Occupant Classification Sensor - Manual Seat

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.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ THE SAFETY BELT PRETENSIONER IS A PYROTECHNIC DEVICE. ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG EQUIPPED VEHICLE AND WHEN HANDLING A SAFETY BELT BUCKLE PRETENSIONER OR SAFETY BELT RETRACTOR PRETENSIONER. NEVER PROBE A PRETENSIONER ELECTRICAL CONNECTOR. DOING SO COULD RESULT IN PRETENSIONER OR AIR BAG DEPLOYMENT AND COULD RESULT IN PERSONAL INJURY.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.

CAUTION: If replacing only the front passenger seat cushion trim cover, the occupant classification sensor must be rezeroed.

NOTE:
^ Occupant classification sensor (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 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.

All vehicles
1 Disconnect the battery ground cable and wait at least one minute.

WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED).

2 Deactivate the supplemental restraint system (SRS).

WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming.

3 Remove the front passenger seat.

WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS, NOTES AND INSTRUCTIONS IN THE SEAT REMOVAL AND INSTALLATION PROCEDURE.







4. Separate the electrical connectors and wire harnesses from the seat pedestal.
1 Release the pin-type retainers and separate the side air bag electrical connector and wire harness from the seat pedestal.
2 Release the pin-type retainers and separate the main seat harness electrical connector and wire harness from the seat pedestal.
3 Disconnect the safety belt buckle latch indicator switch electrical connector.
4 Release the pin-type retainer and separate the side air bag wire harness from the seat cushion frame.







5. Remove the seat pedestal.
1 Remove the nuts.
2 Remove the seat pedestal.







6. Remove the outboard side shield screw.







7. Push in where indicated, lift and pull out, releasing the retaining clip.







8. Release the outboard side shield retainers.
1 Lift and release the retainer.
2 While holding the side shield up, rotate the side shield, disengaging the retainers.







9. Remove the outboard side shield.
1 Carefully pull out and release the side shield front retainer.
2 Remove the outboard side shield.







10. Remove the inboard side shield screw.







11. Push in where indicated, lift and pull out, releasing the retaining clip.







12. Through the opening at the back of the side shield, remove the recliner handle cover.







13. Release the inboard side shield retainers.
1 Lift and release the retainer.
2 While holding the side shield up, rotate the side shield, disengaging the retainers.







14. Remove the inboard side shield.
1 Carefully pull out and release the side shield front retainer.
2 Remove the inboard side shield.







15. Route out the side air bag wire harness and remove the pivot bolt.
1 Route out the side air bag wire harness and electrical connector from under and along the side of the seat cushion frame.
2 Remove the pivot bolt.

NOTE: Note the side air bag wire harness routing for installation.







16. Separate the seat cushion from the seat backrest.
1 Remove the bolts.
2 Remove the seat cushion.







17. Remove the seat track.
1 Remove the bolts.
2 Remove the seat track.







18. Separate the cushion trim cover J-clips from the cushion frame.

Vehicles with an original equipment occupant classification sensor







19. Remove the seat cushion trim cover from the cushion pad.
1 Remove the seat cushion foam pad and trim cover from the seat cushion frame.
2 Separate the hook and loop strips.
3 Remove the seat cushion trim cover from the seat cushion foam pad.

CAUTION:
^ If installing only the front passenger seat cushion trim cover, the seat occupant sensor must be rezeroed.
^ 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.
^ Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam.







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

CAUTION: 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.

21. Turn the seat cushion frame over.







22. Remove the electronic control unit and pressure sensor from the seat cushion frame bracket.
1 Disconnect the electronic control unit and pressure sensor electrical connectors.
2 Bend and release the retaining tabs holding the electronic control unit and pressure sensor in place.
3 Slide the electronic control unit off the bracket.
4 Slide the pressure sensor off the bracket.







23. Separate the seat cushion frame from the occupant classification sensor assembly.
1 While lifting the seat cushion frame, pull the pressure sensor with hose through the seat cushion frame support assembly.
2 Separate the seat cushion frame from the occupant classification sensor assembly.

Vehicles with a service part occupant classification sensor







24. Remove the wire harness tie straps.







25. Remove the electronic control unit and pressure sensor from the seat cushion frame bracket.
1 Bend and release the retaining tabs holding the electronic control unit and pressure sensor in place.
2 Disconnect the electrical connector.
3 Slide the electronic control unit off the bracket.
4 Slide the pressure sensor off the bracket.







26. Remove the occupant classification sensor assembly from the seat cushion frame.
1 Lift the seat cushion trim cover, foam pad and bladder assembly.
2 Feed the hose, pressure sensor, wire harness, electrical connector and electronic control unit through the seat cushion frame support assembly.

CAUTION: 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.







27. Remove the cushion trim cover from the cushion pad.
^ Separate the hook and loop strips.

CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam.

INSTALLATION

WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS AND NOTES AT THE BEGINNING OF THE REMOVAL PROCEDURE.

Vehicles having the original equipment occupant classification sensor installed







1. Position the occupant classification sensor assembly to the seat cushion frame.
^ While laying the seat cushion frame on top of the occupant classification sensor assembly, pull the pressure sensor with hose through the largest opening at the front of the seat cushion frame support assembly.

CAUTION:
^ 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.
^ 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.







2. Bend the three retaining ears back on the occupant classification sensor component bracket.







3. Attach and connect the occupant classification sensor components.
1 Install the electronic control unit onto the seat cushion frame bracket, making sure the retaining ears are completely engaged.
2 Install the pressure sensor onto the seat cushion frame bracket, making sure the retaining ear is completely engaged.
3 Connect the electronic control unit.
4 Connect the pressure sensor.







4. With the seat cushion frame turned on its bottom, install the pin-type retainers holding the occupant classification sensor bladder to the seat cushion frame.

CAUTION:
^ Inspect the occupant classification sensor bladder, seat cushion frame and support assembly for any foreign objects, before installing the occupant classification sensor 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.
^ 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.







5. With the seat cushion pad up, align the seat cushion trim cover to the seat cushion pad and attach the hook and loop strips.

CAUTION:
^ 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.
^ Inspect the seat cushion pad and seat cushion trim cover for any foreign objects, before installing the seat 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.







6. Install the seat cushion pad and trim cover to the seat cushion frame.
1 Position the seat cushion frame to the pad and trim cover.
2 Attach the seat cushion trim cover J-clips to the seat cushion frame.

CAUTION: 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 do so may result in personal injury, in the event of an air bag deployment.

Vehicles having a service part occupant classification sensor installed







7. Position the occupant classification sensor assembly to the seat cushion frame.
1 Position the seat cushion frame face up.
2 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.
3 Position the seat cushion pad and bladder to the seat cushion frame.

CAUTION:
^ Failure to route the seat occupant sensor components through the correct seat cushion support opening can cause component failure.
^ 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.







8. Turn the seat cushion frame bottom side up and bend the three retaining ears back on the occupant classification sensor component bracket.

CAUTION: 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.







9. Attach and connect the occupant classification sensor components.
1 Install the electronic control unit onto the seat cushion frame bracket, making sure the retaining ears are completely engaged.
2 Install the pressure sensor onto the seat cushion frame bracket, making sure the retaining ear is completely engaged.
3 Connect the main seat wire harness occupant classification sensor electrical connector to the service part occupant classification sensor electrical connector.

NOTE: When installing a service part occupant classification sensor, the main seat wire harness pressure sensor electrical connector does not get used.







10. Tie strap all loose wire harnesses and electrical connectors safely out of the way.







11. With the seat cushion pad up, align the seat cushion trim cover to the seat cushion pad and attach the hook and loop strips.

CAUTION:
^ If replacing only the front passenger seat cushion trim cover, the seat occupant sensor must be rezeroed.
^ Inspect the seat cushion pad and seat cushion trim cover for any foreign objects, before installing the seat 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.
^ 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.







12. With the seat cushion frame bottom side up, attach the seat cushion trim cover J-clips to the seat cushion frame.

CAUTION: 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.

All vehicles







13. Install the seat track to the seat cushion frame.
1 Position the seat track to the seat cushion frame.
2 install the bolts (one shown).







14. Position the seat cushion assembly to the seat backrest and install the bolts.







15. Install the pivot bolt and route the side air bag wire harness, as noted in removal, along the side and through the opening in the seat cushion frame.







16. Install the inboard side shield front retainer.







17. Engage the inboard side shield retainers.
1 Lift the inboard side shield.
2 While holding the side shield up, rotate the side shield, engaging the retainers.







18. Install the recliner handle cover.
1 Lift, push in and then down, engaging the side shield retainer.
2 Install the recliner handle cover.







19. Install the inboard side shield screw.







20. Install the outboard side shield front retainer.







21. Engage the outboard side shield retainers.
1 Lift the outboard side shield.
2 While holding the side shield up, rotate the side shield, engaging the retainers.







22. Lift, push in and then down, engaging the side shield retainer.







23. Install the outboard side shield screw.







24. Install the seat pedestal.
1 Position the pedestal to the seat track and install the nuts.
2 Install the side air bag wire harness pin-type retainer to the seat cushion frame.
3 Install the side air bag electrical connector and wire harness pin-type retainers to the seat pedestal.
4 Install the main seat harness electrical connector and wire harness pin-type retainers to the seat pedestal.
5 Connect the safety belt buckle latch indicator switch electrical connector.

25. Install the front passenger seat.

WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS, NOTES AND INSTRUCTIONS IN THE SEAT REMOVAL AND INSTALLATION PROCEDURE.

26. Reactivate the supplemental restraint system (SRS).

WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming.

27. Rezero the occupant classification sensor.
^ With the front passenger seat empty. use a scan tool to trigger the active command and rezero the occupant classification sensor.

CAUTION: 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 vehicle has not been exposed to temperatures below 6°C (42°F) or above 36°C (97°F) within four hours prior to the rezeroing process. If the vehicle has been exposed to temperatures outside the temperature limits (6-36°C ), the vehicle must be exposed and kept at a temperature within the limits for a minimum of four hours.
^ 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 five second time period has passed after cycling the ignition switch ON before the rezeroing process.

NOTE: 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 scan tool is used to trigger the active command to carry out rezeroing of the OCS system.

28. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). Prove Out Procedure

WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.

29. Prove out the supplemental restraint system (SRS). Prove Out Procedure
30. Check the active restraint system for correct operation.







31. Fill out the necessary information on the occupant classification sensor traceability card and return it along with the complete inoperative occupant classification sensor to Ford Motor Company.
^ When returning the inoperative occupant classification sensor include: seat cushion foam pad, bladder, electronic control unit, pressure sensor (transducer), hose, electrical connectors and wire harness (service part occupant classification sensor only).

NOTE: When installing a new occupant classification sensor, a prepaid return postcard is provided with the new occupant classification sensor. The serial number for the new part and the Vehicle Identification Number (VIN) must be recorded and sent to Ford Motor Company