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Seat Occupant Sensor: Service and Repair




Occupant Classification Sensor





Seat with a Production Occupant Classification Sensor (OCS)









Seat with a Service Kit Occupant Classification Sensor (OCS)









Removal and Installation

NOTICE: To prevent system failure, it is necessary to carry out the Occupant Classification Sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command.

NOTE: Occupant Classification Sensor (OCS) system components (seat cushion foam pad, bladder with pressure sensor and Occupant Classification System Module (OCSM)) are calibrated to each other and are serviced as an assembly. 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, OCSM and seat wiring harness) must be installed as an assembly.

NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON.

NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer.

1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering Supplemental Restraint System (SRS) Depowering and Repowering.

2. Remove the passenger seat. For additional information, refer to Seats.

3. Remove the seat backrest. For additional information, refer to Seats.

4. NOTE: Note position of wire routing for installation.

Release the seat wiring harness retainer clip and detach the seat wiring harness connector from the seat cushion frame.





5. Release the cushion trim rear J-clip.

6. Remove the 4 seat track-to-cushion frame bolts and the seat track assembly.

7. Release the remaining cushion trim J-clips.





8. NOTICE: An Occupant Classification Sensor (OCS) system service kit has the OCS system bladder attached to the seat cushion foam pad. Do not separate the OCS system bladder from the seat cushion foam pad. Failure to do so can result in component failure.

Remove the hog rings and the cushion trim from the seat cushion foam pad.





9. NOTE: Note position of wire routing for installation.

Release the 2 seat wiring harness routing clips from the cushion frame.





10. Release the pressure sensor bracket retainer and slide the pressure sensor off the bracket.





11. Remove the OCSM.

1. Remove the 2 screws from the OCSM.

2. Release the OCSM bracket retainer and slide the OCSM off the bracket.





12. NOTICE: A production Occupant Classification Sensor (OCS) system bladder is shown. An OCS system service kit has the OCS system bladder attached to the seat cushion foam pad. Do not separate the OCS system bladder from the seat cushion foam pad. Failure to do so can result in component failure.

Release the 3 OCS system bladder pin-type retainers from the seat cushion frame.





13. NOTE: Note position of wire routing for installation.

Route the OCS system bladder hose and pressure sensor, OCSM and seat wiring harness out through the seat cushion pan opening.

Installation

1. NOTICE: Inspect the Occupant Classification Sensor (OCS) system assembly, seat cushion frame and support assembly for any foreign objects before installing the OCS system assembly to the seat cushion frame. If any foreign objects are found, remove them. Failure to follow these instructions may result in incorrect OCS system operation or failure.

NOTICE: Failure to route the Occupant Classification Sensor (OCS) components through the correct seat cushion support opening can cause component failure.

NOTICE: 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 may result in component failure.

NOTE: If the original equipment OCS system is not being installed, install a OCS system service kit using all parts in the kit.

Position the OCS system to the seat cushion frame.
- Route the OCS system bladder hose and pressure sensor, OCSM and seat wiring harness through the seat cushion pan opening.

2. NOTICE: An Occupant Classification Sensor (OCS) system service kit has the OCS bladder attached to the seat cushion foam pad. Do not separate the OCS system bladder from the seat cushion foam pad. Failure to do so may result in component failure.

Install the 3 OCS system bladder pin-type retainers to the seat cushion frame.

3. Install the OCSM.
- Slide the OCSM back on the OCSM bracket until it is fully seated and locked in past the OCSM bracket retainer.

- Install the 2 screws.

4. Slide the pressure sensor on the bracket until it is fully seated and locked past the bracket retainer.





5. Install the 2 seat wiring harness routing clips to the seat cushion frame.

6. NOTICE: Inspect the seat cushion pad and seat cushion trim for any foreign objects, before installing the seat cushion trim to the seat cushion pad. If any foreign objects are found, remove them. Failure to follow these instructions may result in incorrect operation of the Occupant Classification Sensor (OCS) system and may cause system failure.

Position the cushion trim to the foam pad and install the hog rings.





7. Install the foam pad and cushion trim to the cushion frame and fasten the J-clips.





8. Install the seat track assembly and 4 bolts.
- Tighten to 6 Nm (53 lb-in).

9. Attach the seat cushion trim rear J-clip.

10. Install the seat wiring harness retainer clip and attach the seat wiring harness connector to the seat cushion frame.





11. Install the front seat backrest. For additional information, refer to Seats.

12. Install the passenger seat. For additional information, refer to Seats.

13. Repower the SRS. Do not prove out the SRS at this time. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures.

14. WARNING: Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash.

NOTICE: To prevent system failure, the following precautions must be taken before carrying out the Occupant Classification Sensor (OCS) system reset:
- Make sure the voltage to the Occupant Classification System Module (OCSM) is above 8 volts and less than 18 volts.
- Make sure the Occupant Classification Sensor (OCS) system is not at a temperature below 6°C (42°F) or above 36°C (97°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, 6°C to 36°C (42°F to 97°F) for a minimum of 30 minutes.
- Make sure nothing is present on the passenger seat before carrying out the OCS system reset and nothing is placed on the seat during the process.
- Make sure a minimum 8-second time period has passed after cycling the ignition ON before the carrying out the OCS system reset.


Carry out the Occupant Classification Sensor (OCS) System Reset.

15. If the first system reset attempt was unsuccessful, carry out a thorough visual inspection of the following and repair any concerns found.
- OCS system connector wiring for damage

- Pressure sensor hose for kinks and/or damage

- Seat-related wiring harness and body wiring harness terminals and connectors for damage

16. Carry out a second OCS system reset. If the second attempt is unsuccessful, install a new OCS system service kit.

17. Cycle the ignition from ON to OFF.

18. NOTE: The ignition must be cycled after the OCS system reset.

Cycle the ignition from OFF to ON.

19. Prove out the SRS as follows:
Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back to ON and 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 SRS fault is present, the air bag warning indicator will:
- fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag warning indicator may not illuminate until approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This is the time required for the to complete the testing of the SRS. If the air bag warning 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 warning indicator and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous RCM and OCSM DTCs using a scan tool.

20. NOTE: A prepaid return postcard is provided with a new OCS system service kit. 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 system was installed, fill out the necessary information on the OCS system traceability card and return it along with the complete inoperative OCS system to Ford Motor Company.
- When returning the inoperative OCS system include: seat cushion foam pad, bladder, OCSM, pressure sensor (transducer), hose, electrical connectors and wire harness (service part OCS system only).

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