaging the meter glass. Remove the screws and release the claws, then detach the starter cover assembly. Release the lock, tilt the steering column to the lowest end and fully extend the column by the telescopic system. Release the screws and clips, then detach the meter visor assembly. Remove the screws and pull the steering COMPL upper cover toward you. Remove the screws and pull out the combination meter toward you to disconnect the connectors. Remove the combination meter assembly as shown in the figure.
10. Remove the audio assembly. Remove the left and right screws, and partially pull the audio out from center console. Disconnect the connectors, and remove the audio assembly.
11. Remove the navigation assembly, (model with navigation) Remove the left and right screws. Disconnect the connectors, and remove the navigation assembly.
12. Remove the control panel assembly. Remove the screws, and pull out the control panel assembly toward you. Disconnect the connector, and remove the control panel assembly.
13. Remove the multi display assembly. CAUTION: Be careful not to damage the multi display or instrument panel. Detach the center speaker cover by releasing the claws and hooks. NOTE: An easy way of removal is to first remove the audio assembly or navigation assembly and push up the cover from the backside. Release the clips and claws, detach the multi display panel LWR. Remove the screws and pull out the multi display toward you to disconnect the connectors.
14. Remove the left and right front side speaker assembly. (Models with front side speaker) Release the clips and claws, then detach the side speaker cover. CAUTION: To remove the cover, use a plastic clip remover or equivalent tool. Remove the screws. Preparation tool: Stubby screwdriver Disconnect the connector and remove the front side speaker assembly. NOTE: On the passenger's side, also disconnect the sunload sensor connector.
15. Remove the left and right front pillar trims. Pull the upper part of the front pillar trim towards the center of the vehicle. Insert long-nose pliers into the top part of the trim, grip the clip with the pliers and twist 90° in that position. CAUTION: Be careful not to damage the pillar trim surface and curtain airbag module when inserting the pliers. Holding the clip twisted as in the previous step, remove the front pillar trim from the clip. Remove the clip and the front pillar trim.
16. Remove the glove box lid assembly. Remove the glove box damper. Release the stoppers and remove the glove box lid assembly by pulling it toward you.
17. Release the clips, and remove the instrument panel side cover RH.
18. Remove the glove box back panel. Release the clips, and remove the glove box under cover. Release the clips and claws, and remove the ornament panel assembly P. Remove the screws and release the claws, then detach the glove box back panel. CAUTION: Pay attention to the glove box light LED harness. Disconnect the glove box light LED connector.
19. Disconnect the connector from the passenger's airbag module assembly and remove the bolt. Release the connector and harness clamps and disconnect the airbag connector. Remove passenger's airbag module assembly bolts.
20. Remove the steering shaft assembly. Ref. to «REMOVAL»(ref-371911-S06680302312010091900000) , Steering Column.
21. Remove the instrument panel assembly. Remove the screws. (A), (B), (C), (D), (E), (F), (G), (H), (I) Pull out the instrument panel assembly toward you and release the clamps of the left and right front side speakers. Preparation tool: Stubby screwdriver After checking that all harness clamps and connectors are released and disconnected, remove the instrument panel assembly. CAUTION: Be careful not to damage the instrument panel surface and interior trims.
22. Remove the heater vent duct. Remove the screws, and remove the center vent duct. Release the claws and remove the screws, then detach the side vent duct RH.
23. Release the claws, and remove the passenger's airbag module.
24. Refer to "CAUTION" for handling of a removed airbag module. Ref. to «CAUTION»(ref-371944-S30297997482010091900000) , General Description.

1. Before installation, inspect the following items and replace any faulty part with a new one. Passenger's airbag lid (instrument panel surface) is cracked or deformed. Airbag module is cracked or deformed. Harness and/or connector is cracked, deformed or open. Harness wire is exposed. Mounting bracket is cracked or deformed.
2. Install each part in the reverse order of removal. Tightening torque: Passenger's airbag module: 7.5 N.m (0.76 kgf-m, 5.5 ft-lb) Console box: 6.5 N.m (0.66 kgf-m, 4.8 ft-lb)

Note. Remove the passenger's side by referring to driver's side.

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1. Turn the ignition switch to OFF.
2. Disconnect the ground cable from battery and wait for at least 60 seconds before starting work. NOTE: For the power seat, remove the slide rail installing bolt before removing the battery ground terminal.
3. Remove the front seats. Remove the bolts from the slide rail. Tilt the backrest forward and move the seat to the front most position. Remove the rear bolt cover (A) and remove the two bolts. Move the seat to the rearmost position. Remove the front bolt cover (B) and remove the two bolts. Disconnect the connector under the seat. CAUTION: Disconnect the ground cable from battery, and wait 60 seconds before disconnecting the connector. Seat belt warning light connector (driver's seat) Occupant detection system harness connector (passenger's seat) Side airbag connector Seat heater connector (model with seat heater) Power seat connector (model with power seats) Take out the front seat from the vehicle. CAUTION: Be careful not to damage the body.
4. Remove the seat lifter lever. (Manual seat) Using a flat tip screwdriver, remove the seat lifter lever cover (a). Remove the screw and remove the seat lifter lever.
5. Remove the reclining lever cover. (Manual seat) Pull up the reclining lever and release the claws on the back. Pull out the reclining lever cover.
6. Remove the seat side cover OUT. MANUAL SEAT Remove the screws. Release the claw in the upper section of the seat side cover. Release the claw in the rear section of the seat side cover. Release the claw in the front section of the seat side cover, then remove the seat side cover OUT. POWER SEAT Release the claw in the rear section of the seat side cover. Release the claw in the upper section of the seat side cover. Remove the clip and release the claw in the front section of the seat side cover Disconnect the power seat switch connector and remove the seat side cover OUT.
7. Remove the inner seat belt assembly. Remove the nut and remove the inner seat belt assembly. Remove the clip for the inner seat belt harness located under the seat cushion.
8. Remove the seat side cover IN. MANUAL SEAT Remove the screws. Release the claw in the upper section of the seat side cover. Release the claw in the rear section of the seat side cover, then remove the seat side cover IN. POWER SEAT Remove the screws. Release the claw in the rear section of the seat side cover. Release the claw in the upper section of the seat side cover, then remove the seat side cover IN. Separate the backrest assembly and the seat cushion assembly. Remove the clip for the side airbag harness located under the seat cushion. Remove the bolts from the right and left reclining hinges. While taking care not to damage the airbag harness, separate the backrest assembly and the seat cushion assembly. MANUAL SEAT POWER SEAT Remove the backrest back cover. Remove the screws. Release the hooks by pulling down the back cover and remove the backrest back cover. Remove the side airbag module assembly. CAUTION: When removing the hog rings, be careful not to tear the vinyl sheet within the seat. If the sheet has torn, replace it with a new sheet. Do not open the (plastic) protective cover of the airbag. If any damage is present in the protective cover (such as airbag module cloth coming out), replace the side airbag module assembly with a new one. Remove the hooks and hog rings. Remove the backrest pad & cover from backrest assembly. Remove the mounting nuts of the side airbag module. Remove the side airbag harness from backrest frame assembly. While taking care not to damage the airbag (plastic) protective cover, remove the side airbag module assembly.

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1. Before installation, inspect the following items and replace any faulty part with a new one. Make sure that there is no foreign matter on side airbag module. Front seat, airbag module and mounting bracket are damaged or deformed. Harness and/or connector is cracked, deformed or open. Harness wire is exposed.
2. Install the side airbag module to the backrest frame assembly. Tightening torque: 6 N.m (0.61 kgf-m, 4.4 ft-lb)
3. Install the side airbag harness to backrest frame assembly.
4. Install the backrest cover.
5. Secure the backrest hinge. MANUAL SEAT POWER SEAT Tightening torque: Refer to "COMPONENT" of "General Description". Ref. to «FRONT SEAT»(ref-371917-S21731691342010091900000) , COMPONENT, General Description.
6. Install the side airbag harness to the back of the seat cushion assembly using a cable clip. CAUTION: After restoring the seat, operate the reclining and sliding mechanisms to check that the side airbag harness is not caught.
7. Install the front seat to the body. CAUTION: The seat mounting bolts differ between the front mounting points and the rear mounting points. Make sure that you are using correct bolts at correct positions. Tighten the slide rail installing bolt gradually in several steps to the specified torque in the order as shown in the figure. Front (bolt A): Washer diameter 22 mm (0.87 in) Rear (bolt B): Washer diameter 26 mm (1.02 in) Tightening torque: Front seat assembly: 53 N.m (5.4 kgf-m, 39.1 ft-lb)

1. Before installation, inspect the following items and replace any faulty part with a new one. Airbag cover is scratched or torn. Harness and/or connector is cracked, deformed or open. Harness wire is exposed. Mounting bracket and securing clip are cracked or deformed.
2. Install each part in the reverse order of removal. Tightening torque: 7.5 N.m (0.76 kgf-m, 5.5 ft-lb)

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1. Turn the ignition switch to OFF. CAUTION: Disconnect the ground cable from battery and wait for at least 60 seconds before starting work. NOTE: For a model with power seat, remove the console box assembly before disconnecting the battery ground cable.
2. Remove the console front cover assembly. MT model Remove the shift knob. Release the clips and claws, then pull up the console front cover assembly. NOTE: Turn over the front center pocket mat (a) and pull up the console front cover from the slit. Disconnect the harness connector and remove the console front cover assembly. AT model Remove the select lever knob. Lower the cover grip AT. Remove the clamp grip pin, then remove the select lever knob. Release the clips and claws, then pull up the console front cover assembly. NOTE: Turn over the front center pocket mat (a) and pull up the console front cover from the slit. Disconnect the harness connector and remove the console front cover assembly.
3. Remove the left and right console front side cover assembly. Remove the screws and release the clips (A) to (D) in order. Remove the console front side cover assembly by pulling it up.
4. Remove the console box assembly. Move the seat forward, and remove the bolts after detaching the left and right caps. NOTE: For a model with power seat, connect the battery ground cable and move the seat. Then, disconnect the battery ground cable again and wait for 60 seconds at least before restarting the work. Remove the screws, disconnect the harness connector and remove the console box assembly.
5. Remove the airbag control module. Disconnect the connector from airbag control module. Remove the bolt and nuts and remove the airbag control module.

1. Before installation, inspect the following items and replace any faulty part with a new one. Control module is deformed. Control module connector is damaged. Control module mounting bracket is damaged.
2. Install each part in the reverse order of removal. Tightening torque: Airbag control module: 25 N.m (2.55 kgf-m, 18.4 ft-lb) Console box assembly: 6.5 N.m (0.66 kgf-m, 4.8 ft-lb)

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1. Turn the ignition switch to OFF.
2. Disconnect the ground cable from battery and wait for at least 60 seconds before starting work.
3. Remove the front bumper face assembly. Remove the clips, turn over the front mud guard, and disconnect the fog light connector. (Model with fog light) Remove the clips at the upper side of the bumper. Remove the clips from the fender. Remove the clips at the lower side of bumper. Detach the flange section on the bumper face side from the bracket side front UPR. CAUTION: Do not pull forcibly. It may damage the flange sections of the bumper face. NOTE: While pushing upward the underside of the fog light (a), remove from (b) through (e) in order. Detach the opposite side in the same manner.
4. Remove the headlight assembly. Remove the fender cover assembly UPR. Remove the clip. Release the claws of the fender cover assembly UPR by pulling it forward and remove the fender cover. Remove the headlight assembly. NOTE: When removing the RH headlight, remove the air intake duct. Remove the bolts and clips, and pull out the headlight assembly to the front of the vehicle. Disconnect the connector and remove the headlight assembly. RH headlight connector LH headlight connector
5. Remove the front sub sensor assembly. Remove the bolt, and remove the sensor cover plate. Remove the front sub sensor by removing the bolt and disconnect the connector.

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1. Before installation, inspect the following items and replace any faulty part with a new one. Front sub sensor damage Connector damage Sensor cover plate deformation or damage
2. Install each part in the reverse order of removal. CAUTION: Install the bumper face so that the under cover front end (b) comes inside the front bumper face (a). Tightening torque: Front sub sensor: 13 N.m (1.33 kgf-m, 9.6 ft-lb) Headlight assembly: 7.5 N.m (0.76 kgf-m, 5.5 ft-lb)

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1. Move the seat all the way forward, from which the airbag sensor is to be removed. NOTE: To remove the seat belt retractor assembly
2. Turn the ignition switch to OFF.
3. Disconnect the ground cable from battery and wait for at least 60 seconds before starting work.
4. Release the claws, and then remove the side sill cover-front INN. (On the side where airbag sensor is removed) CAUTION: Do not pull with excessive force. Doing so may damage the claws of the side sill cover INN. NOTE: To release the claws of the side sill cover INN, the following steps are recommended. Take out the weather strip from under the side sill cover INN. Turn over the floor mat and release the claw (C) by accessing from behind the side sill cover INN.
5. Remove the rear seat cushion assembly. Pull up the seat cushion and release the hook. CAUTION: If the hook is removed from vehicle body, replace the hook with the new part to avoid the deterioration of seat securing. Remove the hook (A) by pushing it back while lifting the front side of the seat cushion, and remove the seat cushion assembly.
6. Release the clips and claws, and then remove the side sill cover - rear INN. (On the side where airbag sensor is removed) CAUTION: Do not pull with excessive force. Doing so may damage the claws of the side sill cover INN. NOTE: To release the claws of the side sill cover INN, the following steps are recommended. Take out the weather strip from under the side sill cover INN. Turn over the floor mat and release the claws (C) and (D) by accessing from behind the side sill cover INN.
7. Remove the center pillar trim LWR. (On the side where airbag sensor is removed) Release the clip by pulling the center pillar trim LWR toward you. Expand the claws of center pillar trim LWR outward and remove it from the center pillar trim UPR. CAUTION: Do not expand the center pillar trim LWR excessively. Doing so may damage the trim. NOTE: First release the claw located to the rear of the vehicle.
8. Remove the seat belt retractor. (On the side where airbag sensor is removed) Turn over the floor mat to disconnect the belt tension sensor connector. Remove the bolt to remove the seat belt retractor.
9. Remove the side airbag sensor assembly. CAUTION: Do not separate the side airbag sensor and bracket. It causes the airbag system malfunction. Always replace the new parts when removed the sensors from the bracket. Remove the nuts. Disconnect the airbag connector and remove the side airbag sensor assembly.

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1. Before installation, inspect the following items and replace any faulty part with a new one. The side airbag sensor, sensor bracket, or connector are damaged. Side airbag is deployed. Tightening torque: Side airbag sensor: 7.5 N.m (0.76 kgf-m, 5.5 ft-lb)
2. Install each part in the reverse order of removal. CAUTION: If the hook is removed from vehicle body, replace the hook with the new part to avoid the deterioration of seat securing. NOTE: Assemble the center pillar trim LWR to the center pillar trim UPR securely. Tightening torque: Front seat belt: Ref. to «FRONT SEAT BELT»(ref-371949-S41581386572010091900000) , COMPONENT, General Description.

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1. Disconnect the ground cable from battery and wait for at least 60 seconds before starting work. CAUTION: The airbag system is fitted with a backup power supply. After disconnecting the battery ground cable, the airbag may deploy if you do not wait for 60 seconds before starting the service of airbag system.
2. Remove the rear seat cushion assembly. Pull up the seat cushion and release the hook. CAUTION: If the hook is removed from vehicle body, replace the hook with the new part to avoid the deterioration of seat securing. Remove the hook (A) by pushing it back while lifting the front side of the seat cushion, and remove the seat cushion assembly.
3. Release the clips and claws, and then remove the side sill cover - rear INN. (On the side where airbag sensor is removed) CAUTION: Do not pull with excessive force. Doing so may damage the claws of the side sill cover INN. NOTE: To release the claws of the side sill cover INN, the following steps are recommended. Take out the weather strip from under the side sill cover INN. Turn over the floor mat and release the claws (C) and (D) by accessing from behind the side sill cover INN.
4. Remove the rear quarter trim LWR. (On the side where airbag sensor is removed) Remove the backrest side pad. Remove the screws. Preparation tool: Stubby screwdriver Turn over the bottom end of the backrest side pad in the forward direction so that the claws are released. Remove the backrest side pad by pulling it up. Pull the release lever in the trunk room, and then tilt the backrest forward. Release the clips of the trunk trim panel assembly-side. Remove the clips, and remove the rear quarter trim LWR.
5. Remove the curtain airbag sensor assembly. Remove the nuts. Disconnect the airbag connector and remove the curtain airbag sensor assembly.

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1. Disconnect the ground cable from battery and wait for at least 60 seconds before starting work. CAUTION: The airbag system is fitted with a backup power supply. After disconnecting the battery ground cable, the airbag may deploy if you do not wait for 60 seconds before starting the service of airbag system.
2. Remove the rear seat cushion assembly. Pull up the seat cushion and release the hook. CAUTION: If the hook is removed from vehicle body, replace the hook with the new part to avoid the deterioration of seat securing. Remove the hook (A) by pushing it back while lifting the front side of the seat cushion, and remove the seat cushion assembly.
3. Release the clips and claws, and then remove the side sill cover - rear INN. (On the side where airbag sensor is removed) CAUTION: Do not pull with excessive force. Doing so may damage the claws of the side sill cover INN. NOTE: To release the claws of the side sill cover INN, the following steps are recommended. Take out the weather strip from under the side sill cover INN. Turn over the floor mat and release the claws (C) and (D) by accessing from behind the side sill cover INN.
4. Tilt the backrest forward, and then turn over the backrest backside mat.
5. Remove the backrest side pad assembly. (On the side where airbag sensor is removed) Disconnect the backrest cable and reclining lever cable. Remove the screws and remove the reclining lever assembly by pulling it downward. Preparation tool: Stubby screwdriver Turn over the bottom end of the backrest side pad in the forward direction so that the claws are released. Remove the backrest side pad by pulling it up.
6. Remove the clips, and remove the luggage floor box and rear floor edge cover.
7. Remove the rear quarter trim LWR. (On the side where airbag sensor is removed) Remove the caps, screws, and bolts. (A), (C) Take out the hook and remove the screw inside. (B) Remove the clips, and remove the rear quarter trim LWR.
8. Remove the curtain airbag sensor assembly. Remove the nuts. Disconnect the airbag connector and remove the curtain airbag sensor assembly.

1. Before installation, inspect the following items and replace any faulty part with a new one. The curtain airbag sensor or connector are damaged. Curtain airbag is deployed.
2. Install each part in the reverse order of removal. CAUTION: If the hook is removed from vehicle body, replace the hook with the new part to avoid the deterioration of seat securing. Tightening torque: Curtain airbag sensor: 7.5 N.m (0.76 kgf-m, 5.5 ft-lb)

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1. Position the front wheels straight ahead. (After moving a vehicle 5 m (16 ft) or more 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 60 seconds before starting work.
4. Remove the driver's airbag module assembly. Preparation tool: TORX® T30 Loosen the TORX® bolts located on the sides of the steering wheel. Disconnect the airbag connector and remove the airbag module assembly. Ref. to «PROCEDURE»(ref-371944-S34749869132010091900000) , Airbag Connector. Disconnect the horn harness.
5. Remove the steering wheel. CAUTION: Always use the steering wheel puller for removal to avoid deforming the steering wheel. If the steering wheel has been removed, make sure that the roll connector is not turned from the original position. Disconnect the connector and remove the nut. Put alignment marks and remove the steering wheel.
6. Remove the steering column cover. Lower the lever of the steering column. Release the claws and remove the screws, then detach the steering column lower cover. Separate the steering column upper cover and steering upper cover, and remove the steering column upper cover.
7. Remove the roll connector. CAUTION: Make sure that the roll connector is not turned from the original position. Disconnect the connector under the roll connector. Release the claws and remove the roll connector.

1. Install each part in the reverse order of removal. Tightening torque: Airbag module: 10 N.m (1.0 kgf-m, 7.4 ft-lb)
2. Before installing steering wheel, be sure to adjust the direction of roll connector with steering. Ref. to «ADJUSTMENT»(ref-371944-S42660943702010091900000) , Roll Connector. Tightening torque: Steering wheel: 39 N.m (4.0 kgf-m, 28.8 ft-lb) Clearance between column cover and steering wheel: 2 - 4 mm (0.08 - 0.16 in)