Seat Occupant Sensor: Service and Repair
OCCUPANT CLASSIFICATION SENSORSpecial Tool(s)
Special Tool(s):
Removal
WARNING:
- Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury.
- 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:
- While positioning the seat cushion pan and occupant classification sensor (OCS) assembly, be careful not to damage any of the components. Failure to do so can result in component failure.
- 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.
- 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:
- Occupant classification sensor (OCS) system components (seat wiring harness, seat cushion frame, seat cushion foam pad, bladder with pressure sensor and occupant classification system module [OCSM]) 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, an OCS system service kit (seat cushion frame, seat cushion foam pad, bladder with pressure sensor, seat wiring harness and OCSM) must be installed as an assembly.
- To identify between a production OCS system and an OCS service kit, inspect the OCSM electrical connector.
A production OCS system allows the disconnect of the electrical connector from the OCSM.
An OCS system service kit has the OCSM electrical connector glued to the module. It cannot and should not be disconnected or altered.
- 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 carry out the diagnostic procedure again.
1. Remove the passenger seat.
2. CAUTION: To prevent component damage and avoid setting DTCs, the following precautions must be taken when disconnecting the safety belt buckle pretensioner.
- The position assurance locking wedge must be in the released position when inserting or removing the electrical connector from the safety belt buckle and pretensioner.
- Do not install the electrical connector by pushing on the position assurance locking wedge.
- Make sure the electrical connector and position assurance locking wedge are fully seated after connecting to the safety belt buckle and pretensioner.
Release the locking wedge on the safety belt buckle and pretensioner electrical connector.
3. Disconnect the safety belt buckle switch and pretensioner electrical connectors.
4. 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 BTS electrical connector and route out the wire harness (vehicles with SIR only).
5. Remove the seat cushion nuts.
6. If equipped with manual lumbar, release the J-clip and route out the manual lumbar cable.
7. NOTE: Disconnect and release any remaining electrical connectors and pin-type retainers necessary to remove the seat cushion frame.
Remove the seat cushion frame assembly.
- To aid in removal, recline the seat.
- Remove the safety belt buckle from the seat cushion strap.
8. Release the seat cushion trim cover J-clips and pin-type retainers from the seat cushion frame.
9. At the front outboard side of the seat cushion frame, pull the trim cover back and release the 2 remaining clips.
10. Remove all the hog rings and separate the trim cover from the foam pad of the OCS assembly.
Installation
CAUTION:
- While positioning the seat cushion pan and occupant classification sensor (OCS) assembly, be careful not to damage any of the components. Failure to do so can result in component failure.
- 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.
- 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: OCS system components (seat cushion frame, seat cushion foam pad, bladder with pressure sensor, seat wiring harness and OCSM) 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 cushion foam pad are needed, an OCS system service kit (seat cushion frame, seat cushion foam pad, bladder with pressure sensor, seat wiring harness and OCSM) must be installed as an assembly.
1. Install the seat cushion trim cover.
- Install hog rings to attach the seat cushion trim cover to the seat cushion foam pad of the OCS assembly at all locations from where they were removed.
2. At the front outboard side of the seat cushion frame, attach the 2 clips.
3. On vehicles equipped with SIR seats, attach the seat cushion trim cover J-clips to the seat cushion frame.
- If equipped with manual lumbar, do not attach the rear inboard J-clip at this time.
4. Install the seat cushion assembly and the 4 nuts to the seat track.
- Position the safety belt buckle through the seat cushion strap.
- Tighten to 25 Nm (18 lb-ft).
5. If equipped, connect the backrest heated seat element electrical connector and attach any wire harness retainers to the seat cushion frame.
6. If equipped, connect the power seat track electrical connector and attach any wire harness retainers to the seat cushion frame.
7. 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.
8. CAUTION: To prevent component damage and avoid setting DTCs, the following precautions must be taken:
- The position assurance locking wedge must be in the released position when inserting the electrical connector in the safety belt buckle and pretensioner.
- Do not install the electrical connector by pushing on the position assurance locking wedge.
- Make sure the electrical connector and position assurance locking wedge are fully seated after connecting to the safety belt buckle and pretensioner.
Fully engage the locking wedge on the safety belt buckle and pretensioner electrical connector.
9. On vehicles with SIR seats, connect the BTS electrical connector.
- Route the wire harness and connect the electrical connector.
10. If equipped, connect the manual lumbar cable.
- Route the cable and attach the J-clip.
11. Install the passenger seat. Do not prove the SRS at this time.
- Make sure the safety belts and buckles accessible to the occupants after installation.
- Verify the safety belt retractor operates without excessive effort or binding.
12. 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 of the OCS system 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 trigger the command to carry out the OCS system reset.
- 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 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 command using the scan tool.
13. Cycle the ignition switch from ON to OFF.
14. NOTE: The ignition switch must be cycled after the OCS system reset.
Cycle the ignition switch from OFF to ON.
15. 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 at a 5Hz rate (RCM not configured).
The air bag warning indicator might not light 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 using a scan tool.
16. NOTE: A prepaid return postcard is provided with a new OCS service kit. The serial number for the new part and the vehicle identification number (VIN) must be recorded and sent to Ford Motor Company.
When installing a new OCS service kit, fill out the necessary information on the OCS service kit traceability card and return it along with the complete inoperative OCS system to Ford Motor Company.
- When returning the inoperative OCS system, include the following: seat cushion foam pad, seat cushion frame, bladder, OCSM, pressure sensor (transducer), hose, electrical connectors and wire harness.