SUBJECT: Campaign 083 – 2006 – 2008 Sonata – Occupant

SUBJECT: Campaign 083 – 2006 – 2008 Sonata – Occupant
November 17, 2008
TO:
ALL HYUNDAI DEALER PRINCIPALS/GENERAL MANAGERS:
ALL HYUNDAI DEALERSHIP SERVICE MANAGERS:
ALL HYUNDAI DEALERSHIP PARTS MANAGERS:
ALL HYUNDAI DEALERSHIP SALES MANAGERS:
SUBJECT: Campaign 083 – 2006 – 2008 Sonata – Occupant Classification
System (OCS) Reprogramming – Inspection Procedure Revision
Hyundai Motor America is conducting a Customer Notification Occupant Classification System
(OCS) Reprogramming campaign on certain 2006 – 2008 Model Year Sonatas.
THIS NOTICE HAS BEEN SENT TO YOU BECAUSE THE INSTRUCTIONS RELATING
TO THIS RECALL HAVE BEEN REVISED.
This campaign is to be performed on an individual customer basis. It is not necessary to
reprogram every vehicle’s OCS. The campaign should be conducted upon customer request. If
a customer is uncertain about whether the campaign is necessary, please follow the procedures
in TSB 08-01-006-1. Please inform Hyundai through your DPSM of any customers previously
told that the campaign was unnecessary based on the prior instructions.
Because not every vehicle will receive OCS reprogramming, vehicles eligible for this Campaign
ARE NOT identified as having an open Campaign 083 on Hyundai Motor America’s
“Warranty Vehicle Information” screen via WEBDCS. The “Warranty Claim History”
portion of the “Warranty Vehicle Information” screen for each vehicle will reveal whether a
particular vehicle has been reprogrammed as part of this campaign by identifying “OCC.
CLASSIFICATION SYS REPRG 08-01-006” in the Operation Description column.
The Dealer Letter and Technical Service Bulletin (TSB) #08-01-006-1 containing instructions
on the campaign procedure and submission of the campaign claim, will be posted on Hyundai’s
Website on November 17, 2008.
NOTE: The TSB has been revised. The Inspection Procedures on pages 2 and 3 have been
revised to clarify the conditions under which reprogramming should be performed.
Reprogramming may not be necessary unless a customer indicates that the “PASSENGER AIR
BAG OFF” light remains on when small stature adults are seated in the right front passenger
position or if the customer requests that the OCS be reprogrammed. Please have the seat sent
to be reprogrammed at the Hyundai Warranty Technical Center to ensure that the customer is
satisfied.
It is IMPORTANT TO SUBMIT A CAMPAIGN CLAIM FOR EACH VEHICLE SERVICED so
your dealership can be compensated for your work and Hyundai can maintain accurate records of
campaign completions.
LEGAL LIABILITY NOTICE: You are required to keep confidential any and all information and
documents provided to you by Hyundai Motor America in the conduct of carrying out work for this
campaign. Hyundai Motor America dealers may use owner information provided for the campaign
only for the purpose of conducting and performing this campaign, and for no other purpose.
Hyundai appreciates your cooperation and support. Questions may be directed to your District Parts
and Service Manager or Warranty HELPREP line at 1-877-446-2922.
HYUNDAI MOTOR AMERICA
1
Technical Service
Bulletin
Group
BODY ELECTRICAL
Number
08-01-006-1
Date
Subject
OCCUPANT CLASSIFICATION SYSTEM (OCS) REPROGRAMMING
(CAMPAIGN 083)
INSPECTION PROCEDURE REVISION
CIRCULATE TO:
[X] SERVICE ADVISOR
NOVEMBER, 2008
Model
[ ] GENERAL MANAGER [X] PARTS MANAGER
[X] SERVICE MANAGER [X] WARRANTY MGR
2006-2008 SONATA
[X] TECHNICIAN
[ ] SALES MANAGER
IMPORTANT: THIS CAMPAIGN IS TO BE PERFORMED ON AN INDIVIDUAL
CUSTOMER BASIS. IT IS NOT NECESSARY TO REPROGRAM
EVERY VEHICLE'S OCS. BECAUSE OF THIS, THE WARRANTY
VEHICLE INFORMATION SCREEN WILL NOT IDENTIFY AN OPEN
OR COMPLETED CAMPAIGN 083 ON ANY VEHICLE. HOWEVER,
THE "WARRANTY CLAIM HISTORY" PORTION OF THE
"WARRANTY VEHICLE INFORMATION" SCREEN FOR EACH
VEHICLE WILL REVEAL WHETHER A PARTICULAR VEHICLE HAS
BEEN REPROGRAMMED AS PART OF THIS CAMPAIGN BY
IDENTIFYING "OCC. CLASSIFICATION SYS REPRG 08-01-006-01"
IN THE OPERATION DESCRIPTION COLUMN.
IMPORTANT: INSPECTION PROCEDURES ON PAGES 5 AND 6 HAVE BEEN
REVISED TO CLARIFY THE CONDITIONS UNDER WHICH
REPROGRAMMING SHOULD BE PERFORMED.
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 when some smaller stature adults are seated in the right front
passenger seat of some 2006, 2007 and 2008 model year Sonata vehicles. This
condition occurs in some seating positions, but should not occur when a passenger is
properly seated.
On AN INDIVIDUAL CUSTOMER BASIS, this OCS reprogramming procedure must be
performed if the "PASSENGER AIR BAG OFF" indicator light remains on when small
stature adults are seated in the right front passenger position or if the customer has
requested that it be performed.
Page 3 of 12
NOTE: THE FOLLOWING EVALUATION MAY BE CONDUCTED TO DETERMINE
WHETHER THE REPROGRAMMING IS NECESSARY. EVALUATIONS
SHOULD BE MADE WITH THE PASSENGER WHO EXPERIENCES THIS
CONDITION.
INDICATOR LIGHT
VEHICLES AFFECTED:
• Model: Model years 2006-2008 Sonata vehicles.
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 and passenger seat
belt pretensioner circuitry is enabled and the "PASSENGER AIR BAG OFF"
indicator light is turned off (not illuminated). If an adult passenger is not
detected, or when a child restraint system or child is detected, the passenger air
bag and passenger seat belt pretensioner circuitry is disabled and the
"PASSENGER AIR BAG OFF" indicator light is turned on (illuminated).
• The OCS operates by evaluating a pressure pattern applied to the seat cushion
to detect the presence of an adult occupant. The OCS operates most effectively
when the right front passenger is 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). Both weight and seating position are
necessary to create the seating pressure that indicates the presence of an adult
occupant. If the OCS pressure pattern indicates the seat is occupied by
someone of light weight, or the passenger is out of position, or is taking their
Page 4 of 12
Technical Service
Bulletin
Group
BODY ELECTRICAL
Number
08-01-006-1
weight off of the seat for a period of time, the OCS system may disable the airbag
and illuminate the "PASSENGER AIR BAG OFF" indicator light.
• 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.
WARNING: Aftermarket equipment, such as seat covers, must not be used
because they can affect OCS system operation.
NOTE: The operation of the driver air bag, driver seat belt pretensioner, driver
and passenger side impact air bags, and curtain air bags are not affected
by the OCS.
INSPECTION PROCEDURE:
1. The customer contacts the dealership regarding the "PASSENGER AIR BAG OFF"
indicator light operation.
2. If the customer indicates that the "PASSENGER AIR BAG OFF" light has been
illuminating and requests that the reprogramming be conducted, the campaign
should be performed.
3. If the customer would like an evaluation before deciding whether to have the
reprogramming conducted, request that the customer bring the car to the dealership
with the passenger who has experienced the "PASSENGER AIR BAG OFF"
indicator light condition for evaluation.
4. The Service Advisor should verify whether the passenger is sitting correctly, and
inform the customer on the most effective seating position, as per the following
steps:
a. 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.
b. If the "PASSENGER AIR BAG OFF" indicator light does not turn off,
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.
c. If the "PASSENGER AIR BAG OFF" indicator light turns off when the
occupant is properly seated, confirm that the customer and occupant
understand the necessity of sitting in that position and will sit in that
Page 5 of 12
position. If the customer and occupant confirm that they understand and
will sit in that position, then the vehicle is NOT required to be
reprogrammed.
However, if the customer requests that the OCS be reprogrammed,
please indicate the reason for requesting the reprogramming on the repair
order and follow the SERVICE PROCEDURE beginning on the next page
to ensure that the customer is satisfied.
d. If sitting in the proper position does not cause the "PASSENGER AIR
BAG OFF" indicator light to turn off, the OCS must be reprogrammed to
help detect the presence of a properly seated small stature adult. On the
repair order, indicate that the "PASSENGER AIR BAG OFF" indicator
light does not turn off and follow the SERVICE PROCEDURE beginning
below on this page.
NOTE: Every right front passenger evaluation should be performed as follows:
(1) The passenger must sit in the right front seat,
(2) Turn on the ignition,
(3) Check if the "PASSENGER AIR BAG OFF" indicator light is
illuminated after 30 seconds. A few seconds delay for the OCS
"PASSENGER AIR BAG OFF" indicator light to turn off just after turning
on the ignition does not indicate a problem.
NOTE: If a customer requests service for an instrument cluster "AIR BAG"
warning lamp illumination condition, use a scan tool or GDS to determine
if an OCS-related code (B1448, B1449, or B1450) is present. If the code(s)
is present, indicate the code on the repair order, and follow the service
procedure below.
NOTE: If the code(s) is not an OCS-related code, repair the condition(s) under
normal warranty.
SERVICE PROCEDURE:
1. Record the radio station presets, and
disconnect the vehicle negative
battery cable from the battery.
Page 6 of 12
Technical Service
Bulletin
Group
BODY ELECTRICAL
Number
08-01-006-1
2. Disconnect all connectors from under
the seat and remove the front
passenger seat assembly.
3. Remove the recliner lever by removing
the metal clip.
4. Remove the plastic side outer cover by
unfastening 3 mounting screws.
Page 7 of 12
NOTE: When removing the side outer
cover, verify the clip (p/n 881733K000) is installed on the outer
cover. If the clip remains
lodged on the seat bracket,
remove it and install it onto the
side outer cover.
5. Remove the seat buckle cover by
unfastening the screw.
.
Page 8 of 12
Technical Service
Bulletin
Group
BODY ELECTRICAL
Number
08-01-006-1
6. Unfasten the seat buckle mounting bolt
to get access to the seat cushion
covering fixing hook. Tightening
torque: 39.2~53.9 N.m (4.0~5.5 kgf.m,
28.9~39.8 lb.ft).
7. Raise the front seat and disengage the
2 seat covering fixing hooks on the
bottom side of the seat.
8. Disconnect the OCS wiring connector
and disengage the 2 wiring clips.
Page 9 of 12
9. Disengage the front seat covering
fixing clips.
10. Disengage the right and left seat
covering fixing clips.
11. Remove the seat cushion assembly
from the seat assembly.
NOTE: Document any pre-existing marks or damage on the cushion in the repair
order.
12. Completely wrap the seat cushion in clean plastic or paper. Tape the covering so
it cannot come loose during shipping.
Page 10 of 12
Technical Service
Bulletin
Group
BODY ELECTRICAL
Number
08-01-006-1
NOTE: Do not send the entire seat assembly. Send only the seat cushion
assembly.
13. Tape an envelope with a copy of the repair order and the dealer shipping account
number to the seat cushion assembly wrapping. Also, include a return shipping
label.
14. Select a suitable sturdy box with a dimension size of 22” L x 22” W x 6" H. Use of
a larger box may result in additional dimension weight charges, Large Package
surcharge and Fuel surcharge.
15. Send the seat cushion assembly to Hyundai's Warranty Technical Center (WTC)
address listed below via FedEx Overnight. Use your FedEx Dealer Discount
Program account. Using another carrier or shipper number may result in shipping
charges that exceed the freight reimbursed by HMA.
NOTE: Both OUTBOUND and RETURN shipment of the seat cushion should be
prepaid (bill sender) by the dealer. Place the Return Shipping Label with
the repair order. See the following page of this TSB for freight
reimbursement procedure.
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.
16. Fax a copy of the repair order to (714) 378-5179. 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.
17. When the reprogrammed seat cushion arrives, verify that you have received the
correct seat cushion assembly
18. Reinstall the cushion assembly in reverse order of removal.
19. Reinstall the seat assembly and connect all connectors and wire tie clips.
Tightening torque for seat mounting bolts:
35~55 Nm (3.5-5.5 kgf.cm, 25~40 lb.ft)
Page 11 of 12
20. Reconnect the battery cable, reprogram the radio stations, reset the clock, and
verify no codes were stored in the SRS module.
NOTE: If the cushion is not returned to your dealership within 3 working days
after shipping to the WTC, please contact (877) 446-2982 for assistance.
WARRANTY INFORMATION:
OP CODE
81B012R0
OPERATION
OP TIME
Evaluation, seat cushion removed, packaged, shipped, unpackaged, and reinstalled.
0.6 M/H
CAMPAIGN CLAIM NOTES - PLEASE READ IN ITS ENTIRETY:
NOTE 1: Submit claim using the Campaign Claim Entry Screen.
NOTE 2: Rental amount of 4 days, X $35.00 = $140.00, will be automatically
added to the campaign claim.
NOTE 3: Freight amount will be automatically added, based upon the dealer’s
region as shown below.
REGION
OVERNIGHT FREIGHT
Central Region
$148.00
Eastern Region
$154.00
California Region
$128.00
South Central Region
$144.00
Southern Region
$154.00
Western Region
$138.00
Page 12 of 12
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