Seat Occupant Sensor: Service and Repair
OCCUPANT CLASSIFICATION SENSORSpecial Tool(s)
Special Tool(s):
Seat With OEM Occupant Classification Sensor (OCS):
Seat With a Service Kit Occupant Classification Sensor (OCS):
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.
CAUTION:
- There are 3 occupant classification sensor (OCS) system service kits available for this vehicle (base seat, heated seat and power heated seat). Always make sure the correct OCS system service kit is installed.
- 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 to carry out the OCS system reset command.
NOTE:
- The heated seat element on the front passenger seat cushion is not serviceable separately. If a new heated seat element is needed on the front passenger seat cushion, a new occupant classification sensor (OCS) system service kit equipped with a heated seat element must be installed.
- 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, electronic control unit and seat wiring harness) must be installed as an assembly.
- To identify between a production OCS system and a OCS system service kit inspect the OCSM electrical connector. A production OCS system allows the disconnect of the OCSM electrical connector. A OCS system service kit has the OCSM electrical connector glued to the OCSM. 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 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.
All seats
1. Position the seat to access all the seat track-to-floor pan bolts.
2. Depower the SRS.
3. Remove the passenger seat.
4. Remove the seat backrest.
5. Remove the seat track.
6. Release the seat trim cover and foam pad.
- Release all the seat cushion trim cover J-clips and the pin-type retainer from the seat cushion frame assembly.
7. 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.
Separate the trim cover from the foam pad.
- Release the hook-and-loop fasteners and remove the hog rings.
8. NOTE: Production pressure sensor shown, service kit pressure sensor similar.
Bend to release the retaining tab and remove the pressure sensor from the bracket.
Seats with power
9. Disconnect the seat control switch electrical connector from the side trim cover.
All seats
10. NOTE: Note position of wire routing for installation.
Release all the seat wire harness routing clips and electrical connector retainers from the seat cushion frame assembly.
Seats with a production occupant classification sensor (OCS)
11. Release the 2 OCS system bladder pin-type retainers and separate it from the seat cushion frame assembly.
All seats
12. Remove the rivets and separate the OCSM from the seat cushion frame bracket.
13. NOTE: Note position of hose routing for installation.
Remove the OCS system from the seat cushion frame assembly.
- Feed the hose, pressure sensor, wire harness, electrical connector and OCSM through the opening in the seat cushion frame assembly.
Installation
All seats
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:
- Failure to route the seat occupant sensor components through the correct seat cushion support opening may 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 may result in component failure.
NOTE: If the original equipment OCS system is not being installed, install an OCS system using service kit all parts in the kit.
Position the OCSM to the seat cushion frame.
- Feed the hose, pressure sensor, wire harness, electrical connector and the OCSM through the seat cushion frame assembly.
2. NOTE: Make sure the OCSM is properly secured to the bracket.
Position the OCSM onto the seat cushion frame bracket and install new rivets.
3. Bend the retaining tab back on the pressure sensor bracket.
Seats with an OCS system service kit
4. Position the OCS service kit foam pad and attach the 2 pin-type retainers to the seat cushion frame assembly.
Seats with a production OCS system
5. Attach the 2 OCS system bladder pin-type retainers to the seat cushion frame assembly.
All seats
6. Attach all the seat wire harness routing clips and electrical connector retainers to the cushion frame assembly.
Seats with power
7. Connect the seat control switch electrical connector to the side trim cover.
All seats
8. Install the pressure sensor onto the seat cushion frame 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.
9. Align the seat cushion trim cover to the seat cushion foam pad and attach the hog rings and hook-and-loop fasteners.
10. Attach the seat cushion trim cover J-clips and the pin-type retainer to the seat cushion frame assembly.
11. Install the seat track.
12. Install the seat backrest.
13. Install the passenger seat into the vehicle.
14. Repower the SRS. Do not prove out the SRS at this time.
15. 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.
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.
- 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 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 occupant classification sensor (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.
16. Cycle the ignition switch from ON to OFF.
17. NOTE: The ignition switch must be cycled after the OCS system reset.
Cycle the ignition switch from OFF to ON.
18. 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.
19. 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 service kit 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 only).