Seat Occupant Sensor: Service and Repair
OCCUPANT CLASSIFICATION SENSORSpecial Tool(s)
Special Tool(s):
Seat With A Production Occupant Classification Sensor:
Seat With A Service Kit Occupant Classification Sensor:
Removal
WARNING:
- Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of 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.
- 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.
NOTE:
- Occupant classification sensor (OCS) system components (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, a new OCS system service kit (seat cushion foam pad, bladder with pressure sensor, OCSM and seat wiring harness) must be installed as an assembly.
- 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.
1. Remove the passenger seat.
2. Remove the seat backrest.
3. NOTE: Note position of wire routing for installation.
Release the seat wiring harness retainer clip and detach the seat wiring harness connector from the seat cushion frame.
4. Release the cushion trim cover rear J-clip.
5. Remove the 4 seat track-to-cushion frame bolts and the seat track assembly.
6. Release the remaining cushion trim cover J-clips.
7. CAUTION: An occupant classification sensor (OCS) system service kit will have the OCS system bladder attached to the seat cushion foam pad. Do not separate the OCS system bladder from the seat cushion foam pad. Failure to do so can result in component failure.
Remove the hog rings and the cushion trim cover from the seat cushion foam pad.
8. NOTE: Note position of wire routing for installation.
Release the 2 seat wiring harness routing clips from the cushion frame.
9. Release the pressure sensor bracket retainer and slide the pressure sensor off the bracket.
10. Remove the OCSM.
1 Remove the 2 screws from the OCSM.
2 Release the OCSM bracket retainer and slide the OCSM off the bracket.
11. CAUTION: A production occupant classification sensor (OCS) system bladder is shown. An OCS system service kit will have the OCS system bladder attached to the seat cushion foam pad. Do not separate the OCS system bladder from the seat cushion foam pad. Failure to do so can result in component failure.
Release the 3 OCS system bladder pin-type retainers from the seat cushion frame.
12. NOTE: Note position of wire routing for installation.
Route the OCS system bladder hose and pressure sensor, OCSM and seat wiring harness out through the seat cushion pan opening.
Installation
1. 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:
- Inspect the occupant classification sensor (OCS) system assembly, seat cushion frame and support assembly for any foreign objects before installing the OCS system assembly to the seat cushion frame. If any foreign objects are found, remove them. Failure to follow these instructions may result in incorrect OCS system operation or failure.
- Failure to route the seat occupant sensor components through the correct seat cushion support opening can cause component failure.
- 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 may result in component failure.
NOTE: If the original equipment OCS system is not being installed, install a OCS system service kit using all parts in the kit.
Position the OCS system to the seat cushion frame.
- Route the OCS system bladder hose and pressure sensor, OCSM and seat wiring harness through the seat cushion pan opening.
2. CAUTION: An occupant classification sensor (OCS) system service kit will have the OCS bladder attached to the seat cushion foam pad. Do not separate the OCS system bladder from the seat cushion foam pad. Failure to do so may result in component failure.
Install the 3 OCS system bladder pin-type retainers to the seat cushion frame.
3. Install the OCSM.
- Slide the OCSM back on the OCSM bracket until it is fully seated and locked in past the OCSM bracket retainer.
- Install the 2 screws in the OCSM.
4. Slide the pressure sensor on the bracket until it is fully seated and locked past the bracket retainer.
5. Install the 2 seat wiring harness routing clips to the seat cushion frame.
6. CAUTION: 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 follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and may cause system failure.
Position the cushion trim cover to the foam pad and install the hog rings.
7. Install the foam pad and cushion trim cover to the cushion frame and fasten the J-clips.
8. Install the seat track assembly and 4 bolts.
- Tighten to 6 Nm (53 lb-in).
9. Attach the seat cushion trim cover rear J-clip.
10. Install the seat wiring harness retainer clip and attach the seat wiring harness connector to the seat cushion frame.
11. Install the front seat backrest.
12. Install the passenger seat into the vehicle.
13. Repower the SRS. Do not prove out the SRS at this time.
14. 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 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 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 is unsuccessful, a new OCS system service kit must be installed.
Carry out the OCS system reset active command.
15. Cycle the ignition switch from ON to OFF.
16. NOTE: The ignition switch must be cycled after the OCS system reset.
Cycle the ignition switch from OFF to ON.
17. 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 indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will:
- fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag warning indicator may not illuminate 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 RCM and OCSM DTCs using a scan tool.
18. NOTE: A prepaid return postcard is provided with a new OCS system service kit. 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 OCS system 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 (service part OCS system only).