OCS Mat Sensor Replacement - RIO Passenger Seat (SC097)

Publication date: 2012-07-01
Reference number: SC097

OCS MAT SENSOR REPLACEMENT - RIO PASSENGER SEAT

SERVICE CAMPAIGN BULLETIN

Reference Number(s): SC097, Date of Issue: July 2012

KIA:	Rio (JB) 2006-2008MY
GROUP:	Safety Recall Campaign

SERVICE INFORMATION

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.

NOTE: There is no charge to the vehicle owner for this repair. Under applicable law, you may not sell or otherwise deliver any affected Rio (JB) until it has been repaired pursuant to the procedures set forth in this bulletin.

NOTE: To improve customer satisfaction, always remember to refer to WebDCS Warranty Coverage (validation) Inquiry Screen (Service> Warranty Coverage> Warranty Coverage Inquiry) for a list of any additional campaigns or service actions that may need to be performed on the vehicle before returning it to the customer.

File Under: <Voluntary Safety Recall Campaign>

OCS MAT SENSOR REPLACEMENT SERVICE PROCEDURE

Record customer's radio presets.
P lace the ignition key in the 'OFF' position.

WARNING: Disconnect battery and make sure voltage is bled off before performing Service Procedure. Otherwise accidental airbag deployment could occur, which may cause personal injury.

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)
Remove the seat cushion assembly from the seat tract frame by removing the four (4) nuts (A).
Undo the four (4) cushion covering hooks (B) under the seat cushion assembly.
Remove the seat covering by unhooking the cushion covering hooks (C) marked on the photo (Front, right side, left side).
Undo the OCS wire harness attaching clips (D) located at the center of the seat cushion panel as shown in the photos.
Remove the seat cushion panel and non-woven fabric (E) from the seat cushion.
NOTE: Be careful not to damage the non-woven fabric, because it will be reused when reassembling.
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.
NOTE: Please do not remove the two (2) hog rings located in the rear of the seat.
Replace the hog ring clips with new clips (P/N: 88627 11201) using Snap-on (YA808) upholstery pliers or equivalent.
Slowly detach the OCS mat sensor (H) from the seat cushion to help prevent damage or tearing to the cushion foam.
Carefully and slowly remove the OCS ECU (I) from the seat cushion.
NOTE: Make sure not to damage the seat cushion foam when detaching the OCS ECU.
Install the new OCS mat sensor assembly to the seat cushion.
Detach the protective tape (J) from new OCS mat sensor assembly.
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.
NOTE: Place the new OCS mat sensor in the correct position prior to applying pressure and adhering it to seat cushion.
Attach the OCS ECU to the underside of the seat cushion inward as far as possible.
NOTE: Carefully reinstall removed non-woven fabric and use new hog rings when reinstalling seat covering.
Reinstall all removed components in reverse order of removal. Reconnect the battery.
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.
Check for any diagnostic trouble codes (DTC) and erase any DTC(s) present.
Reset customer's radio station presets as recorded earlier.

AFFECTED VEHICLE PRODUCTION RANGE

Model	Production Date Range
Rio (JB)	February 20, 2005 through December 9, 2007

REQUIRED PART

Part Name	Part Number	Figure	Quantity
OCS Mat Sensor Assembly	88907 1G000QQK		1
Hog Ring (Staple Clip)	88627 11201		6

WARRANTY CLAIM INFORMATION

Claim Type	Causal P/N	Qty.	N Code	C Code	Repair Description	Labor Op Code	Op Time	Replacement P/N	Qty
R	88907 1G000	0	N86	C03	(SC097) OCS Mat Sensor Replacement	121034R0	0.6 M/H	88907 1G000QQK	1
R	88907 1G000	0	N86	C03	(SC097) OCS Mat Sensor Replacement	121034R0	0.6 M/H	88627 11201	6

NOTE: Labor time includes R&R seat, seat cushion, and clearing DTC's.