Occupant Classification Sensor - Service Kit
OCCUPANT CLASSIFICATION SENSOR - SERVICE KITSpecial Tool(s)
Special Tool(s):
Part 1:
Part 2:
Removal
WARNING:
- To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death.
- Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash.
CAUTION: It is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat backrest is separated from the seat cushion, the seat cushion is disassembled, a new trim cover is installed or an OCS system service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. Failure to follow these instructions may result in incorrect operation of the OCS system and may cause system failure.
NOTE:
- To identify between a production occupant classification sensor (OCS) and an OCS system service kit, inspect the occupant classification system module (OCSM) electrical connector. A production OCS allows the disconnect of the OCSM electrical connector. An OCS system service kit has the OCSM electrical connector glued to the OCSM. It cannot and should not be disconnected or altered.
- If removing an OEM OCS, refer to Occupant Classification Sensor - Original Equipment. Occupant Classification Sensor - Original Equipment
- The air bag warning indicator 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. Remove the passenger front seat.
Seats with manual recline
3. Pull out and remove the recline handle.
Seats with power
4. Remove the power seat switch knobs.
All seats
5. 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
6. Remove the power seat control switch, and remove the side shield.
Seats with heat
7. Disconnect the heated seat electrical connector.
All seats
8. Release all the seat cushion trim cover J-clips.
9. Release the hook-and-loop strip at the rear of the seat cushion trim cover.
10. Remove the hog rings and seat cushion trim cover.
Seats with power
11. CAUTION: Do not oversize the seat cushion frame holes used to rivet the occupant classification system module (OCSM) in place. Failure to follow this instruction may result in component damage and/or system failure.
Separate the OCS components from the seat cushion frame.
1 Cut the tie strap.
2 Remove the electrical tape from the OCS service kit harness and pressure sensor hose.
3 Remove the rivets with a 5 mm (3/16 in) drill and separate the OCSM from the seat cushion frame bracket.
4 Bend and release the retaining tab holding the pressure sensor in place.
5 Slide the pressure sensor off the bracket.
6 Release the pin-type retainer and disconnect the electrical connector.
Seats with manual seat track
12. CAUTION: Do not oversize the seat cushion frame holes used to rivet the occupant classification system module (OCSM) in place. Failure to follow this instruction may result in component damage and/or system failure.
Separate the OCS components from the seat cushion frame.
1 Cut the tie strap.
2 Remove the electrical tape from the OCS service kit harness and pressure sensor hose.
3 Remove the rivets with a 5 mm (3/16 in) drill and separate the OCSM from the seat cushion frame bracket.
4 Bend and release the retaining tab holding the pressure sensor in place.
5 Slide the pressure sensor off the bracket.
6 Release the pin-type retainer and disconnect the electrical connector.
All seats
13. Remove the OCS from the seat cushion frame.
- Feed the hose, pressure sensor, wire harness, electrical connector and OCSM through the seat cushion frame support assembly.
Installation
Seats with heat
1. Install the new cushion heated seat element onto the new cushion foam pad.
All seats
2. Bend the retaining tab back on the pressure sensor bracket.
3. WARNING: Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash.
CAUTION:
- Failure to route the occupant classification sensor (OCS) system components through the correct seat cushion support opening may cause component failure.
- While positioning the seat cushion frame and occupant classification sensor (OCS) system assembly, be careful not to damage any of the components. Failure to do so may result in component failure.
Position the OCS system assembly to the seat cushion frame.
- Slide the pushpin clip retainer onto the double header connector.
- Connect the double header connector to the 18-way connector on the OCS system service kit harness.
- Feed the occupant classification system module (OCSM), 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 and install the OCS system bladder pin-type retainers.
Seats with manual seat track
4. NOTE:
- When installing a new OCS, the main seat wire harness pressure sensor electrical connector is not used.
- The OCSM must be correctly positioned and securely riveted in place. Failure to do so may set a DTC in the RCM.
Attach and connect the OCS components.
1 Position the OCSM 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 OCS electrical connector to the OCS service kit 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 aside.
5 Using electrical tape, tape the OCS service kit wire harness to the pressure sensor hose.
- Do not tie strap the OCS service kit wire harness to the pressure sensor hose.
Seats with power
5. NOTE:
- When installing a new OCS, the main seat wire harness pressure sensor electrical connector is not used.
- The OCSM must be correctly positioned and securely riveted in place. Failure to do so may set a DTC in the RCM.
Attach and connect the OCS components.
1 Position the OCSM 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 OCS electrical connector to the OCS service kit 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 aside.
5 Using electrical tape, tape the OCS service kit wire harness to the pressure sensor hose.
- Do not tie strap the OCS service kit wire harness to the pressure sensor hose.
All seats
6. 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. WARNING:
- Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash.
- 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.
CAUTION:
- 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 cover installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command.
- 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 sensor module (OCSM) is above 8.0 volts and less than 18.0 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 switch ON before the carrying out the OCS system reset process.
NOTE: If the first attempt to carry out the OCS system reset is unsuccessful, a second attempt must be made. If the second attempt to carry out the OCS system reset is unsuccessful, a new OCS system service kit must be installed.
Carry out the OCS system reset.
16. Cycle the ignition switch from ON to OFF.
17. NOTE: The ignition switch must be cycled after carrying out the OCS reset.
Cycle the ignition switch from OFF to ON.
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 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 switch 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 fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the RCM and OCSM using a scan tool.
19. NOTE: When installing a new OCS system, a prepaid return postcard is provided with the new OCS system. 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 occupant classification sensor 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 (OCS system service kit part only).
