Seat Occupant Sensor: Service and Repair
OCCUPANT CLASSIFICATION SENSOR
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.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury.
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury.
- The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards.
CAUTION: If installing only a new front passenger seat cushion trim cover, the occupant classification sensor must be rezeroed.
NOTE:
- 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 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.
- 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 carry out the diagnostic procedure again.
1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.
The first row side impact sensors are located at or near the base of the B-pillars.
The second row side impact sensors (if equipped) are located at or near the base of the C-pillars.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable and wait at least one minute.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure.
Deactivate the supplemental restraint system (SRS).
3. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure.
Remove the passenger seat.
Part 1:
Part 2:
4. Remove the components in the order indicated in the illustration and table.
Item 9: Climate Control Duct Removal Note
1. Separate the climate control duct.
Item 10: Connector Removal Note
1. Disconnect the two electrical connectors.
Item 11: Connector Removal Note
1. Separate the connectors from the seat cushion frame.
2. Separate and disconnect the blower motor electrical connector.
Item 14: Manual Lumbar Adjuster Removal Note
1. Release the manual lumbar adjustment screw.
1 From inside the lumbar adjustment mechanism, push the screw stop in toward the center.
2 While pushing the screw stop toward the center, rotate the lumbar adjustment mechanism counterclockwise.
3 The screw stop will pass clear of the internal stop, releasing the manual lumbar adjustment screw.
2. Remove the manual lumbar cable.
1 Continue turning the manual lumbar mechanism counterclockwise until the cable support comes out.
2 Push the screw out enough to remove the cable end.
3. Route the manual lumbar adjuster cable out from the seat cushion frame.
Item 16: Seat Cushion Assembly Removal Note
1. Remove the seat cushion frame, trim cover, foam pad and occupant classification sensor as an assembly.
Item 17: Seat Cushion Trim Cover Removal Note
1. Separate the seat cushion trim cover retainers.
- For vehicles with an original equipment occupant classification sensor (OCS), remove the seat cushion trim cover retainers and separate the seat cushion pad and trim cover from the seat cushion frame.
- For vehicles with a service part OCS, remove the seat cushion trim cover retainers from the seat cushion frame.
Item 18: Occupant Classification Sensor (OCS) Removal Note
1. For vehicles with an original equipment occupant classification sensor (OCS), remove the pin-type retainers.
2. Releasing the pressure sensor retainer.
- For vehicles with an original equipment OCS, fold the bladder away and pry up, releasing the pressure sensor retainer.
- For vehicles with a service part OCS, fold the seat cushion pad and bladder away and pry up, releasing the pressure sensor retainer.
3. Remove the climate control components.
1 Remove the screws.
2 Separate the wire harness from the seat cushion pan.
3 Separate the climate control duct and remove the assembly.
4. Remove the OCS.
1 Remove the screws.
2 Separate the pressure sensor.
3 Separate the wire harness from the seat cushion pan.
4 Route the OCS components back through the seat cushion pan and remove the assembly.
5. CAUTION: If installing only a new front passenger seat cushion trim cover, the occupant classification sensor must be rezeroed.
Separate the trim cover from the seat cushion pad.
INSTALLATION
WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the removal procedure.
Part 1:
Part 2:
1. NOTE: Make sure the battery ground cable is still disconnected before proceeding with the installation portion of this procedure.
Install the components in the order indicated in the illustration and table.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure.
NOTE: Make sure the battery ground cable is still disconnected before proceeding with the installation portion of this procedure.
Install the passenger seat into the vehicle. Do not reactivate or prove out the system at this time.
3. CAUTION: 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 vehicle has not been exposed to temperatures below 6°C (42°F) or above 36°C (97°F) within four hours prior to the rezeroing process. If the vehicle has been exposed to temperatures outside the temperature limits (6-36°C), the vehicle must be exposed and kept at a temperature within the limits for a minimum of four hours.
- 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 five second time period has passed after cycling the ignition switch ON before the rezeroing process.
NOTE:
- 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 scan tool is used to trigger the active command to carry out rezeroing of the OCS system.
- When using a New Generation Star (NGS) tester, the OCS system rezero function is on the Ford Service Function (red) card. To rezero the OCS system:
- select "SERVICE BAY FUNCTIONS"
- select "RCM"
- select "SYSTEM RESET"
- select the vehicle from the menu
- view the on-screen information then press "TRIGGER"
The NGS screen will then display "OCS RESET: REZERO." Press "DONE" (button 8) to rezero the OCS system. The NGS will return to the vehicle menu once rezeroing of the OCS system is complete.
NOTE: To rezero the OCS system using the Worldwide Diagnostic System (WDS):
- select the "Toolbox" icon
- select "Body" from the menu
- select "Restraints" from the menu
- select "Seat Weight Sensor ReZero"
After selecting "Seat Weight Sensor ReZero", follow the on-screen prompts to carry out rezeroing of the OCS system.
NOTE: If the first attempt to rezero the OCS system is unsuccessful, a second attempt must be made.
Rezero the occupant classification sensor.
- With the front passenger seat empty, use a scan tool to trigger the active command and rezero the occupant classification sensor.
4. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure.
Reactivate the supplemental restraint system (SRS).
5. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). Prove Out Procedure
6. Check the active restraint system for correct operation.
7. 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: seat cushion foam pad, bladder, electronic control unit, pressure sensor (transducer), hose, electrical connectors and wire harness (service part occupant classification sensor only).
Item 1: Occupant Classification Sensor INSTALLATION Note
1. Bend the pressure sensor retaining tab back.
2. CAUTION: Inspect the occupant classification sensor assembly and seat cushion frame for any foreign objects before installing the occupant classification sensor assembly to the seat cushion frame. 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.
Install the occupant classification sensor (OCS).
1 Feed the OCS components back through the cushion pan opening.
2 Position the electronic control unit and install the screws.
3 Route the wire harness and install the pin-type retainers.
4 Install the pressure sensor onto the bracket.
3. Install the climate control component.
1 Position the climate control component into the duct and tie strap it in place.
2 Install the screws.
3 Route the wire harness and install the pin-type retainer to the seat cushion pan.
4. CAUTION: Inspect the occupant classification sensor assembly and seat cushion frame for any foreign objects before installing the occupant classification sensor assembly to the seat cushion frame. 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.
Vehicles having the original occupant classification sensor installed, position the bladder and install the pin-type retainers.
5. CAUTION:
- Inspect the seat cushion pad and seat cushion trim cover for any foreign objects, before installing the seat trim cover to the seat cushion pad. 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.
- If replacing only the front passenger seat cushion trim cover, the occupant classification sensor must be rezeroed.
Install the cushion trim cover to the cushion foam pad.
6. CAUTION: Inspect the seat cushion frame and seat cushion pad for any foreign objects before installing the cushion pad and trim cover assembly to the seat cushion frame. 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.
Attach the seat cushion trim cover retainers to the seat cushion frame.
- For vehicles having a service part occupant classification sensor installed, position the seat cushion trim cover with foam pad and OCS bladder to the seat cushion frame and attach the trim cover to the frame.
- For vehicles having the original occupant classification sensor installed, position the seat cushion trim cover with foam pad to the seat cushion frame and attach the trim cover to the frame.
Item 2: Seat Cushion Assembly Installation Note
1. Align the seat cushion assembly to the seat track.
Item 7: Connector Installation Note
1. Connect and attach the blower motor electrical connector to the seat cushion frame.
2. Attach the connectors to the seat cushion frame.
Item 8: Connector Installation Note
1. Connect the two electrical connectors.
Item 9: Climate Control Duct Installation Note
1. Attach the climate control duct and secure it with a tie strap.