Recall 08V-384 - Seat Occupancy Detection Mat

SI B65 19 08
Audio, Navigation, Monitors, Alarms, SRS

July 2009
Technical Service

This Service Information bulletin supersedes SI B65 19 08 dated June 2009.
PERFORM THE PROCEDURE OUTLINED IN THIS SERVICE INFORMATION ON ALL AFFECTED VEHICLES BEFORE CUSTOMER DELIVERY OR THE NEXT TIME THEY ARE IN THE SHOP FOR MAINTENANCE OR REPAIRS.

Under the National Traffic and Motor Vehicle Safety Act of 1966, as amended, if there has been a recall campaign, dealers must assure that all new vehicles and new items of replacement equipment are free of safety defects and comply with all applicable Federal Motor Vehicle Safety
Standards at the time of delivery to the consumer. This means that dealers may not deliver new motor vehicles or new items of replacement equipment to consumers unless the safety defect or noncompliance has been remedied before delivery.

[NEW] designates changes to this revision

SUBJECT
Recall Campaign 08V-384: Modify Seat Occupancy Detection Mat

MODEL
[NEW] E83 with base and sport seats

E60, E61 with base and sport seats

E90, E91 with sport seats

SITUATION
The passenger seat occupancy mat can fatigue, depending on the manner and frequency of the front passenger's entry and exit. Specifically, over time, microcracks could develop in the side bolster section of the mat. If a microcrack leads to a break of an electrical conductor, the system will recognize a failure. As a result, the front passenger air bags, with the exception of the head protection system, will be deactivated. The air bag warning lamp, as well as the passenger air bag "on-off" lamp, will be
illuminated to make the occupants aware of the deactivation.

This recall modifies the seat mat to prevent fatigue; it will not fix an already faulty mat.

A copy of the customer notification letter is included.

AFFECTED VEHICLES
This Recall Campaign involves E83 (X3), E60, E61 (5 Series), and E90, E91 (3 Series) vehicles which were produced from June 30, 2003 to November 18, 2005; March 18, 2003 to November 22, 2005; and October 13, 2004 to January 1, 2006, respectively.

In order to determine whether a specific vehicle is affected by this Service Action, it will be necessary to utilize the "Service Menu" of the DCS (Dealer Communication System) or the Key Reader. Based on the response of the system, either proceed with the corrective action or take no further action.

PROCEDURE
As a prerequisite, only the following BMW diagnostic equipment may be used:

^ DIS V57 or later, in association with the OPPS/OPS. In addition, adapter cable 52 1 010 is required.

or

^ ISTA D2.12.0 or later, in association with the ICOM and the new adapter cable 52 0 000. This new adapter cable has been shipped to all dealers free of charge.

1. Connect the diagnostic system and power supply to the vehicle.

2. Carry out a vehicle test. If there are fault code memory entries for the seat occupancy detection mat, work through the test plan and, if necessary, replace and enable the mat in accordance with Repair Instruction RA 52 13 400. Note: Enabling of the replacement seat mat must be via diagnosis or ISTA/P (depending on the production date of the vehicle).

No other measures are necessary in this case (it is not necessary to perform the modification on a replacement OC3 mat).

3. Note: Before continuing, ensure there are no stored faults relating to the seat occupancy system.

4. Using the BMW diagnosis equipment, select "Service functions / Body / Seat occupancy detector / Program seat occupancy detection mat". Then select the test plan S6577_62001 to program the seat occupancy detection system.

5. Switch off the ignition and follow the test plan instructions to connect the adapter cable to the vehicle.

Note that the current test plan refers only to the use OPS/OPPS. If the ICOM is being used, this is connected the same way but using adapter cable 52 0 000.

Switch on the ignition and wait for the OPS/OPPS or ICOM to reconnect before continuing.

6. At the first selection screen, select "(1) Program seat occupancy detection system (OC3)".

7. Follow the instructions in the test module.

Note:
If programming cannot be performed because no data is available (the actual message on the screen reads "Programming cannot be carried out as no data exists.."), no further measures are required. The mat is up to date.

8. After programming is completed, disconnect the mat for at least 5 seconds , according to the instructions in the test module. This allows the OC3 mat to complete a full reset.

9. Follow the instructions in the test module.

Note 1:
If the coding fails (the actual message on the screen reads "Seat occupancy mat defective. Replace the seat occupancy mat in accordance with repair instructions"), do not replace the seat occupancy mat as instructed. The cause of the coding failure was most likely because the seat mat was not disconnected properly and the necessary reset did not occur. Restart the procedure from step 4.

Note 2:
The coding changes the part number in the OC3 mat in addition to writing new algorithm data for the seat mat sensitivity. Once successfully coded, the message as described in step 7 is shown if programming is attempted a second time.

10. Once the seat occupancy detection has been successfully programmed and coded, switch off the ignition and unplug the adapter cable.

11. Perform the modification to the seat occupancy detection mat in accordance with Repair Instruction REP 65 77...(Overhaul solution for OC3 mat). For a video of the repair procedure, refer to the October 2008 edition of Service Roundtable on ICP.

Note 1:
For the E90 and E91, it is only necessary to remove the seat if it is a manual seat.

[NEW]Note 2:
For E83 with sport seats, an additional piece of felt must be attached to the side bolster. See Attachment 6 (E83 Sport Seat Repair). This additional instruction will be included in the repair instructions with the release of ISTA D2.14.0.

12. After modifying the seat occupancy detection mat and reinstalling all removed parts, reconnect the adapter cable and switch on the ignition.

13. Either continue in the original test plan from step 10 or, if the original test plan was exited:

Select "Service functions / Body / Seat occupancy detector / Program seat occupancy detection mat". Then select the test plan S6577_62001. At the first selection screen, select "(2) Enable seat occupancy
detection system (OC3)".

14. Follow the instructions in the test module to enable the seat mat. The test module is completed when "End of test module" is displayed.

15. Delete any fault codes that automatically set because of the connection of the special adapter cable for programming.

LABEL INSTRUCTIONS

This Recall Campaign has been assigned code number
530. After the vehicle has been checked and corrected,
if necessary, obtain a label (SD 92-352) and:

A. Emboss your BMW center warranty number in the middle of the label (1);

B. Punch out code number 530 (2) printed on the label; and

C. Affix the label to the B-pillar as shown.

If the vehicle already has a label from a previous Service Action/Recall Campaign, affix the new label next to the old one. Do not affix one label on top of another one, because a number from an underlying label could appear in the punched-out hole of the new label.