Voluntary Safety Recall Campaign Occupant Classification System Reprogramming (NTB16-052A)

Front Passenger Air Bag Status Light

Performing the procedures in the bulletin (campaign R1609) changes the operation of the passenger air bag status light.

• After performing this campaign, the passenger air bag status light will be ON (illuminated) when the front passenger seat is empty.

Air Bag Warning Light

This campaign does not change the operation of the air bag warning light.

Airbag Diagnostic Sensor Unit Reprogram

1. Make sure ASIST has been synchronized to the current date and all updates have been installed. 
   NOTE: The PC automatically gets applicable reprogramming software during ASIST synchronization.
2. Open the vehicle hood, connect GR8 and set to ECM Power Supply Mode.
3. Turn the ignition ON (engine OFF / not Ready).
4. Turn hazards ON.
5. Connect the CONSULT-III plus VI (C-III plus VI) to the vehicle.
6. Connect the VI to the CONSULT PC with a USB cable  .
7. Start the CONSULT PC, open ASIST and then select "R1608 & R1609 ACU Reprogram  " on ASIST under Specialty Tools (Figure 1).
8. Read the on screen CAUTION  statement before proceeding.
9. Select Accept  .
10. Select VI-2 from the drop down list and then Next  .
11. Select Reprogramming  .
12. Select AIRBAG  .
13. Is the screen in Figure 6 displayed?

    NO:  Proceed to step 14.

    YES: 

    1. Select End  and discontinue airbag reprogramming.
    2. Proceed to OCS CONTROL UNIT REPROGRAM .
14. Confirm that the Battery Voltage is between 12.0V and 15.5V.
    • If the Battery Voltage is not between 12.0V and 15.5V, resolve before proceeding.
15. Select Start  .
    • REPROGRAMMING PROGRESS  screen will be displayed (Figure 8).
    • Reprogram will take approximately 3 minutes.
    • Once the reprogramming has finished the screen in Figure 9 will be displayed.
      WARNING: Airbag control unit damage may occur if reprogramming is interrupted.
16. Confirm that the "Software Version (Before)" and "Software Version (After)" are different.
17. Select End  .
18. Save the confirmation page, print and attach it to the repair order.

    Leave the ignition ON and proceed to OCS CONTROL UNIT REPROGRAM  on the next page.

OCS Control Unit Reprogram

1. Install the driver for the J-51594 OCS reprogramming cable as follows:
   1. Keep the PC connected to the internet.
   2. Connect the J-51594 OCS reprogramming cable to the PC USB port.
   3. Wait 1 minute, the drivers will install automatically.
      NOTE: Step 1 above is only required the first time this procedure is performed. It is recommended that it be performed at the beginning of each day to confirm you have the latest software installed in your PC.
2. Turn the ignition ON, engine OFF / not Ready (if not still ON) and turn ON the hazard warning flasher lights (if not still ON).
3. Connect the J-51594 OCS reprogramming cable:
   • Connect to the vehicle's DLC connector and the PC USB port.
   • Make sure the cable is securely connected at both ends.
4. Prepare the vehicle for OCS Reprogramming as follows:
   • Level the vehicle. 
   • No objects on the passenger seat. 
   • No occupants in the vehicle - including the servicing technician. 
   • PC is outside of the vehicle on a suitable support.
     • Do not set the PC on the vehicle.
   • Do not touch the vehicle during the OCS Reprogramming.
   • Minimize vibrations of the vehicle. 8 NTB16-052b
5. Open ASIST (if not still open).
6. Select "R1608 & R1609 OCS Reprogram  " on ASIST under Specialty Tools (Figure 11).
   NOTE: If you get a black message screen as shown in Figure 12, this indicates that the reprogramming cable is not connected, or the cable driver did not install correctly.
   1. Close ODS Repro.
   2. Close ASIST.
   3. Start over from step  1.
7. Select Start Repro  .
   NOTE: If the error message "an error occurred on connection" displays:
   1. Disconnect the J-51594 OCS reprogramming cable, both ends.
   2. Reconnect the cable; make sure it is securely connected at both ends.
8. Turn the ignition ON (engine OFF / not Ready).
9. Select OK  .
   • After selecting OK in Figure 14, the OCS reprogramming will start. 
   • Items 1 through 4 (Figure 15) will likely complete quickly.
   • If the OCS reprogramming stops (displays NG) at item 1, 2, 3 or 4, refer to Figures 20 through 23 on pages 13 and 14.
10. Cycle the ignition OFF > ON.
11. Select OK  .
    • After selecting OK in Figure 16, the OCS reprogramming will likely complete items 5 through 7 quickly (see "Complete" screen, Figure 18 below).
    • If the OCS reprogramming stops (displays NG) at item 5, 6 or 7, refer to Figures 24 through 26 on pages 15 and 16.
12. When this screen displays (Figure 18), OCS reprogramming is complete.
13. Select OK  .
14. Close the program (click on the red X in the upper right corner).
15. Turn the ignition OFF.
16. Disconnect the J-51594 OCS reprogramming cable.
17. Turn the ignition ON and observe the air bag warning light and the front passenger air bag status light:
    • The air bag warning light should illuminate for 7 seconds and then go out.
    • The front passenger airbag status light should illuminate for 7 seconds and then either stay illuminated or go out, depending on the occupation of the front passenger seat.
      NOTE: If the air bag warning light or the front passenger airbag status light does not operate as described above, there may be an issue not covered by this campaign. Refer to ASIST and the appropriate ESM for additional diagnostic and repair information.

      OCS Reprogramming is Complete 

    NOTE:

    • Zero Point Reset was included in the reprogramming - it is not necessary to perform as a separate step.
    • Figures 20 through 26 on pages 13 through 16 are provided as reference if the OCS reprogramming stops (displays NG) at one of the items (1-7).

Airbag Diagnostic Sensor Unit Reprogram and OCS Control Unit Reprogram

1. Open the engine hood and connect the GR8 to the 12V battery and set it to ECM power supply mode.
   CAUTION:

   • Connect the GR8 to the 12V battery and select ECM Power Supply Mode. If the vehicle battery voltage goes below 12.0V or above 15.5V  during reprogramming, the control unit may be damaged  .
   • Be sure to turn OFF all vehicle electrical loads.

     If a vehicle electrical load remains ON, the control unit may be damaged  .

2. Connect the BOSCH MTS 6513 to the vehicle Data Link Connector (DLC).
3. Wait for the BOSCH MTS 6513 to boot.
   • A beep will be heard.
   • A green light on the BOSCH MTS 6513 will indicate it is powered ON.
   • When boot-up is complete and the Start Screen (see Figure A2) is displayed, the BOSCH MTS 6513 is ready for reprogramming.
     NOTE:

     • If the screen in Figure A2 does not display, the correct software has not been loaded into the BOSCH MTS 6513.
     • On screen instructions will help guide you through the reprogramming process.
4. Turn the hazards (4 way flashers) ON.
5. Select enter on the key pad.
   NOTE: During this procedure you will be asked several times to "select enter on the key pad". Each time, use the key pad enter button shown in Figure A3.
6. Turn the ignition ON (engine OFF / not Ready).
7. Select enter on the key pad.
   NOTE: The VIN is read automatically.
8. Select enter on the key pad.
   NOTE:

   • System call will be perfromed.
   • Progress bar will be displayed during system call.
   • The screen in Figure A6 (next page) will dispay when system call is complete.
   • If system call does not complete and the screen in Figrue A6 does not display, the vehicle may not apply to this campaign.
9. Select enter on the key pad.
   NOTE: Airbag Diagnostic Sensor Unit Reprogram)
   

   • The current version of the Airbag Diagnostic Sensor Unit software is read automatically to determine if it needs to be reprogrammed.
   • If the Airbag Diagnostic Sensor Unit does not  require reprogramming, the process will skip to OCS reprogramming (Figure A8 on the next page).
   • If reprogramming is required  , reprogramming will begin automatically. A progress bar will be displayed showing the percent complete, and the car icon will flash during the reprogramming process (see Figure A7).
   • Approximate reporgram time is 3 to 5 minutes.
10. When reprogramming is complete, the screen in Figure A8 (next page) will display.
11. Select enter on the key pad.
    NOTE: (OCS Reprogram)
    

    • The current version of the OCS software is read automatically.
    • Reprogramming will begin automatically. A progress bar will be displayed showing the percent complete, and the car icon will flash during the reprogramming process (see Figure A9).
    NOTE: During the OCS reprogramming you will be prompted to turn the ignition OFF, then back ON (see steps 12 through  15).
12. Turn the ignition OFF.
13. Select enter on the key pad.
14. Turn the ignition ON (engine OFF / not Ready).
15. Select enter on the key pad.
16. When reprogramming is complete, the screen in Figure A12 will display.
17. Prepare the vehicle for zero point reset as follows:
    • Level the vehicle. 
    • No objects on the passenger seat. 
    • No occupants in the vehicle - including the servicing technician. 
    • Do not touch the vehicle during the zero point reset.
    • Minimize vibrations of the vehicle.
18. Select enter on the key pad.

1. 18. Turn the ignition OFF.
2. 19. Select enter on the key pad.
3. 20. Turn the ignition ON (engine OFF / not Ready).
4. 21. Select enter on the key pad.
   • The screen in Figure A15 will display while zero point reset is being performed.
   • The screen in Figure A16 will display when zero point reset is complete.
5. 22. The reprogramming process is complete. Select the enter button on the key pad to display the result screens.
6. 23. Turn the hazards (4-way flashers) OFF.
7. 24. Turn the Ignition OFF.
8. 25. Disconnect the BOSCH MTS 6513 from the vehicle DLC.
   IMPORTANT: Make sure the BOSCH MTS 6513 powers down (wait about 30 seconds) before connecting to another vehicle. This will confirm any saved vehicle information is erased.
9. 26. Disconnect the GR8 from the vehicle 12V battery.
10. 27. Turn the ignition ON and observe the air bag warning light and the front passenger air bag status light:
    • The air bag warning light should illuminate for 7 seconds and then go out.
    • The front passenger airbag status light should illuminate for 7 seconds and then either stay illuminated or go out, depending on the occupation of the front passenger seat.
      NOTE: If the air bag warning light or the front passenger airbag status light does not operate as described above, there may be an issue not covered by this campaign. Refer to ASIST and the appropriate ESM for additional diagnostic and repair information.

      Reprogramming is Complete