ORC – AIRBAG SYSTEM

The vehicle is equipped with six airbags (steering wheel airbag, passenger's airbag, side bags, curtain
bags) and advanced retention systems on the seat belts to guarantee optimal protection to front and
rear occupants in case of accident.
The ORC system is equipped as follows:

Number of charges:
 Driver's airbag 1
 Passenger's airbag 1
 Knee bag 0
 Side bags 2
 Curtain bag 2
 Front pretensioners 4
 Rear pretensioners 2
 Battery disconnect switch 1

The ORC system uses the various sensors to classify the type of impact that the car undergoes:
Number of sensors for EMEA/APAC market:
 Front impact accelerometer sensors 1
 Side impact pressure sensor 2
 Side impact accelerometer sensors 2

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Airbag (ORC) module position on vehicle

Airbag (ORC) module

The occupant restraint module (ORC), located on the central tunnel under the console, monitors the
impact and occupant sensors and activates restraint system devices in the event of an impact. The
ORC also contains impact sensors that are used to determine the level of deployment and to verify the
information received from the remote sensors.
An arrow printed on the ORC label indicates the installation orientation. The arrow must point toward
the front of the vehicle. The ORC must be installed correctly for correct restraint system operation.
The ORC module will set a specific DTC which cannot be deleted, not even using the diagnostic tool.
This will happen when the following conditions are reached:

 Three impacts with deployment of the pretensioners;

 Three impacts with deployment of curtain bags;
 Front-on crash (with deployment of driver's airbag, passenger's airbag and pretensioners).
 Any other combination of the above mentioned cases until the three deployment limit is
reached

When one of the above mentioned limits is reached, the ORC module will have to be replaced.

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The front passenger airbag can be deactivated via the car menu. A dedicated LED inserted in the
ceiling light indicates its deactivation.

NOTE: The yaw or lateral acceleration sensor is installed inside the ORC module and is
used for the correct operation of the vehicle dynamic stability functions.

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Front impact sensor

The front impact sensor detects frontal impacts and supports deployment of the driver/passenger
airbags and pretensioners. The sensor contains an accelerometer which measure the vehicle
deceleration rate in the event of an impact. The sensor is located on the crossmember on driver's side.
In head-on frontal collisions, the impact sensor in the ORC is used as primary sensor while the front
sensors provide confirmation of the event. In angled or offset front impacts, the front sensor is used as
primary sensor while the ORC sensors provide confirmation of the event.
Side impact pressure sensors

One pressure sensor is located in each of the front doors to protect front row passengers in the event
of side crashes.
The pressure sensors can detect a sudden change in air pressure within the door which is consistent
with a direct impact to the door. The sensor signal alone cannot command the explosion of the airbag.
The ORC or a second sensor must detect a simultaneous crash event to deploy the side airbags.

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B-pillar side impact sensor

The airbag system of the vehicle is provided with two side collision sensors of the accelerometer type
placed on each side of the vehicle to detect side collisions in order to activate the curtain bags, the
side bags and the pretensioners.
The side impact sensors are located behind the B-pillar lining and specifically in the lower part.

Seat belt buckle switch

The buckles of driver and front and rear passenger seat belts have a resistive sensor for monitoring
their fastening.

Buckle technical details

Operating range: 9V - 15V

Rated current: 10 mA
Open circuit current: 1° for 1 sec.
Rated current voltage drop: 0.05V
Working current: 10 – 400Ma

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Occupant detection sensor (ODS)
The ODS is a resistive pressure switch. The ODS closes when a pre-programmed load is placed on
the seat. The ODS is used to trigger a seat belt reminder if a passenger is detected on the seat. The
ODS does not affect the level of airbag deployment.
Driver's airbag

The driver's airbag has a single pyrotechnic charge. The driver's airbag module is anchored to the
steering wheel by means of anchoring clips (there are no screws).
Passenger's airbag

The passenger airbag is integral to the top of the dashboard and bolts to its frame. The passenger's
side airbag contains a single pyrotechnic charge.

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Side window air bags

The side curtains use a hybrid inflator. To deploy the airbag the ORC sends a current to the airbag
inflator which ignites the chemical pellets. The gases produced by the combustion of the pellets
produce a pressure sufficient to break the containment cap of a cylinder of inert gas. The gases are
directed into the side airbags causing them to inflate. The curtain bags stay inflated for a few seconds
to protect passengers in the event of a roll-over. The deflation rate of the airbags is controlled by the
tightness of the airbag fabric mesh.

Side bags fitted on seat

The vehicle fits side bags integrated in the side of the front seats (outer side) to improve the safety of
driver and passenger in case of side crashes.

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Seat belt pretensioners

1. Front seat belt anchor pretensioner

2. Front seat belt retractor pretensioner
3. Rear seat belt retractor pretensioners
The airbag system is provided with seven pretensioners (four on the front part and three on the rear
part). A pretensioner is fitted on the seat belt anchoring on both sides (driver and passenger) and the
other pretensioner is present in the seat belt retractor. The pretensioners are located in the seat belt
retractors at the back. They are operated by the ORC jointly with the two front airbags. When the ORC
sends the proper electrical signal to the pretensioners, the electrical energy generates enough heat to
initiate a small pyrotechnic gas generator.
On the retractor pretensioner, a gas generator is installed in one end of a steel tube which contains
numerous steel balls. As the gas expands, it pushes the steel balls through the tube into a cast metal
housing, where a ball guide directs the balls into engagement with the teeth of a sprocket that is
geared to one end of the retractor spool.

As the balls drive past the sprocket, the sprocket turns and drives the seat belt retractor spool causing
the slack to be removed from the front seat belts. The ball trap captures the balls as they leave the
sprocket and are expelled from the housing.

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On the anchor pretensioner, the gas generator is installed in one end of the tubular metal piston
housing, which contains a piston secured to one end of a cable. The cable is routed around an integral
guide to the buckle anchor, which is secured to the opposite end of the cable. As the gas expands, it
pushes the piston and the cable through the tube and pulls the buckle anchor downward, removing the
slack from the front seat belt.
Battery disconnect switch pyrotechnic fuse

1. Coupling on the positive battery terminal

2. Coupling for connecting additional components
3. Battery pyrotechnic fuse
A pyrotechnic fuse is fitted on the vehicle and specifically in the small fusebox installed on the positive
battery terminal. In case of accident with deployment of the airbags, the ORC will cause this fuse to
blow.
By exploding, it will break the foil which allows battery voltage to reach the starter motor, alternator
and the various components which must be powered. Once this charge has exploded, the vehicle
cannot be restarted until the used fused is replaced with a new one.

WARNING
Carefully check the vehicle for fuel leaks, for instance in the engine compartment, under the vehicle or
near the tank area. After a collision, bring the ignition device to STOP to prevent the battery from
running down.

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Diagnosis and repair
WARNING
BEFORE ANY DIAGNOSIS OR REPAIR OF THE RESTRAINT SYSTEM IS CONDUCTED, READ
AND FOLLOW ALL WARNINGS AND CAUTIONS IN SERVICE INFORMATION. FAILURE TO
FOLLOW THESE WARNINGS AND CAUTIONS COULD RESULT IN SERIOUS INJURY OR DEATH.
SENSOR DIAGNOSIS
The ORC will set DTCs when a sensor fault is detected. The sensors cannot be tested and are
diagnosed by the process of elimination. After having disconnect the ORC and sensor wiring, the
electric circuits of the sensors must be checked to determine electric continuity, presence of short-
circuits to positive, earth or each other. Only after eliminating all possible circuit faults is the sensor
replaced.
SQUIB DIAGNOSIS
The ORC will set DTCs when a squib concern is detected. The squibs cannot be tested and are
diagnosed by the process of elimination. Squib circuits are tested using special SRS special
equipment.
SBA (Seat Belt Alert) system
The SBA system warns the front and rear seat occupants if their seat belt is not fastened.
The system signals unfastened seat belts with visual warnings (warning lights on in the instrument
panel and icons on the display) and an acoustic signal.
The ORC will send the buckle condition messages to the IPC via can network for the activation of the
indications.

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Wiring diagram

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Key:
1. ORC module
2. BCM
3. Passenger's airbag status warning light
4. Front impact sensor
5. Passenger's airbag
6. Driver's airbag
7. RH impact pressure sensor
8. RH side impact sensor
9. LH side impact sensor
10. LH side impact pressure sensor
11. Passenger front pretensioner
12. Driver front pretensioner
13. Driver retractor
14. Passenger retractor
15. RH curtain bag
16. LH curtain bag
17. Battery pyrotechnic fuse
18. RH rear buckle switch
19. LH rear buckle switch
20. Middle rear buckle switch
21. RH rear retractor
22. RH rear retractor
23. LH side bag
24. LH front buckle switch
25. Passenger present
26. LH seat frame
27. RH seat frame
28. RH side bag
29. RH buckle switch
30. IPC module power
31. E-Call (function not active for commercial launch)

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ORC pin-out

connector A
Pin Function Pin Function
1 Front LH side bag (-) 30 Battery disconnect system (-)
2 Front LH side bag (+) 31 Right curtain airbag (-)
3 Front RH side bag (+) 32 Right curtain bag (+)
4 Front RH side bag (-) 33 Left curtain airbag (+)
5 Front driver retractor pretensioner - 34 Left curtain bag (-)
6 Front driver retractor pretensioner + 35
7 Front passenger retractor pretensioner + 36
8 Front passenger retractor pretensioner - 37
Front passenger anchor pretensioner -
9 (sill end) 38
Front passenger anchor pretensioner +
10 (sill end) 39 Driver buckle switch signal
Front driver anchor pretensioner + (sill
11 end) 40 Passenger buckle switch signal
Front driver anchor pretensioner - (sill
12 end) 41 RL buckle switch signal
13 42 RR buckle switch signal
14 43 RC buckle switch signal
15 44
16 45 Front buckle switch and sensor earth
17 46 Rear buckle switch earth
18 47
19 48
20 49
21 50
22 51 Side ECS LH signal
23 CAN-C2 H 52 Side ECS LH earth
24 CAN-C2 L 53 Side ECS RH earth
25 Rear right retractor pretensioner + 54 Side ECS RH signal
26 Rear right retractor pretensioner -
27 Rear left retractor pretensioner -
28 Rear left retractor pretensioner +
29 Battery disconnect system (+)

Connector B
Pin Function Pin Function
1 TBM Crash Notification (ACN) 16
2 Driver 1st Stage AirBag (+) 17
3 Driver 1st Stage AirBag (-) 18
4 19
5 20
6 21 C_CAN_L_1
7 22 PAD OFF Signal
8 23 PAD On Signal
9 24
10 INT from F50 for AIRBAG 25
11 C_CAN_H_1 26 Early Crash Sensor 1 – central or left (+)
12 Passenger 1st Stage AirBag (+) 27 Early Crash Sensor 1 – central or left (-)
13 Passenger 1st Stage AirBag (-) 28
14 29
15 30 GND_for_ORC

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