Occupant Classification Sensor - Service Kit
OCCUPANT CLASSIFICATION SENSOR - SERVICE KITWorldwide Diagnostic System (WDS):
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.
- To reduce the risk of personal injury, do not use any memory saver devices.
- Do not separate components.
CAUTION: It is necessary to rezero the occupant classification sensor (OCS) system when a front passenger seat cushion is disassembled, a new trim cover installed, or an OCS service kit is installed. A diagnostic tool is used to trigger the active command to carry out rezeroing of the OCS system.
NOTE:
- If a seat equipped with a SRS component is being serviced, the SRS must be depowered.
- 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 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.
- If removing an OEM OCS, refer to the appropriate procedure.
- 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 supplemental restraint system (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 perform 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 system.
3. Remove the passenger seat.
Seats with manual recline
4. Pull out and remove the recline handle.
Seats with power
5. Remove the power seat switch knobs.
All seats
6. Remove the rear screw, pull out on the side and front and separate the side shield.
- Vehicles with manual seats, remove the side shield.
Seats with power
7. Remove the power seat control switch, and remove the side shield.
Seats with heat
8. Disconnect the heated seat electrical connector.
All seats
9. Release all the seat cushion trim cover J-clips.
10. Release the hook and loop strip at the rear of the seat cushion trim cover.
11. Remove the hog rings and seat cushion trim cover.
Seats with power
12. CAUTION: Do not oversize the seat cushion frame holes used to rivet the ECU in place.
Separate the occupant classification sensor (OCS) components from the seat cushion frame.
1 Cut the tie strap.
2 Remove the rivets with a 5-mm (3/16-inch) drill and separate the electronic control unit (ECU) from the seat cushion frame bracket.
3 Bend and release the retaining tab holding the pressure sensor in place.
4 Slide the pressure sensor off the bracket.
5 Release the pin-type retainer and disconnect the electrical connector.
Seats with manual seat track
13. CAUTION: Do not oversize the seat cushion frame holes used to rivet the ECU in place.
Separate the occupant classification sensor (OCS) components from the seat cushion frame.
1 Cut the tie strap.
2 Remove the rivets with a 5-mm (3/16-inch) drill and separate the electronic control unit (ECU) from the seat cushion frame bracket.
3 Bend and release the retaining tab holding the pressure sensor in place.
4 Slide the pressure sensor off the bracket.
5 Release the pin-type retainer and disconnect the electrical connector.
All seats
14. Remove the OCS from the seat cushion frame.
- Feed the hose, pressure sensor, wire harness, electrical connector and electronic control unit through the seat cushion frame support assembly.
Installation
All seats
1. Seats receiving a new OCS service kit, install the new cushion heated seat element onto the new cushion foam pad.
2. Bend the retaining tab back on the pressure sensor bracket.
3. WARNING: Do not separate 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.
Position the occupant classification sensor assembly to the seat cushion frame.
- Using a service occupant classification sensor, feed the electronic control unit, 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.
Seats with manual seat track
4. NOTE:
- When installing a new occupant classification sensor, the main seat wire harness pressure sensor electrical connector is not used.
- 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.
Attach and connect the occupant classification sensor components.
1 Position the electronic control unit onto the seat cushion frame bracket and install new rivets.
2 Install the pressure sensor onto the seat cushion frame bracket, making sure the retaining tab is completely engaged.
- Make sure the pressure sensor hose is routed correctly and is not kinked during installation.
- When installed correctly, an audible click will be heard and the pressure sensor will not be able to be removed from its bracket without disengaging the retaining tab.
3 Connect the main seat wire harness occupant classification sensor electrical connector to the service kit occupant classification sensor electrical connector, and then attach the connector pin-type retainer to the seat track bracket.
4 Tie strap the wire harness and electrical connector safely out of the way.
Seats with power
5. NOTE:
- When installing a new occupant classification sensor, the main seat wire harness pressure sensor electrical connector is not used.
- 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.
Attach and connect the occupant classification sensor components.
1 Position the electronic control unit onto the seat cushion frame bracket and install new rivets.
2 Install the pressure sensor onto the seat cushion frame bracket, making sure the retaining tab is completely engaged.
- Make sure the pressure sensor hose is routed correctly and is not kinked during installation.
- When installed correctly, an audible click will be heard and the pressure sensor will not be able to be removed from its bracket without disengaging the retaining tab.
3 Connect the main seat wire harness occupant classification sensor electrical connector to the service kit occupant classification sensor electrical connector, and then attach the connector pin-type retainer to the seat track bracket.
4 Tie strap the wire harness and electrical connector safely out of the way.
All seats
6. 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.
Align the seat cushion trim cover to the seat cushion foam pad and attach the hog rings.
7. Attach the hook and loop strip at the rear of the seat cushion trim cover.
8. Attach all the seat cushion trim cover J-clips.
Seats with heat
9. Connect the heated seat electrical connector.
Seats with power
10. Install the power seat control switch to the side shield.
All seats
11. Install the side shield and rear screw.
Seats with power
12. Install the power seat switch knobs.
Seats with manual recline
13. Install the recline handle.
All seats
14. Install the passenger seat.
15. Repower the SRS. Do not prove out the SRS at this time.
16. 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 or an OCS service kit is installed. A diagnostic 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 NGS+ (NGS with Vehicle Communication Module (VCM) and the latest software) to rezero the OCS system:
- select "ACTIVE COMMAND MODES"
- select "SYSTEM SELECTABLE CALIBRATION"
- view the on-screen information then press "TRIGGER"
The NGS+ will display "TEST/FUNCTION COMPLETED" once rezeroing of the OCS system is complete.
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 diagnostic tool to trigger the active command and rezero the OCS.
17. NOTE: The ignition switch must be cycled after rezeroing the OCS system.
Cycle the ignition switch from ON to OFF.
18. Prove out the 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 six seconds and then turn off. If an air bag 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 RCM using a diagnostic tool.
19. Check the active restraint system for correct operation.
20. NOTE: When installing a new OCS, 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, electronic control unit, pressure sensor (transducer), hose, electrical connectors and wire harness (service part OCS only).