Recall - OCS Mat Sensor Replacement

GROUP
Safety Recall
Campaign

MODEL
Rio (JB)
2006-2008MY

NUMBER
097

DATE
July 2012

VOLUNTARY SAFETY RECALL CAMPAIGN

SUBJECT:
OCS MAT SENSOR REPLACEMENT - RIO PASSENGER SEAT (SC097)

This bulletin provides information relating to replacement of the Occupant Classification System (OCS) passenger seat mat in certain Rio vehicles produced from February 20, 2005 through December 9, 2007. There is a possibility that the passenger seat sensor mat may experience fatigue cracking through use over time. If sufficient cracking occurs, the
OCS will cease to function, the airbag warning light on the instrument panel will illuminate, and during an impact, the front passenger airbag may deploy even with a child present in the front passenger seat.





To correct this issue, follow the repair procedure below to replace the mat in the passenger side seat cushion. Verify that the vehicle is in the affected range by VIN and production date, and then perform the Service Procedure outlined in this bulletin.

OCS Mat Sensor

OCS Mat Sensor Replacement Service Procedure





1. Record customers radio presets.

Place the ignition key in the OFF position.


Remove the passenger seat assembly according to the applicable Service Manual / KGIS.

Tightening Torque Specifications
(Seat mounting bolt & nut):

29 ~ 39 lb-ft (39 ~ 53 Nm)





2. Remove the seat cushion assembly from the seat tract frame by removing the four (4) nuts (A).





3. Undo the four (4) cushion covering hooks (B) under the seat cushion assembly.





4. Remove the seat covering by unhooking the cushion covering hooks (C) marked on the photo (Front, right side, left side).





5. Undo the OCS wire harness attaching clips (D) located at the center of the seat cushion panel as shown in the photos.





6. Remove the seat cushion panel and non-
woven fabric (E) from the seat cushion.





7. Fold back both bolster sides of the seat covering to gain access to the three (3) hog ring clips (F) on each side totaling six (6), then remove clips.

8. Slowly detach the OCS mat sensor (H) from the seat cushion to help prevent damage or tearing to the cushion foam.





9. Carefully and slowly remove the OCS ECU (I) from the seat cushion.





10. Install the new OCS mat sensor assembly to the seat cushion.

Detach the protective tape (J) from new OCS mat sensor assembly.





11. Attach the new OCS mat sensor (K) to the seat cushion, aligning the front side of the OCS mat sensor assembly to the front
side (L) of the seat cushion as shown in the photo.





12. Attach the OCS ECU to the underside of the
seat cushion inward as far as possible.

13. Reinstall all removed components in reverse order of removal. Reconnect the battery.





14. Check the operation of PASSENGER AIR BAG "OFF" indicator lamp.

1) Indicator lamp ON (M):

- Infant or child restraint system with a 12 month old.

- Unoccupied





2) Indicator lamp OFF (N): Properly positioned adult or child age 13 and up.

15. Check for any diagnostic trouble codes (DTC) and erase any DTC(s) present.

Reset customers radio station presets as recorded earlier.





AFFECTED VEHICLE PRODUCTION RANGE:





REQUIRED PART:





WARRANTY CLAIM INFORMATION: