Occupant Classification Sensor - Service Kit

Occupant Classification Sensor - Service Kit













Removal

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.

NOTICE: Do not install a new heater mat on a front passenger seat cushion. If a new cushion heater mat is needed on the front passenger seat, an Occupant Classification Sensor (OCS) service kit equipped with a heater mat must be installed. Failure to follow this instruction may result in incorrect operation of the OCS system.

NOTE: To identify between a production Occupant Classification Sensor (OCS) sensor 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.

NOTE: If removing an OEM OCS, refer to Occupant Classification Sensor - Original Equipment Occupant Classification Sensor - Original Equipment.

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

1. Remove the passenger seat.

2. If equipped, remove the manual recline handle.

3. Remove the seat cushion side shield.
- Remove the rear seat cushion shield screw, pull out on the side and front and separate the seat cushion side shield from the seat.

- If equipped, disconnect the seat control switch electrical connector.

- Remove the seat cushion side shield.

4. If equipped, disconnect the heated seat electrical connector.

5. Release all the seat cushion trim cover J-clips.

6. Release the hook-and-loop strip at the rear of the seat cushion trim cover.

7. Remove the hog rings and seat cushion trim cover.





8. NOTICE: 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 system service kit components from the seat cushion frame.

- Cut the tie strap.

- Remove the electrical tape from the OCS service kit harness and pressure sensor hose.

- Remove the rivets with a 5 mm (3/16 in) drill and separate the OCSM from the seat cushion frame bracket.

- Bend and release the retaining tab holding the pressure sensor in place.

- Slide the pressure sensor off the bracket.

- Release the pin-type retainer and disconnect the electrical connector.

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

- Remove the OCS from the seat cushion frame.

Installation

1. Bend the retaining tab back on the pressure sensor bracket.





2. 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.

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

NOTICE: 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 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.





3. NOTE: When installing a new OCS, the main seat wire harness pressure sensor electrical connector is not used.

NOTE: 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.
- Position the OCSM onto the seat cushion frame bracket and install new rivets.

- 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.

- 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.

- Tie strap the wire harness and electrical connector safely aside.

- 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.

4. Align the seat cushion trim cover to the seat cushion foam pad and attach the hog rings.





5. Attach the hook-and-loop strip at the rear of the seat cushion trim cover.

6. Attach all the seat cushion trim cover J-clips.

7. If equipped, connect the heated seat electrical connector.

8. Install the seat cushion side shield.
- If equipped, connect the seat control switch electrical connector.

- Attach the side shield to the seat cushion frame.

- Install the rear side shield screw.

9. If equipped, install the manual recline handle.

10. Install the passenger seat.

11. 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, 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.

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 8.0 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 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 carrying out the OCS system reset process.


Carry out the OCS system reset. If the system reset was successful, proceed to Step 15, otherwise proceed to Step 12.

12. If the first system reset attempt was unsuccessful, carry out a thorough visual inspection of the following:
- OCS system wiring

- Check the pressure sensor hose for kinks and/or damage

- Related seat wiring harness, body wiring harness terminals and connectors

13. If the damage is found, repair and/or install new components as necessary.

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

15. Prove out the SRS as follows:

Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch 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.

16. NOTE: When installing a new OCS system, a prepaid return postcard is provided. 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 post card and return it along with the complete inoperative OCS 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.