MSA5P0136C Service Bulletin/Repair Instructions

Technician

Reference

Booklet

SUPPLEMENTAL

RESTRAINT SYSTEM (SRS)

Module 604
MSA5P0136C

June 2013
This Technical Reference Booklet (TRB) is designed to be used in a classroom

environment or as a guide for self study.

The TRB is not intended to be used as a supplement or substitute for the

Subaru Service Manual. Always consult the appropriate Service Manual

when performing any diagnostics, maintenance or repair to any Subaru

vehicle.
© Copyright 2013

Subaru of America, Inc.
All rights reserved. This book may not be

reproduced in whole or in part without the

express permission of Subaru of America,

Inc. Specifications in this Guide are based

on the latest product information available at

the time of publication. Some images shown

are for illustration purposes only.

Subaru of America, Inc. reserves the right at

any time to make changes or modifications

to systems, procedures, descriptions, and

illustrations contained in this book without

necessarily updating this document.

Information contained herein is considered

current as of June 2013.
SRS Disclaimer:

The airbag Supplemental Restraint System (SRS) affords the driver and the front passenger

additional protection in moderate to severe frontal and side-impact collisions and outboard

2nd row passengers additional protection in moderate to severe side impact collisions. This

system provides supplemental protection only, and seat belts must be worn in order to avoid

injuries to out-of-position occupants upon bag deployment and to provide the best combined

protection in a serious accident. *Children should always be properly restrained in one of

the rear seats. See Owner's Manual for recommended seating position.
© Subaru of America, Inc. 2013
912 to 924
Supplemental Restraint System (SRS-604)
Table of Contents
SRS Airbag System Overview................................................................... 6

SRS System Precautions........................................................................... 6

Component Overview................................................................................ 7

Component Operation.............................................................................. 8

Roll Connector Phasing....................................................................... 10

Connector Double Lock Sensors......................................................11

Airbag Module............................................................................................ 12

Airbag............................................................................................................ 13

Airbag Deployment................................................................................... 13

Airbag Warning Lamps............................................................................. 14

Diagnostics and Servicing....................................................................... 14

SRS System Servicing............................................................................. 15

1996 Model Legacy and Outback.......................................................... 17

1998 Model Forester............................................................................... 18

2000 Model Legacy and Outback.......................................................... 20

2001 Model Legacy..................................................................................... 21

2002 Model Impreza WRX......................................................................... 22

2003 Supplemental Restraint System (SRS)..................................... 23

2005 Legacy Airbag System..................................................................... 26

Calibration Process................................................................................ 30

SRS Interior................................................................................................ 33

Side Impact Sensor................................................................................. 35

Subaru B9 Tribeca..................................................................................... 36

Pressure Sensor Type-Occupant Detection System................................ 36

2007 and Newer Tribeca Airbag Systems.......................................... 38

2008 Supplemental Restraint System (SRS)..................................... 39

2009 Forester SRS Airbags.................................................................... 42

2010MY Legacy and Outback................................................................... 43

2012MY Impreza Airbag Systems............................................................ 45

Occupant Detection System (ODS)..................................................... 51

2014 Forester............................................................................................. 56

Driver Side Front Airbag........................................................................... 56

Curtain Airbag.......................................................................................... 57

Knee Airbag............................................................................................. 58

Dual Deployment Seatbelt Pretensioners................................................ 59
4
June 2013
Supplemental Restraint System (SRS-604)

SRS Test Harnesses................................................................................. 62

Special Tools............................................................................................. 62

Service Bulletins .................................................................................... 63

Tech TIPS....................................................................................................... 64
5
June 2013
Supplemental Restraint System (SRS-604)

SRS Airbag System

Overview
SRS System Precautions
1.	Whenever servicing the SRS System

disconnect the battery and wait at least

10 minutes before proceeding.
The SRS Airbag System is a safety device

designed to function in conjunction with a knee

bolster, seat belts, and shoulder belts. Similar

to other manufacturers, it deploys in frontal

and side collisions. It is an electrically operated

system which uses a chemical deployment

device.
2. Always store the SRS Airbag Module

(steering wheel pad) facing up.

3. All of the SRS components are sealed DO NOT DISASSEMBLE.

4. All of the SRS wiring is enclosed in a yellow

housing for quick identification. Use care

whenever working near a yellow housing.

These wires may not be repaired if they

are damaged. They MUST be replaced.

5. Do not drop any of the components. This

could alter their sensitivity.

6. The SRS Module must avoid extreme heat

exposure (200 degrees F. or greater).

NOTE:
5

SRS Components
The SRS System features built-in SelfDiagnostics and a redundant Safety Design

built into the SRS control module.
7.	Wear protective clothing when handling

deployed Airbag components. Always

use gloves and eye protection. Although

the residue is NON toxic, it may cause

minor eye and skin irritation.
The system safeguards include double locking

connectors with Diagnostic Sensors, a selfshorting inflator SRS Airbag Module connector

to prevent accidental deployment during

servicing, and a Steering Roll Connector. A

capacitor supplies backup power.
8.	Never place yourself or test equipment

between the Airbag Module and seat

when serving the Airbag System.

NOTE:
Finally, for redundancy, there are two front

Inertia Sensors and two Safety Sensor Circuits.

NOTE:
EXPOSURE TO TEMPERATURES

OF 300 DEGREES F. OR

GREATER WILL CAUSE

DEPLOYMENT.
THE SRS Airbag SYSTEM IS

THOROUGHLY DESIGNED

TO PREVENT ACCIDENTAL

DEPLOYMENT, HOWEVER,

CAUTION SHOULD ALWAYS

BE USED WHEN SERVICING

OR DIAGNOSING THE SYSTEM.

THE SRS SYSTEM, WHEN

HANDLED PROPERLY, IS LESS

HAZARDOUS TO SERVICE

THAN A CAR BATTERY OR

FUEL SYSTEM.

6
REVIEW ALL CAUTIONS

OUTLINED IN THE SERVICE

MANUAL REGARDING SKIN

AND EYE EXPOSURE TO

DEPLOYED Airbag RESIDUES.
June 2013
Supplemental Restraint System (SRS-604)

Component Overview
The following is an overview of the first

Subaru vehicle (1992 SVX) to be equipped

with the SRS Airbag system.

The Airbag and Inflator Module are attached to

the steering wheel and covered by the steering

wheel pad. It contains the Deployment module,

Airbag and cover pad.
9

Steering Roll Connector
The steering roll connector is mounted between

the steering wheel and the combination switch.

It is an integral part of the combination switch

assembly. The design of this assembly allows

for steering wheel rotation. It also provides

the hard wire connection between the Airbag

module and the SRS system harness.
7

Front Sensors and ECM
10

Double Lock Connector
8
All SRS connectors are equipped with double

locks and sensors. The sensors are used

to indicate that the connector is not doublelocked. For identification purposes, they are

green in color.
Front Sensor
There are two (2) front sensors located inside

the front fenders behind each inner fender

liner. In addition, there are two Safety Sensors

located inside the ECM.
7
June 2013
Supplemental Restraint System (SRS-604)
Component Operation

The ECM controls the SRS Airbag System by

constantly monitoring the input signals from

the front sensors, the Safety Sensors and the

double lock circuit. It also generates output

signals to the warning lamps and to the inflator

module.
11

SRS ECM Location
The ECM is located under the center console.

It receives sensor input signals in the event

of a frontal impact. It then sends a signal to

trigger Airbag deployment. The ECM has selfdiagnostic capabilities, incorporating long term

memory.
14
The ECM sends a continuous low voltage

Open ECM

signal to monitor the sensors, the harness, the

deployment module, and to check for connector The ECM contains two Safety Sensors which

provide input signals, and two capacitors which

integrity.

supplement low battery voltage.

The capacitors also provide backup voltage in

the event of a total loss of battery voltage. They

are triggered by an internal voltage regulator.

NOTE:
12

Combination Meter
There are two (2) Airbag warning lamps

located in the combination meter. For safety

purposes, there are also two (2) independent

drive circuits. Only one lamp should illuminate

at time.
8
THE CAPACITORS CAN

ACTIVATE THE SRS Airbag UP

TO 10 MINUTES AFTER A TOTAL

LOSS OF BATTERY VOLTAGE.

THE REGULATOR MONITORS

BATTERY VOLTAGE AND

CAN SUPPLEMENT BATTERY

VOLTAGE AS NEEDED IN THE

EVENT OF A COLLISION.
June 2013
Supplemental Restraint System (SRS-604)
15
16
Front Sensor Cut-Away
Safety Sensor
Redundancy is provided by the front left hand

and right hand sensors. The hollow roller

design provides a movable mass. The roller

is mounted on a flat surface and held in place

by a flat roller spring. The roller spring allows

forward roller movement during frontal impacts

of 12.5 MPH or greater. In this case, the roller

and spring assembly makes contact with the

circuit terminal.
Two Safety Sensors located inside the ECM

provide redundancy. They operate similar

to the Front Sensors in that they provide a

B+ circuit to the Inflator. Although they are

similar in construction and operation to the

Front Sensors, the Safety Sensors are more

sensitive.
Weight added to the center of the roller makes it

heavier, which in turn, makes the sensor more

When the roller makes contact with the circuit sensitive to impact. The ECM must be replaced

terminal, it sends a collision signal to the ECM. if one of the Safety Sensors fail.

This completes the sensor circuit and provides

a ground circuit to the inflator.

The metal housing of the front sensors are

surrounded by resin and filled with inert gas

to prevent moisture damage.

CAUTION: DO NOT OPEN THE SENSOR

HOUSING. THE INTERNAL

COMPONENTS ARE NOT

SERVICEABLE.
The continuous sensor harness is molded

directly into the sensor body. The harness has

only one sensor connector, which is located

at the ECM. This provides a one-piece circuit

path to the ECM. A damaged harness or sensor

must be replaced as an assembly.
9
June 2013
Supplemental Restraint System (SRS-604)
Roll Connector Phasing

The roll connector MUST be phased to

the steering system. With the front wheels

centered, align the inner “center” indicator

(early versions of the SRS Airbag system)

located behind the window in the roll connector,

with the “center” indicator located on the

rotating cover next to the window. There is also

an alignment arrow on the connector case.
17

Steering Roll Connector
The Steering Roll Connector is a continuous flat

ribbon-type cable. The cable coils around the

hub which allows 2.65 turns (either direction)

from the center steering position. This provides

a direct hard wire connection between the SRS

Airbag Module and the ECM harness. It also

includes the Horn Circuit. This eliminates the

potential circuit interruption inherent to sliding

contact-type connectors, which also prevents

false trouble codes.
19

Roll Connector Indicator
Two guide pins are used to align the roll

connector with the steering wheel.
If the inner indicator shows “1R” in the window,

rotate the cover one full rotation to the right. If

the inner indicator shows “2R” in the window,

rotate the cover two full rotations to the right.

Similarly, if the indicator shows either “1L”

or “2L”, rotate the cover one or two left hand

rotations. Consult the service manual phasing

of newer model roll connectors.

NOTE:
10
TO MAINTAIN PROPER

STEERING WHEEL ALIGNMENT,

CENTER THE FRONT

WHEELS AND SCRIBE AN

ALIGNMENT MARK BETWEEN

THE STEERING WHEEL HUB

AND THE SHAFT, PRIOR TO

DISASSEMBLY.
June 2013
Supplemental Restraint System (SRS-604)

Connector Double Lock

Sensors
The following are examples from the 1992 SVX.

Double lock sensor mechanisms are identified

by a green color. They are used on all SRS

electrical connectors. The system uses four 4

double lock sensors between:

1. The main ECM connection
22
2. The system power supply and the warning

light.
Primary Double Lock Connector (unlocked)
Double lock sensor terminals make contact

when they are unlocked and they separate when

they are locked. The green tabs mechanically

4. The roll connector and the Airbag module prevent the connector from being removed. The

located behind the steering wheel pad.

primary double lock will not latch unless the

connectors are completely inserted.

3. The ECM harness and the roll connector

at the combination switch.
23
21

Schematic (Artwork)
Releasing Primary Double Lock
These sensors connect the double lock

detecting circuit to the negative side of the

igniter circuit. This provides a ground signal

circuit for the warning light system.
In order to release the primary double lock, use

a small screw driver. Press in on the metal loop

and simultaneously raise the green latch. Then

to remove the individual connectors, press

down on the primary connector locks.
If any green double-lock lever is not properly

latched, the SRS warning lamp will be

illuminated and a Trouble Code will be

displayed (Code 14).

The primary double lock at the ECM secures

the main harness connector as well as the two

front sensor harness connectors.
11
June 2013
Supplemental Restraint System (SRS-604)

Note:
Double locks are utilized on all

models; however the double

lock sensing circuits have been

discontinued.
Airbag Module

The Airbag module comes as a one piece

assembly with the horn buttons. It is mounted

to the steering wheel with two or four #30

tamper-proof Torx bolts.
24

Connector Lock Operation
Secure the primary double lock by pressing the

green latch down until a click is heard.
27

Airbag Module (Artwork)
25
The Airbag module consists of three

subcomponents:
Two Step Lock
The procedure for locks #2 and #3 are similar

1. Inflator

to the primary double lock, except that they are

2. Airbag

released at the primary lock in two steps. First,

press down once on the spring-loaded green

3. Inflator harness with connector

latch and it will pop out. Then press it down a

second time in order to remove the connector. NOTE: The Airbag Module is serviced

To secure the double lock, push in the green

only as an assembly. DO NOT

latch until a click is heard.

attempt to disassemble or

repack the airbag.

Double lock locations:

1. The main ECM connection

2. The system power supply and the warning

light.

3. The ECM harness and the roll connector

at the combination switch.

4. The roll connector and the Airbag module

located behind the steering wheel pad.
12
June 2013
Supplemental Restraint System (SRS-604)

Inflator Igniter
Airbag Deployment
The inflator igniter is designed to ignite a squib

after it receives an input from the ECM. The

igniter is an electrically heated device which

generates temperatures in excess of 300

degrees F. to ignite the squib.
In order to activate the system, a frontal force

of 12.5 MPH or greater is required. This force

overcomes the inertia and the tension of the

roller springs of the rollers in the front sensors

and the Safety Sensors. The rollers then make

contact with the circuit terminals. The front

sensors provide a ground circuit while the

Safety Sensors provide a positive circuit.

In order for the ECM to activate the inflator, it

must receive at least one collision signal from

the front sensors and at least one collision

signal from the Safety Sensors.
After receiving a signal from the ECM, the

igniter instantly heats up to 300 degrees F.,

igniting the squib which burns the nitrogen

pellets to create nitrogen gas. The generated

29

N2 goes through the screen into the Airbag.

The outer skin (steering wheel pad) of the

Squib (Artwork)

inflator Airbag module then ruptures as the

The squib consists of fire transmissive material Airbag deploys. The driver’s forward movement

used to ignite nitrogen pellets. The nitrogen is absorbed by the Airbag as it vents the N2

pellets generate nitrogen gas (N2) during through two 1.58 inch (40mm) holes.

combustion. This creates rapid gas expansion

The Operational Time Sequence is almost

which, in turn, inflates the Airbag.

instantaneous:

The built-in screen cools and removes hot

1. Collision: Zero seconds

cinders from the N2 before the N2 enters the

2. Operation of the inflator: 30 millisecond

Airbag.

3. Discharge of the N2: About 60 millisecond
Airbag
4. Completion: About 110 milliseconds
The Airbag itself is located behind the steering

NOTE:

wheel center pad. It is made out of nylon material

which expands to a diameter of approximately

30 inches (762mm) when inflated. (The design

and shape of the Airbags has changed over the

years to provide increased safety to the vehicle

occupants and to comply with government

regulations).
A VEHICLE WITH A DEPLOYED

Airbag MUST BE TOWED TO THE

DEALER FOR SERVICE.
The bag is coated on the inside with silicone

and is coated on the outside with talcum

powder or cornstarch. This provides lubrication

12 3 4 5

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