FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
Courtesy of Operation CHARM: Car repair manuals for everyone.
Home >> Mercury >> 2011 >> Grand Marquis V8-4.6L Flex Fuel >> Repair and Diagnosis >> Sensors and Switches >> Sensors and Switches - Restraints and Safety Systems >> Seat Occupant Sensor >> Service and Repair

Seat Occupant Sensor: Service and Repair




Occupant Classification Sensor





Seat with OEM Occupant Classification System (OCS)

NOTE: 40% seat is shown, 50% seat is similar.











Seat with a Service Kit Occupant Classification System (OCS)

NOTE: 40% seat is shown, 50% seat is similar.











Removal

WARNING: Never disassemble or tamper with safety belt buckle/retractor pretensioners or adaptive load limiting retractors or probe the electrical connectors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors which increases the risk of serious personal injury or death.

NOTE: To identify between a production Occupant Classification System (OCS) system and an OCS system service kit, inspect the Occupant Classification System Module (OCSM) electrical connector. A production OCS system allows the disconnect of the OCSM electrical connector. An OCS system service kit has the OCSM electrical connector glued to the module. It cannot and should not be disconnected or altered.

NOTE: The heater mat on the front passenger seat cushion is not serviceable separately. If a new heater mat is needed on the front passenger seat cushion, a new OCS system service kit and a new heater mat must be installed.

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.

All seats

1. Remove the front passenger seat. For additional information, refer to Seating Seat - Front.

2. Remove the front seat backrest. For additional information, refer to Seating Seat Backrest - Front Removal and Installation.

3. Remove the seat track. For additional information, refer to Seating Seat Track.

Heated seats

4. Disconnect the seat cushion heater mat electrical connector.

Seats with manual recline

5. Remove the seat backrest recliner handle.

Seats with power lumbar

6. Release the tabs at the front and back to separate the power lumbar switch and bezel from the seat cushion frame.

7. Disconnect the electrical connector and remove the power lumbar switch.

All seats

8. Release the remaining seat cushion cover J-clips.

9. NOTICE: It is necessary to carry out the Occupant Classification System (OCS) system reset when a front passenger seat cushion is disassembled, a new seat cushion cover installed or an OCS service kit is installed. A scan tool is used to carry out the OCS system reset.

NOTICE: Use care when separating the seat cushion cover from the hook-and-loop strip. The hook-and-loop strip can be torn from the seat cushion foam. Failure to follow this procedure can result in component damage and/or system failure.

Separate the hook-and-loop strips. Position the seat cushion cover aside.





10. Bend the retaining tab holding the pressure sensor in place down and aside.





Seats with an original equipment Occupant Classification System (OCS) system

11. Remove the seat cushion pad from the seat cushion frame.

12. If necessary, remove the 2 pin-type retainers and the mat, otherwise position the mat aside.

13. Remove the OCSM and separate the pressure sensor from the OCSM bracket.

1. Release the pressure sensor hose.

2. Disconnect the electrical connector and slide the pressure sensor off the bracket.

3. NOTICE: Do not oversize the seat cushion frame holes used to rivet the Occupant Classification System Module (OCSM) in place. Failure to follow these instructions may result in incorrect operation of the Occupant Classification System (OCS) system and may cause system failure.

Using a 5 mm (3/16 in) drill, remove the 3 rivets.

4. Remove the OCSM bracket.

5. Disconnect and remove the OCSM.





14. Remove the pin-type retainers holding the occupant classification sensor bladder to the seat cushion frame.

15. 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.

Separate the OCS bladder and pressure sensor from the seat cushion frame.

- Feed the pressure sensor and hose through the seat cushion support assembly.





Seats with an OCS system service kit

16. Separate the OCS system components from the seat cushion frame.

1. Release the pressure sensor hose.

2. Slide the pressure sensor off the bracket.

3. Cut the tie-straps.

4. NOTICE: Do not oversize the seat cushion frame holes used to rivet the Occupant Classification System Module (OCSM) in place. Failure to follow these instructions may result in incorrect operation of the Occupant Classification System (OCS) system and may cause system failure.

Using a 5 mm (3/16 in) drill, remove the 3 rivets.

5. Remove the OCSM bracket.

6. Disconnect the service part OCS electrical connector.





17. NOTE: Make note of the opening that the OCS system components are being fed through on the seat cushion support assembly for installation purposes.

Remove the OCS system from the seat cushion frame.

- Feed the hose, pressure sensor, wire harness, electrical connector and OCSM through the seat cushion frame support assembly.





18. If necessary, remove the 2 pin-type retainers and the cushion mat. Otherwise, position the mat aside.

Installation

WARNING: Occupant classification system(OCS) parts are calibrated as an assembly and must only be replaced in the configuration they are sold. Never separate parts of an assembly. Failure to follow this instruction may result in incorrect operation of the OCS and increases the risk of serious personal injury or death in a crash.

All seats

1. Bend the pressure sensor bracket retaining ear back so it will engage upon assembly.





Vehicles with heated seats

2. NOTE: The heater mat on the front passenger seat cushion is not serviceable separately. If a new heater mat is needed on the front passenger seat cushion, a new OCS system service kit and a new heater mat must be installed.

Attach the heater mat to the seat cushion pad.

Seats having the original equipment OCS system installed

3. NOTICE: Failure to route the seat Occupant Classification System (OCS) system components through the correct seat cushion support opening can cause system failure and incorrect OCS system operation.

NOTICE: Inspect the Occupant Classification System (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 this instruction may result in system failure and the incorrect operation of the OCS system.

Position the OCS system assembly to the seat cushion frame.

- Feed the pressure sensor with hose through the largest opening at the front of the seat cushion frame support assembly as noted during removal.





4. NOTICE: Inspect the Occupant Classification System (OCS) bladder, seat cushion frame and support assembly for any foreign objects, before installing the OCS system to the seat cushion frame. If any foreign objects are found, remove them. Failure to follow this instruction may result in system failure and the incorrect operation of the OCS system.

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

5. If the cushion mat was removed, position the mat over the bladder and install pin-type retainers, otherwise position the mat over the bladder.

6. Attach and connect the OCS system components.

1. Position the OCSM to the seat cushion frame and connect the electrical connector.

2. Install the 2 rivets to hold the OCSM in place.

3. Position the OCSM bracket through the opening in the front of the seat cushion frame.

4. Install the OCSM bracket rivet.

5. Install the pressure sensor onto the seat cushion frame bracket, making sure the retaining ear is completely engaged.
- Connect the pressure sensor electrical connector.

6. Attach the pressure sensor hose.





7. NOTICE: Inspect the seat cushion pad and frame for any foreign objects before installing the seat cushion frame to the seat cushion pad. If any foreign objects are found, remove them. Failure to follow this instruction may result in system failure and the incorrect operation of the Occupant Classification System (OCS) system.

Install the seat cushion pad to the seat cushion frame.

Seats having an OCS system service kit installed

8. NOTICE: Inspect the Occupant Classification System (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 this instruction may result in system failure and the incorrect operation of the OCS system.

NOTICE: Failure to route the seat Occupant Classification System (OCS) system components through the correct seat cushion support opening can cause 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 assembly to the seat cushion frame.

- Using an OCS system service kit, feed the OCSM, electrical connector, wire harness, pressure sensor and hose through the largest opening at the front of the seat cushion frame support assembly as noted during removal.
- Position the seat cushion pad and bladder to the seat cushion frame.





9. NOTE: When installing a OCS system service kit, the main seat wire harness pressure sensor electrical connector does not get used.

Attach and connect the OCS system components.

1. Position the OCSM onto the seat cushion frame and install the 2 rivets.

2. Position the OCSM bracket through the opening in the front of the seat cushion frame.

3. Install the OCSM bracket rivet.

4. Install the pressure sensor onto the seat cushion frame bracket, making sure the retaining ear is completely engaged.

5. Attach the pressure sensor hose.

6. Connect the main seat wire harness OCSM electrical connector to the OCSM service part electrical connector.

7. Tie-strap all loose wire harnesses and electrical connectors safely aside.





All seats

10. Align the seat cushion cover to the seat cushion pad and fasten the hook-and-loop strips.





11. Position the seat cushion cover and attach the J-clips.

Seats with power lumbar

12. Connect the power lumbar switch electrical connector.

13. Attach the power lumbar switch and bezel to the seat.

Seats with manual recline

14. Install the seat backrest recliner handle.

Heated seats

15. Connect the seat cushion heater mat electrical connector.

All seats

16. Install the seat track. For additional information, refer to Seating Seat Track.

17. Install the front seat backrest. For additional information, refer to Seating Seat Backrest - Front Removal and Installation.

18. Install the front passenger seat. For additional information, refer to Seating Seat - Front.

19. 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 system (OCS) 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 System (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 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 System (OCS) System Reset.

20. 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

21. Carry out a second OCS system reset. If the second attempt is unsuccessful, install a new OCS system service kit. For additional information, refer to Occupant Classification Sensor in the Removal and Installation portion of Supplemental Restraint System Service and Repair.

22. Cycle the ignition switch from ON to OFF.

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

Cycle the ignition switch from OFF to ON.

24. 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 warning indicator with the air bag modules installed. The air bag warning 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.
The flashing might not occur until approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This is the time required for the RCM 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 faults discovered must be diagnosed and repaired.
Clear all continuous DTCs from the RCM using a scan tool.

25. NOTE: When installing a new OCS system 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.

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, electronic control unit, pressure sensor (transducer), hose, electrical connectors and wire harness (service part OCS system only).





pro multis Credits:Operation CHARM About Operation CHARM