Occupant Classification Sensor - Service Kit
OCCUPANT CLASSIFICATION SENSOR - SERVICE KITSpecial Tool(s):
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:
- There are three occupant classification sensor (OCS) system service kits available for this vehicle (base seat, heated seat and climate controlled 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, a seat side shield removed, 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.
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 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 only by installing a new assembly. If the new assembly does not correct the condition, install the original equipment 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 or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.
The front impact severity sensor is located under the hood latch bracket.
The first row side impact sensors (if equipped) are located under the seat, beneath the carpet.
The second row side impact sensors (if equipped) are located at or near the base of the C-pillar.
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. Refer to Air Bag(s) Arming and Disarming.
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. CAUTION:
- While positioning the seat cushion pan and occupant classification sensor (OCS) assembly, be careful not to damage any of the components. Failure to do so can result in component failure.
- It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, 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.
Remove the parts in the order indicated in the illustrations and tables.
Item 1: Recliner Handle Cover Removal Note
1. Release the recliner handle cover tab and remove the cover.
Item 9: Side Air Bag Module Connector Removal Note
1. If equipped, separate the side air bag module electrical connector and wire harness from the seat riser and cushion pan.
Item 10: Climate Control Seat Duct Removal Note
1. If equipped, separate the climate control duct and disconnect the backrest thermal electric device electrical connector.
2. If equipped, disconnect the two seat backrest heated seat element electrical connectors.
Item 13: Connectors Removal Note
1. If equipped, disconnect and separate the electrical connectors and wire harnesses necessary to remove the seat cushion assembly.
Item 15: Seat Cushion Assembly Removal Note
1. Remove the seat cushion assembly.
- Disconnect and release any remaining electrical connectors and pin-type retainers necessary to separate the seat cushion pan from the seat track and riser.
Item 16: Seat Cushion Trim Cover Removal Note
1. CAUTION: It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, 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.
Release the seat cushion trim cover J-clips from the seat cushion pan.
- If equipped, disconnect the seat cushion heated seat element electrical connector.
2. CAUTION:
- Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam.
- It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, 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.
If installing an OCS service kit, remove the hog rings and separate the trim cover from the foam pad.
- After removing the hog rings, reach a hand between the trim cover and foam pad and carefully separate the hook and loop strips.
Item 17: Pressure Sensor Removal Note
1. Using a suitable tool, pry the bracket tab, releasing the pressure sensor. Separate the pressure sensor from the seat cushion pan and disconnect the electrical connector.
Item 18: Electrical Connector Removal Note
1. Disconnect the occupant classification sensor and remove any retainers from its wiring harness.
Item 21: Occupant Classification Sensor (OCS) Removal Note
1. Remove the OCS.
- Feed the OCS components (hose, transducer, wire harness, electronic control unit (ECU) and connectors) through the seat cushion pan opening.
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. 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.
- It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, 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.
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.
Install the parts in the order indicated in the illustrations and tables.
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 supplemental restraint system at this time.
3. Connect the battery ground cable.
4. WARNING: Do not separate components.
CAUTION:
- It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, 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.
- 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 eight 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).
- When using a New Generation STAR (NGS) Tester you must use the appropriate memory card with the latest update to carry out this function.
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.
5. NOTE: The ignition switch must be cycled after rezeroing the OCS system. Cycle the ignition switch from ON to OFF.
6. WARNING: 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.
With the restraint system diagnostic tools still installed at the remaining deployable devices, prove out the supplemental restraint system (SRS). Prove Out Procedure
7. Disconnect the battery ground cable and wait at least one minute.
8. 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. Refer to Air Bag(s) Arming and Disarming.
Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming.
9. Connect the battery ground cable.
10. 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
11. Check the active restraint system for correct operation.
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).
Item 1: Occupant Classification Sensor (OCS) (For OCS Service Kit) Installation Note
1. Bend the tab back on the pressure sensor component bracket.
2. CAUTION: Inspect the seat cushion pad and seat cushion trim cover for any foreign objects, before installing the seat cushion 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.
Using hog rings, attach the seat cushion trim cover to the seat cushion foam pad.
- If equipped with heated seats, make sure the wire harness is accessible after trim cover attachment.
3. 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 safety system failure.
Feed the OCS service kit components (hose, pressure sensor, electronic control unit wire harness, and connectors) through the seat cushion pan opening.
4. 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.
Position the seat cushion foam pad with OCS bladder to the seat cushion pan and set in place.
5. CAUTION: It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, 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.
Attach the seat cushion trim cover J-clips to the seat cushion pan.
- If equipped with heated seats, connect the cushion element electrical connector.
6. NOTE: When installing an occupant classification sensor service kit, the main seat wire harness pressure sensor electrical connector does not get used.
Install the OCS components to the seat cushion pan.
1 Install the pressure sensor onto the seat cushion pan bracket, making sure the retaining ear is completely engaged.
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 Connect the main seat wire harness occupant classification sensor electrical connector to the service part occupant classification sensor electrical connector.
5 Tie-strap the unused main seat wire harness pressure sensor electrical connector safely out of the way.
6 Tie-strap all loose wire harnesses and electrical connectors safely out of the way.
Item 4: Connector Installation Note
1. If equipped, connect and install the electrical connectors and wire harnesses to the seat cushion pan.
Item 7: Climate Control Seat Duct Installation Note
1. If equipped, connect the climate control duct and the backrest thermal electric device electrical connector.
2. If equipped, connect the two seat cushion heated seat element electrical connectors.
Item 8: Side Air Bag Module Connector Installation Note
1. If equipped, route the side air bag module wire harness and electrical connector and attach to the seat riser and cushion pan.