Passive Restraint Drive Unit Replacement Kit (91006)

PASSIVE RESTRAINT DRIVE UNIT REPLACEMENT KIT

TECHNICAL SERVICE BULLETIN

PASSIVE DRIVE UNIT REPLACEMENT

Model: ALL STERLING 825, 827 BUILT PRIOR TO VIN 246769 W/PASSIVE RESTRAINTS

Date: 5/24/91

No: 91006

Group: General

SERVICE INFORMATION

V ehicles manufactured prior to VIN 246769 were equipped with a relay control unit (RCU), "white box", passive restraint control unit. Vehicles manufactured after VIN 246769 are equipped with an electronic control until (ECU), 'black box", passive restraint control unit/

The RCU is no longer available as a replacement part. Should a customer comment on a passive restraint drive system problem, follow the procedure below.

SERVICE PROCEDURE

1. 1. Verify the customer complaint, ensuring all connectors are properly engaged.
2. 2. Follow the diagnostic procedure in the 2.5 or 2.7 Electrical Troubleshooting Service Information, prior to replacing any part.
3. 3. If either drive unit or control unit is required, both sides must be replaced. A replacement kit is available, Part Number: 767 767302 71. This kit includes the following parts:
   • L.H. Drive Unit with ECU.
   • R.H. Drive Unit with ECU.
   • 2 Connector adaptor harnesses.
   • Owner Information hang tag.
   • Technical Information

WHEN REPLACING AND RCU EQUIPPED DRIVE UNIT

1. 4. Follow the procedure in the service information to replace both the L.H. and R.H. passive drive unit assemblies. When removing the upper and lower "B" post finishers be extremely careful to avoid breaking the finishers. Successful finisher removal can be achieved as follows:
   1. Remove the "B" and "C" post felt finishers to gain access to the upper and lower "B" post passive system finishers.
   2. With a "V" north upholstery or door trim pad removal tool locate the clips on the upper finisher attachment on the rear of the finisher.
   3. Pry the clip form its retaining hole in the "B" post as shown in Fig. Fig 1 , being careful not to break the clip retaining housing in the finisher.
   4. Release both clips on the upper and lower finisher in this manner and remove the finisher.
2. 5. Install each connector adaptor harness through the opening at the base of the B/C post. Reinstall the anti-rattle foam pad to prevent connector rattle (See Fig 2 ).

(The two connector adaptor harnesses supplied with the kit will be required to complete the connection between the new ECU and the existing vehicle main harness connector).

1. 6. IMPORTANT: Lubricate the passive restraint guide channel as described. This will eliminate the possibility of stall protection being activated because of excessive track friction See Stall Protection Operation).
2. 7. Install the Owner Information hang tag provided, on the inside rear view mirror.

SYSTEM OPERATION

The following operating differences between the RCU and ECU systems should be noted and pointed out to your Sterling customer (Ref: Owner Information hang tag).

• The shoulder belt retracts only when the door is opened and not every time the ignition is switched off.
• Rapid opening of the door before coming to a complete stop may no trigger the belt to retract. This is NOT a malfunction, but a safety feature. Simply close and re-open the door to trigger proper operation.

STALL PROTECTION OPERATION

The ECU unit contains a "Stall Protection" feature to protect the drive system from mechanical interference. This feature is activated anytime stalling of the buckle occurs during travel between the "A" and "B: post position. The ECU monitors the current required to drive the buckle around the track. If the current becomes excessive, "Stall Protection" will be activated, causing the buckle to reverse its direction of travel. Stall protection can be activated by any of the following:

• A locked up shoulder belt retractor reel.
• A dirty or unlubricated track.
• Occupant interference while the buckle is travelling.

VEHICLES WITH ECU (Black Box) ALREADY INSTALLED

If a vehicle is brought into your dealership for passive restraint repairs and it has an ECU unit installed, DO NOT install the upgrade kit in Step 3. Only the part diagnosed as causing the malfunction should be replaced (See Parts Information) and a Warranty Claim submitted using the appropriate labor code.

Description	Part Number
RCU to ECU Replacement Kit	767 767302 71

Description	Part Number
R. H. Passive Drive	767 767302 74
L.H. Passive Drive	767 767302 75
ECU (Black Box)	865 865500 54
Track Lubricant	767 767301 56
- Must be ordered separately.