Seat Cushion - Passenger
SEAT CUSHION-PASSENGERSpecial Tool(S):
Special Tool(s)
Part 1:
Part 2:
Disassembly
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 the occupant classification sensor (OCS) system components.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury.
CAUTION: It is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover is installed or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out the OCS system reset.
NOTE:
- 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 disconnection 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. An OCS system service kit also has an in-line 10-pin connector between the OCS ECU and the seat wiring harness.
- 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 and a new heated seat element must be installed.
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered.
- The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a 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 carry out the diagnostic procedure again.
All seats
1. Position the seat to access all the seat track-to-floor pan bolts and the safety belt anchor.
2. Depower the SRS.
3. Remove the front seat.
4. Remove the front seat backrest.
5. Remove the seat track.
Seats with an original equipment (OE) OCS
6. Disconnect the occupant classification sensor (OCS) pressure sensor electrical connector.
7. Remove the OCS bladder pin-type retainers.
8. NOTE: Make note of the opening that the pressure sensor and hose are being fed through on the seat cushion support assembly for installation purposes.
Remove the OCS bladder, hose and pressure sensor from the seat cushion frame.
9. Disconnect the electronic control unit (ECU) electrical connector.
Seats with an OCS service kit
10. Disconnect the OCS service kit electrical connector.
Power seats with an OCS service kit
11. Remove the tie strap retaining the unused pressure sensor electrical connector from the seat wiring harness.
All seats
12. CAUTION: Do not oversize the seat cushion frame holes used to rivet the ECU in place.
NOTE: OE ECU shown, service kit OCS similar.
Using a 5 mm (3/16 in) drill, remove the 2 rivets and the ECU from the seat cushion frame bracket.
Seats with an OCS service kit
13. NOTE: Make note of the opening that the OCS service kit components are being fed through on the seat cushion support assembly for installation purposes.
Remove the OCS service kit from the seat cushion frame.
- Remove any tie straps securing wire harnesses or electrical connectors.
- Feed the hose, pressure sensor, wire harness, electrical connector and ECU through the seat cushion frame support assembly.
Heated seats
14. Remove the rivet, tip the heated seat module and slide the retainers out of the cushion pan bracket, disconnect and remove the heated seat module.
Seats with power recline
15. Disconnect the power seat backrest adjust motor electrical connector.
16. Drive out the 2 large roll pins.
17. Remove the 3 bolts and the power seat backrest adjust motor assembly.
Vehicles with manual recline seats
18. Drive out the 2 large roll pins and remove the manual seat backrest adjuster.
All vehicles
19. Remove the seat wire harness.
20. Remove the hog rings and cushion trim cover.
Assembly
Heated seats
1. Seats receiving a new OCS service kit, install the new cushion heated seat element onto the new cushion foam pad.
All seats
2. Position the cushion trim cover to the cushion foam pad and install the hog rings.
3. Install the seat wire harness.
Seats with manual recline
4. Position the manual seat backrest adjuster and drive the 2 large roll pins into the cushion pan and through the front manual seat backrest adjuster eyelets.
Seats with power recline
5. Position the power seat backrest adjuster to the cushion pan and install the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
6. Drive the 2 large roll pins into the cushion pan and through the front power seat backrest adjuster eyelets.
7. Connect the power seat backrest adjuster electrical connector.
Heated seats
8. Slide the heated seat module onto the bracket, making sure it is locked in place and install the rivet. Connect the heated seat module electrical connector.
Seats with an OCS service kit
9. WARNING: Do not separate the OCS system components.
CAUTION:
- Inspect the occupant classification sensor assembly, seat cushion frame and support assembly 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.
- Failure to route the seat occupant sensor components through the correct seat cushion support opening can cause component failure.
- While positioning the seat cushion frame and occupant classification sensor assembly, be careful not to damage any of the components. Failure to do so can result in component failure.
NOTE: If the original equipment (OE) occupant classification sensor (OCS) is not being installed, install a service kit OCS using all parts in the kit.
Position the OCS assembly to the seat cushion frame.
- Using a service OCS, feed the ECU, electrical connector, wire harness, pressure sensor and hose through the largest opening at the front of the seat cushion frame support assembly.
- Position the seat cushion pad and bladder to the seat cushion frame.
10. Install the ECU.
1 Position the ECU and install the rivets.
2 Connect the electrical connector.
- The ECU must be correctly positioned and securely riveted in place. Failure to do so can set a diagnostic trouble code (DTC) in the restraints control module (RCM).
Power seats with an OCS service kit
11. Tie strap the unused pressure sensor electrical connector to the seat wiring harness.
Seats with an OE OCS
12. Install the ECU and rivets to the cushion frame bracket.
- The ECU must be correctly positioned and securely riveted in place. Failure to do so can set a diagnostic trouble code (DTC) in the restraints control module (RCM).
13. Connect the ECU electrical connector.
14. WARNING: Do not separate the OCS system components.
CAUTION:
- Inspect the occupant classification sensor bladder, seat cushion frame and support assembly 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.
- Failure to route the seat occupant sensor components through the correct seat cushion support opening can cause component failure.
- While positioning the seat cushion frame and occupant classification sensor assembly, be careful not to damage any of the components. Failure to do so can result in component failure.
NOTE: If the original equipment occupant classification sensor (OCS) is not being installed, install a service kit OCS using all parts in the kit.
Position the OCS bladder to the cushion frame.
- Feed the pressure sensor and hose through the center opening in the cushion frame wires.
15. Install the OCS bladder pin-type retainers.
All seats
16. NOTE: Make sure the pressure sensor is correctly installed and retained to the seat track bracket and the pressure sensor hose is not kinked during installation.
Install the seat track.
17. Install the front seat backrest.
18. Install the seat.
19. Repower the SRS. Do not prove out the SRS at this time.
20. WARNING: Do not separate the OCS system components.
CAUTION:
- It is necessary to carry out the OCS system reset when a front passenger seat cushion is disassembled, a new trim cover is installed or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out the OCS system reset.
- Make sure the seat is completely assembled before carry out the OCS system reset.
- The following precautions must be taken before carrying out the OCS system reset.
- 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 OCS system reset 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 carrying out the OCS system reset process and nothing is placed on the seat during the process.
- Make sure a minimum 8-second time period has passed after cycling the ignition switch ON before carrying out the OCS system reset process.
NOTE:
- For best results, 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 carry out the OCS system reset is unsuccessful, a second attempt must be made.
Carry out the OCS system reset active command using the scan tool.
- With the front passenger seat empty, use a scan tool to trigger the active command.
21. NOTE: The ignition switch must be cycled after the OCS system reset.
Cycle the ignition switch from ON to OFF.
22. 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 scan tool.
23. NOTE: When installing a new OCS service kit, a prepaid return postcard is provided with the new OCS. The serial number for the new part and the vehicle identification number (VIN) must be recorded and sent to Ford Motor Company.
If a new OCS was installed, fill out the necessary information on the OCS traceability card and return it along with the complete inoperative occupant classification sensor to Ford Motor Company.
- When returning the inoperative OCS, include: seat cushion foam pad, bladder, ECU, pressure sensor (transducer), hose, electrical connectors and wire harness (service part OCS only).