Occupant Classification Sensor - Service Kit, Early Build
OCCUPANT CLASSIFICATION SENSOR - SERVICE KIT, EARLY BUILDDiagnostic Tool, Restraint System:
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: 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.
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, an OCS system early build service kit (OCS service kit, early build), and an OCS system service kit (OCS service kit) inspect the OCS ECU electrical connector.
A production OCS system allows the disconnect of the electrical connector from the OCS ECU.
An OCS system early build service kit (OCS service kit, early build) has the OCS ECU electrical connector glued to the ECU, it cannot and should not be disconnected or altered. There is no in-line connector between the seat wiring harness and the OCS ECU.
An OCS system service kit (OCS service kit) has the OCS ECU electrical connector glued to the ECU, it cannot and should not be disconnected or altered. An OCS system service kit also has an in-line 10-pin connector between the OCS ECU and the seat wiring harness.
NOTE:
- If removing an original equipment OCS, refer to Occupant Classification Sensor - Original Equipment. If removing a late build OCS service kit, refer to Occupant Classification Sensor - Service Kit.
- 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 carry out the diagnostic procedure again.
1. 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.
The front impact severity sensor is located on the hood latch support bracket.
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).
Disconnect the battery ground cable and wait at least one minute.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming.
Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming.
3. 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.
Remove the passenger seat.
4. CAUTION:
- While positioning the seat cushion pan and occupant classification sensor assembly, be careful not to damage any of the components. Failure to do so can result in component failure.
- 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.
Remove the parts in the order indicated in the illustrations and tables.
5. 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 scan tool is used to trigger the active command to carry out rezeroing of the OCS system.
Release the seat cushion trim cover J-clips from the seat cushion pan.
6. At the front outboard of the seat cushion pan, pull the trim cover back and release the two remaining clips.
7. 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 scan tool is used to trigger the active command to carry out rezeroing of the OCS system.
Remove all the hog rings and separate the trim cover from the foam pad.
8. Bend the retaining tab away from the pressure sensor, then slide the pressure sensor off the bracket.
- Fold the seat cushion foam pad and the occupant classification sensor bladder back to access the pressure sensor retaining tab.
9. Remove the screws and separate the electronic control unit (ECU).
10. If equipped, disconnect the heated seat module.
11. NOTE: If an Occupant Classification Sensor - Service Kit is being installed, a new seat wiring harness will need to be installed. The seat cushion pan will be reused.
Separate the seat wire harness from the seat cushion pan.
12. Slide the wire support keeper back to allow for clearance.
13. Remove the hog rings attaching the seat cushion foam pad to the seat cushion pan.
14. Separate the seat cushion pan from the OCS system (foam pad, bladder, electronic control unit, pressure sensor and seat wire harness.
- Pull all the OCS components (hose, pressure sensor, seat wire harness, electronic control unit) through the seat cushion pan opening.
Item 1: Electrical Connector Removal Note
1. If equipped, disconnect the backrest heated seat element electrical connector and release any wire harness retainers attached to the seat cushion pan.
2. If equipped, disconnect the power seat motor electrical connector and release any wire harness retainers attached to the seat cushion pan.
3. If equipped, disconnect the power seat switch electrical connector.
4. NOTE: The safety belt buckle pretensioner electrical connector was disconnected in the deactivation procedure.
Disconnect the safety belt buckle switch electrical connector. If attached, release the safety belt buckle switch and safety belt buckle pretensioner wire harnesses from the seat track.
Item 2: Belt Tension Sensor Electrical Connector (Vehicles With Seat Integrated Restraints Only) Removal Note
1. NOTE: Vehicles without seat integrated restraints (SIR) will have the belt tension sensor (BTS) connector at the B-pillar and will not have to be disconnected for this procedure.
Disconnect the connector, release the J-clip and route out the wire harness.
Item 4: Seat Cushion Assembly Removal Note
1. If equipped with lumbar, release the J-clip and route out the lumbar cable.
2. NOTE: Disconnect and release any remaining electrical connectors and pin-type retainers necessary to remove the seat cushion pan.
Remove the seat cushion and pan assembly.
- To aid in removal, recline the seat.
- Remove the safety belt buckle from the seat cushion strap.
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.
1. If not done already, slide the wire support keeper back to allow for clearance.
2. CAUTION:
- Inspect the occupant classification sensor assembly, seat cushion pan and support assembly for any foreign objects before installing the occupant classification sensor assembly to the seat cushion pan. 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 classification sensor components through the correct seat cushion support opening can cause component failure.
- While positioning the seat cushion pan and occupant classification sensor assembly, be careful not to damage any of the components. Failure to do so can result in component failure.
Feed the OCS early build service kit components (hose, pressure sensor, seat wire harness electronic control unit) through the seat cushion pan.
3. Slide the wire support keeper back to its original position.
4. CAUTION:
- Inspect the occupant classification sensor assembly, seat cushion pan and support assembly for any foreign objects before installing the occupant classification sensor assembly to the seat cushion pan. 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 pan and occupant classification sensor assembly, be careful not to damage any of the components. Failure to do so can result in component failure.
Align the occupant classification sensor early build service kit foam pad wire to the seat cushion pan ears and install the hog rings.
5. Bend the tab back and slide the pressure sensor onto the bracket.
6. Position the ECU and install the screws.
7. If equipped, install the heated seat module and connect the electrical connector.
8. Route the seat wire harness and attach the pin-type retainers to the seat cushion pan.
9. 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 scan tool is used to trigger the active command to carry out rezeroing of the OCS system.
- 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.
- While positioning the seat cushion pan and occupant classification sensor assembly, be careful not to damage any of the components. Failure to do so can result in component failure.
Install hog rings to attach the seat cushion trim cover to the seat cushion foam pad at all locations they were removed from.
10. At the front outboard of the seat cushion pan, attach the two clips.
11. 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 scan tool is used to trigger the active command to carry out rezeroing of the OCS system.
Attach the seat cushion trim cover J-clips to the seat cushion pan.
- If equipped with seat integrated restraints (SIR), do not attach the RH rear J-clip at this time, so as to route the belt tension sensor wire harness between the trim cover and seat cushion pan later in the procedure.
- If equipped, do not attach the LH rear J-clip at this time so as to route the lumbar cable between the trim cover and seat cushion pan later in the procedure.
CAUTION:
- While positioning the seat cushion pan and occupant classification sensor assembly, be careful not to damage any of the components. Failure to do so can result in component failure.
- 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.
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.
12. 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.
NOTE: Make sure the battery ground cable is still disconnected before proceeding with the installation portion of this procedure.
Install the passenger seat into the vehicle. Do not reactivate or prove out the supplemental restraint system at this time.
13. Connect the battery ground cable.
14. 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 scan 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 New Generation STAR (NGS) Tester you must use the appropriate memory card with the latest update to carry out this function.
To rezero the OCS system:
- select "SERVICE BAY FUNCTIONS"
- select "RCM"
- select "SYSTEM RESET"
- select the vehicle from the menu
- view the on-screen information, then press "TRIGGER"
The NGS screen will then display "OCS RESET: REZERO." Press "DONE" (button 8) to rezero the OCS system. The NGS will return to the vehicle menu once rezeroing of the OCS system is complete.
NOTE: To rezero the OCS system using the Worldwide Diagnostic System (WDS):
- select the "Toolbox" icon
- select "Body" from the menu
- select "Restraints" from the menu
- select "Seat Weight Sensor ReZero"
- After selecting "Seat Weight Sensor ReZero", follow the on-screen prompts to carry out rezeroing of the OCS system.
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 scan tool to trigger the active command and rezero the occupant classification sensor.
15. NOTE: The ignition switch must be cycled after rezeroing the OCS system.
Cycle the ignition switch from ON to OFF.
16. WARNING: 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.
With the restraint system diagnostic tools still installed at the remaining deployable devices, prove out the supplemental restraint system (SRS). Prove Out Procedure
17. Disconnect the battery ground cable and wait at least one minute.
18. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming.
Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming.
19. Connect the battery ground cable.
20. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). Prove Out Procedure
21. Check the active restraint system for correct operation.
22. 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.
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 the following: seat cushion foam pad, bladder, electronic control unit, pressure sensor (transducer), hose, electrical connectors and wire harness (service part occupant classification sensor only).
Item 1: Seat Cushion Assembly Installation Note
1. Make sure the trim cover J-clips left unattached for purposes of routing the belt tension sensor wire harness or lumbar cable are accessible after the seat cushion assembly has been positioned to the seat track.
2. Position the safety belt buckle through the seat cushion strap.
Item 3: Electrical Connector Installation Note
1. If equipped, connect the backrest heated seat element electrical connector and attach any wire harness retainers to the seat cushion pan.
2. If equipped, connect the power seat switch electrical connector.
3. If equipped, connect the power seat motor electrical connector and attach any wire harness retainers to the seat cushion pan.
4. NOTE: If equipped with manual lumbar, make sure this wire harness is routed above the manual lumbar cable.
Connect the safety belt buckle pretensioner and safety belt buckle switch electrical connectors and attach the wire harness retainer to the seat track.
Item 4: Belt Tension Sensor Electrical Connector (Vehicles With Seat Integrated Restraints Only) Installation Note
1. Route the wire harness, connect the electrical connector and attach the J-clip.
Item 5: Lumbar Cable Installation Note
1. If equipped with lumbar, route the cable and attach the J-clip.