Occupant Classification Sensor - Service Kit Removal/Installation
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OCCUPANT CLASSIFICATION SENSOR - SERVICE KIT REMOVAL/INSTALLATION
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.
NOTE: 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.
NOTE: To identify between a production occupant classification sensor (OCS) system and a service OCS system (OCS service kit), inspect the electronic control unit (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.
NOTE: The seat wiring harness will be reused. The occupant classification sensor (OCS) service kit connector connects to the seat wiring harness electronic control unit ECU connector. The pressure sensor seat wiring harness connector will be left unplugged and secured by a tie strap.
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Depower the system. See Supplemental Restraint System (SRS) Depowering And Repowering.
2. Remove the passenger seat. See Service and Repair.
NOTE: The seat wiring harness will be reused.
3. Disconnect the electrical connectors and wiring clips.
a. Disconnect the OCS ECU electrical connector.
b. Disconnect the pressure sensor electrical connector.
c. Release the two wiring clips on the wiring harness from the cushion pan.
i. If equipped with heated seats, disconnect the heated seat module electrical connector, release the wiring clip on the wiring harness from the cushion pan, and disconnect the 2 cushion element electrical connectors.
4. Remove the 4 seat track-to-cushion frame bolts.
5. Remove the seat cushion and pan assembly.
- To aid in removal, recline the seat.
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.
6. Detach the seat cushion trim cover J-clips from the seat cushion pan and remove the seat cushion trim cover.
CAUTION: Use care when separating the seat upholstery from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat cushion foam pad.
7. Bend the retaining tab away from the pressure sensor, then slide the pressure sensor off the bracket.
8. Remove the 2 rivets and detach OCS ECU from the seat cushion pan.
CAUTION: Care must be taken to prevent damage to the seat cushion pan when removing the rivets. Failure to follow these instructions may result in component damage and/or system failure.
9. Remove the OCS.
- Pull all the OCS components (hose, pressure sensor, wire harness, ECU and connectors) through the seat cushion pan opening.
Installation
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.
CAUTION: Do not install a new cushion heater mat on a front passenger seat cushion, it is not serviceable separately. If a new cushion heater mat is needed on the front passenger seat, an Occupant Classification (OCS) system service kit equipped with a heater mat must be installed. Failure to follow this instruction may result in incorrect operation of the OCS system.
1. Bend the retaining tab back on the pressure sensor component bracket.
2. Feed the OCS service kit components (hose, pressure sensor, ECU, wire harness, and connectors) through the seat cushion pan opening.
CAUTION: Inspect the occupant classification sensor (OCS) assembly, seat cushion pan and support assembly for any foreign material before installing the OCS assembly to the seat cushion pan. If any foreign material is found, remove it. Failure to do so may result in personal injury, in the event of an air bag deployment.
CAUTION: Route the seat occupant classification sensor (OCS) components through the correct seat cushion support opening. Failure to follow these instructions may result in component damage and/or system failure.
CAUTION: While positioning the seat cushion pan and occupant classification sensor (OCS) assembly, be careful not to damage any of the components. Failure to follow these instructions may result in component damage and/or system failure.
3. Install the OCS components to the seat cushion pan.
a. Install the pressure sensor onto the seat cushion pan bracket, making sure the retaining tab is completely engaged. 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.
b. Slide the ECU into the seat cushion pan bracket. The ECU must be correctly positioned and securely fastened in place. Failure to do so can set a DTC in the restraints control module (RCM).
c. Install the rivets.
NOTE: When installing a service part occupant classification sensor, the seat wire harness pressure sensor electrical connector is not used.
NOTE: Make sure the pressure sensor hose is not kinked during installation.
4. Attach the seat cushion trim cover J-clips to the seat cushion pan.
5. Position the seat cushion and pan assembly to the seat track.
- To aid in installation, recline the seat.
CAUTION: While positioning the seat cushion pan and occupant classification sensor (OCS) assembly, be careful not to damage any of the components. Failure to follow these instructions may result in component damage and/or system failure.
6. Install the 4 seat track-to-cushion frame bolts.
- Tighten to 25 Nm {2.5 kgf-m, 18 ft-lbf}.
7. Connect the electrical connector(s) and wiring clips.
a. Connect the seat wire harness OCS electrical connector to the service part OCS electrical connector.
b. Install the two wiring clips on the wiring harness to the cushion pan.
c. If equipped with heated seats, connect the heated seat module electrical connector, install the wiring clip on the wiring harness to the cushion pan, and connect the two cushion element electrical connectors.
d. Tie strap the unused seat wire harness pressure sensor electrical connector safely out of the way.
e. Tie strap all loose wire harnesses and electrical connectors safely out of the way.
8. Install the front passenger seat and repower the SRS. Do not prove out the system at this time. See Service and Repair.
9. Carry out the OCS system reset.
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.
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 increase the risk of serious personal injury or death in a crash.
CAUTION: The following precautions must be taken before carrying out the occupant classification sensor (OCS) system reset. Failure to follow these instructions may result in incorrect operation of the OCS system and may cause system failure.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 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.
10. If the first system reset attempt was unsuccessful, carry out a thorough visual inspection of the following and repair any concerns found:
- OCS system connector and wiring for damage
- Pressure sensor hose for kinks and/of damage
- Seat-related wiring harness and body wiring harness terminals and connectors for damage
11. Carry out a second OCS system reset. If the second attempt was unsuccessful, install a new OCS system service kit.
NOTE: The ignition switch must be cycled after the occupant classification sensor (OCS) system reset is successful.
12. 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 six seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will either:
- fail to light.
- remain lit continuously.
- flash at a 5 Hz 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 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 RCM and OCS module DTCs using a scan tool.
13. Fill out the necessary information on the occupant classification sensor traceability card and return it along with the complete inoperative occupant classification sensor to Mazda North American Operations.
- When returning the inoperative occupant classification sensor, include the following: seat cushion foam pad, bladder, ECU, 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 Mazda North American Operations.