Occupant Classification System (OCS) Reprogramming (05-90-003-1)

OCCUPANT CLASSIFICATION SYSTEM (OCS) REPROGRAMMING

TECHNICAL SERVICE BULLETIN

SERVICE MANAGER

Please review entire TSB with all Service Advisors, Technicians and Warranty Administrators.

DESCRIPTION

The Occupant Classification System (OCS) "PASSENGER AIR BAG OFF" indicator light may not turn off or may switch on and off when some smaller stature adults are seated in the right front passenger seat of some 2004 and 2005 model year Elantra vehicles.

This OCS reprogramming procedure may be performed on an individual customer complaint basis only,  and only if the "PASSENGER AIR BAG OFF" indicator light remains on or switches on and off when small stature adults are seated in the right front passenger position.

VEHICLES AFFECTED

• Model: 2004-2005 ELANTRA vehicles produced beginning June 12, 2003.

GENERAL INFORMATION

• The OCS is designed to detect when the right front passenger seat is occupied by a child restraint system or a child so the air bag for that seat can be disabled. The OCS is also designed to detect when the right front passenger seat is occupied by an adult of sufficient stature to make potential air bag deployment appropriate.
• When an adult passenger is detected, the passenger air bag, passenger side impact air bag, and passenger seat belt pretensioner circuitry is enabled and the "PASSENGER AIR BAG OFF" indicator light is turned off. If an adult passenger is not detected, or when a child restraint system or child is detected, the passenger air bag, passenger side impact air bag, and passenger seat belt pretensioner circuitry is disabled and the "PASSENGER AIR BAG OFF" indicator light is turned on.
• To be able to properly detect a seated adult passenger, the OCS requires the right front passenger to be properly seated (sitting upright with the seat back in an upright position, centered on the seat cushion, with legs comfortably extended along the seat surface). Since weight and  seating position are both used as criteria for evaluating the presence of an occupant, if the OCS senses the seat is occupied by someone of light weight, or the passenger is out of position or is taking their weight off of the seat for a period of time, the system will disable the air bag and illuminate the "PASSENGER AIR BAG OFF" indicator light.
• When a small stature adult passenger is seated in the proper position with the "PASSENGER AIR BAG OFF" indicator light turned off, a momentary illumination of the light may indicate that the system briefly sensed a reduction in weight on the seat, or a change in the weight distribution on the seat because the passenger temporarily changed position.
• The OCS light may also turn on for tall and light weight adults when their feet are pulled to a position on the floor close to the seat cushion, raising their legs off the front of the cushion.

INSPECTION PROCEDURE

1. The customer must contact the dealership regarding the "PASSENGER AIR BAG OFF" indicator light operation.
2. Make an appointment when customer can bring both the car and the passenger who has experienced the "PASSENGER AIR BAG OFF" indicator light condition.
3. The Service Advisor must verify the passenger is sitting correctly, as per the following steps:
   1. Make sure that the adult passenger at issue is present for the initial confirmation procedure. Ask the passenger to sit in his or her normal position in the right front seat. Turn on the ignition and observe the "PASSENGER AIR BAG OFF" indicator light.
   2. If the "PASSENGER AIR BAG OFF" indicator light does not turn off, or switches on and off when the passenger moves in the seat, please ask the right front passenger to sit upright, not to lean or recline, and to comfortably extend their legs to make sure their legs contact the front portion of the seat cushion.
   3. If sitting in the proper position does not cause the "PASSENGER AIR BAG OFF" light to turn off, and not switch on and off, the OCS may be reprogrammed to help detect the presence of a properly seated small stature adult.
   4. If sitting in the proper position does cause the "PASSENGER AIR BAG OFF" light to turn off, then the vehicle should NOT  be reprogrammed.
   NOTE: A few seconds delay for the OCS light to turn on or off does not indicate a problem. Temperature changes may slightly affect the seat material and sensing characteristics of the OCS.
4. If the OCS qualifies to be reprogrammed, perform the following service procedures:

SERVICE PROCEDURE

1. Record the radio station presets, and disconnect the vehicle negative battery cable from the battery.
2. Remove the 4 passenger seat mounting bolts.
   Fig 2: Identifying Passenger Seat Mounting Bolt Locations

   
3. Tilt the passenger seat back. Disconnect the connectors under the passenger seat, and release the wire tie clips from the seat pan.
   Fig 3: Tilting Passenger Seat Back

   
   Fig 4: Disconnecting Harness Connectors And Clips

   
4. Remove the 4 nuts holding the passenger seat cushion assembly to the seat frame.
   Fig 5: Identifying Location Of Nuts Holding Passenger Seat Cushion Assembly To Seat Frame

   
   Fig 6: Close Up View Of Passenger Seat Cushion Assembly

   
5. Slightly raise the passenger seat cushion until the seat belt buckle wire harness wire tie can be unclipped from the seat pan.
6. Remove the seat cushion from the vehicle.
   NOTE: Document any pre-exisiting marks or damage on the cushion in the repair order.
7. Completely wrap the seat cushion in clean plastic or paper. Tape the covering so it cannot come loose during shipping.
   NOTE: Do not send the entire seat. Send only the seat cushion assembly.
8. Tape an envelope with a copy of the repair order to the seat cushion assembly wrapping.
9. Select a suitable sturdy box. Place the wrapped cushion into the box with enough packing material to keep it from shifting during transit.
10. Send the seat cushion assembly to the Hyundai Warranty Technical Center (WTC) address listed below via an overnight delivery company, such as UPS.
    Fig 7: Removing Seat Cushion Assembly

    

    Hyundai Warranty Technical Center Attention: OCS 

    18335 Mount Langley, Unit A Fountain Valley, CA 92708 

    NOTE: Do not include any other WTC parts with the OCS shipment.
11. Fax a copy of the repair order to (714) 242-1656.  The repair order should include a contact name, phone number, the delivery carrier's name and tracking number.
    NOTE: After the OCS has been reprogrammed, the seat cushion will be returned to your dealership so it may be reinstalled in the customer's vehicle.
12. When the reprogrammed seat cushion arrives, verify that you have received the correct seat cushion assembly.
13. Reinstall the cushion assembly in reverse order of removal.
14. Reinstall the seat and connect all connectors and wire tie clips.

    Tightening torque for seat mounting bolts: 

    35~55 Nm (350-550 kgf.cm, 25~40 lb.ft) 

15. Reconnect the battery cable, reprogram the radio stations, reset the clock, and verify no codes were stored in the SRS module.

WARRANTY INFORMATION

OP CODE	OPERATION	CAUSAL PART NUMBER	OP TIME	NATURE CODE	CAUSE CODE
88021F00	Evaluation only	88200-2D800-FAH	0.2 M/H	(1) N69	(2) C40
88021F02	Evaluation, seat cushion removed, packaged, shipped, unpackaged, and reinstalled		0.7 M/H
88200RZZ	Freight charges and rental car expenses	--	--	--	--
(1) Warning Light On (2) Improper Adjustment

Submit all claims using the Warranty Claim Entry Screen. 

WARRANTY CLAIM SUBMISSION NOTES - PLEASE READ IN ITS ENTIRETY

1. Submit all related expenses on one warranty claim. 
2. All  freight charges, both to ship the cushion to the WTC and to return the cushion from the WTC to the dealer, should be included in the Sublet amount. 
3. Shipments from the WTC to the dealer will be  freight collect. Include the freight collect amount in Sublet. 
4. All  service loaner or rental car charges must be included in the Sublet amount. 
5. If a service loaner or rental car is required for more than 5 days, contact your District Parts and Service Manager (DPSM) for authorization. 
6. Sublet code must be C1 - Customer Satisfaction.