Occupant Classification Sensor - Service Kit
OCCUPANT CLASSIFICATION SENSOR - SERVICE KITWorldwide Diagnostic System (WDS):
Special Tool(s)
Removal
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
- Do not separate components.
CAUTION:
- There are 2 occupant classification sensor (OCS) system service kits available for this vehicle (base seat and heated seat). Always make sure the correct OCS service kit is installed.
- It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, or an OCS service kit is installed. A diagnostic tool is used to trigger the active command to carry out rezeroing of the OCS system.
NOTE:
- The heated seat element on the front passenger seat cushion is not serviceable separately. If a new heated seat element is needed on the front passenger seat cushion, a new occupant classification sensor (OCS) service kit equipped with a heated seat element must be installed.
- Occupant classification sensor (OCS) system components (seat cushion foam pad, bladder with pressure sensor and electronic control unit) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, a new OCS system service kit (seat cushion foam pad, bladder with pressure sensor and electronic control unit) must be installed as an assembly.
- To identify between a production OCS system and a service OCS system (OCS service kit) inspect the electronic control unit (ECU) electrical connector. A production OCS system allows the disconnect of the ECU electrical connector. A service OCS system (OCS service kit) has the ECU electrical connector glued to the ECU. It cannot and should not be disconnected or altered.
- If removing an OEM OCS, refer to the appropriate procedure.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again.
1. Depower the system.
2. Remove the passenger seat.
3. Disconnect the electrical connector(s) and wiring clips.
1 Disconnect the seat wire harness OCS electrical connector from the service part OCS electrical connector.
2 Release the 2 wiring clips on the wiring harness from the cushion pan.
3 If equipped with heated seats, disconnect the heated seat module electrical connector, release the wiring clip on the wiring harness from the cushion pan, and disconnect the 2 cushion element electrical connectors.
4. Remove the 4 seat cushion bolts retaining the seat cushion to the seat track.
5. CAUTION: While positioning the seat cushion pan and occupant classification sensor assembly, be careful not to damage any of the components. Failure to do so can result in component failure.
Remove the seat cushion and pan assembly.
- To aid in removal, recline the seat.
6. CAUTION: Use care when separating the seat upholstery from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat cushion foam pad.
Detach the seat cushion trim cover J-clips from the seat cushion pan and remove the seat cushion trim cover.
7. Bend the retaining tab away from the pressure sensor, then slide the pressure sensor off the bracket.
8. CAUTION: Care must be taken to prevent damage to the seat cushion pan when removing the rivets.
Remove the 2 rivets and detach OCS ECU from the seat cushion pan.
9. Remove the OCS.
- Pull all the OCS components (hose, pressure sensor, wire harness, ECU and connectors) through the seat cushion pan opening.
Installation
1. Bend the retaining tab back on the pressure sensor component bracket.
2. CAUTION:
- Inspect the occupant classification sensor assembly, seat cushion pan and support assembly for any foreign objects before installing the occupant classification sensor assembly to the seat cushion pan. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment.
- Failure to route the seat occupant classification sensor components through the correct seat cushion support opening can cause component failure.
- While positioning the seat cushion pan and occupant classification sensor assembly, be careful not to damage any of the components. Failure to do so can result in component failure.
Feed the OCS service kit components (hose, pressure sensor, ECU, wire harness, and connectors) through the seat cushion pan opening.
3. NOTE:
- When installing a service part occupant classification sensor, the seat wire harness pressure sensor electrical connector is not used.
- Make sure the pressure sensor hose is not kinked during installation.
Install the OCS components to the seat cushion pan.
1 Install the pressure sensor onto the seat cushion pan bracket, making sure the retaining tab is completely engaged.
- When installed correctly, an audible click will be heard and the pressure sensor will not be able to be removed from its bracket without disengaging the retaining tab.
2 Slide the electronic control unit (ECU) into the seat cushion pan bracket.
- The ECU must be correctly positioned and securely fastened in place. Failure to do so can set a diagnostic trouble code (DTC) in the restraints control module (RCM).
3 Install the rivets.
4. Attach the seat cushion trim cover J-clips to the seat cushion pan.
5. CAUTION: While positioning the seat cushion pan and occupant classification sensor assembly, be careful not to damage any of the components. Failure to do so can result in component failure.
Position the seat cushion and pan assembly to the seat track.
- To aid in installation, recline the seat.
6. Install the 4 seat cushion bolts retaining the seat cushion to the seat track.
- Tighten to 15 Nm (11 lb-ft).
7. Connect the electrical connector(s) and wiring clips.
1 Connect the seat wire harness OCS electrical connector to the service part OCS electrical connector.
2 Install the 2 wiring clips on the wiring harness to the cushion pan.
3 If equipped with heated seats, connect the heated seat module electrical connector, install the wiring clip on the wiring harness to the cushion pan, and connect the 2 cushion element electrical connectors.
4 Tie strap the unused seat wire harness pressure sensor electrical connector safely aside.
5 Tie strap all loose wire harnesses and electrical connectors safely aside.
8. Install the passenger seat into the vehicle.
9. Repower the system. Do not prove out the system at this time.
10. CAUTION:
- Make sure the seat is completely assembled before rezeroing.
- The following precautions must be taken before rezeroing the OCS system:
- Make sure the OCS system components are connected and no faults are present.
- Make sure the OCS system is not at a temperature below 0°C (32°F) or above 45°C (113°F) when initiating the rezeroing process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 0°C to 45°C (32°F to 113°F) for a minimum of 30 minutes.
- Make sure nothing is present on the passenger seat before rezeroing and nothing is placed on the seat during the rezeroing process.
- Make sure a minimum 8-second time period has passed after cycling the ignition switch ON before the rezeroing process.
NOTE:
- For best results in rezeroing, the OCS system should be at or near room temperature, 10°C to 29°C (50°F to 85°F).
- If the first attempt to rezero the OCS system is unsuccessful, a second attempt must be made.
- The ignition switch must be cycled after rezeroing the OCS system.
Rezero the occupant classification sensor.
- With the front passenger seat empty, use a diagnostic tool to trigger the active command and rezero the occupant classification sensor.
11. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will:
- fail to light.
- remain lit continuously.
- flash.
The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the restraints control module using a diagnostic tool.
12. NOTE: When installing a new occupant classification sensor, a prepaid return postcard is provided with the new occupant classification sensor. The serial number for the new part and the vehicle identification number (VIN) must be recorded and sent to Ford Motor Company.
Fill out the necessary information on the occupant classification sensor traceability card and return it along with the complete inoperative occupant classification sensor to Ford Motor Company.
- When returning the inoperative occupant classification sensor, include the following: seat cushion foam pad, bladder, electronic control unit, pressure sensor (transducer), hose, electrical connectors and wire harness (service part occupant classification sensor only).