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Seat Occupant Sensor: Service and Repair




Occupant Classification Sensor





Service Kit Occupant Classification Sensor (OCS) System









Removal

NOTICE: 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 cover installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset.

NOTE: An OCS system service kit has the electrical connector glued to the Occupant Classification System Module (OCSM). It cannot and should not be disconnected or altered.

NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON.

NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer.

1. Remove the passenger seat. For additional information, refer to the Removal and Installation portion of Seating Front Seat.

2. Remove the screw, slide up and remove the recliner handle.

3. If equipped, remove the height adjust handle.
- Release the locking tab behind the handle.





4. Remove the screw and outboard side shield.
- Release at the rear, slide and rotate forward to remove.

5. Remove the screw and inboard side shield.
- Detach the safety belt buckle wire harness.

6. Release all backrest cover strap clips from under the seat.

7. Release all J-clips and invert the cushion cover.

8. Remove all hog rings and cushion cover.

9. Detach the seat electrical bulkhead connector and wire harness from the seat track.

10. Insert a suitable tool to release the locking tabs and remove the brown safety belt buckle electrical connector and yellow side air bag connector from the seat electrical bulkhead connector.





11. Release the 2 pin-type retainers and separate the OCS bladder from the cushion half pan.

12. Release the clip and detach the pressure sensor hose from the suspension spring.





13. Insert a suitable tool between the pressure sensor and bracket to release the locking tab and remove the pressure sensor from the cushion half pan bracket.





14. Remove the 2 screws and detach the OCSM from the cushion half pan.





15. Remove the OCS system components and seat wiring through the opening in the suspension spring.





Installation

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 system (OCS) and increases the risk of serious personal injury or death in a crash.

1. WARNING: Occupant classification system(OCS) parts are calibrated as an assembly and must only be replaced in the configuration they are sold. Never separate parts of an assembly. Failure to follow this instruction may result in incorrect operation of the OCS and increases the risk of serious personal injury or death in a crash.

Install the OCS bladder and foam.

- Route the OCS system components and seat wiring through the opening in the suspension spring.

- Position the OCS bladder to the cushion half pan and install the 2 pin-type retainers.





2. Bend the locking tab back on the pressure sensor bracket and install the pressure sensor onto the bracket making sure the locking tab is completely engaged.
- Check the pressure sensor bracket mounting for tightness. If the bracket is loose, install a new rivet to tighten the bracket.





3. Attach the 2 pin-type retainers and OCS bladder to the cushion half pan.

4. Attach the pressure sensor hose clip to the suspension spring.





5. Install the OCSM and 2 screws.





6. Install the brown safety belt buckle electrical connector and yellow side air bag connector to the seat electrical bulkhead connector.





7. Install the wire harness.
- Install the wire harness and retainers to the seat track.

- Attach the seat electrical bulkhead connector to the seat track.

8. Install the cushion cover and all hog rings to the foam pad.

9. Fasten all cushion cover J-clips.

10. Install the inboard side shield and screw.
- Attach the safety belt buckle wire harness.

11. Install the outboard side shield and screw.

12. If equipped, install the height adjust handle.

13. Install the recliner handle and screw.

14. Install the passenger seat. For additional information, refer to the Removal and Installation portion of Seating Front Seat.

15. NOTICE: 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 is installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset.

Make sure no Occupant Classification System Module (OCSM) DTCs are present. If DTC C1941 has been stored in OCSM memory it will clear upon a successful system reset. All other OCS system DTCs must be diagnosed and repaired before carrying out the OCS system reset.

16. 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 system (OCS) and increases the risk of serious personal injury or death in a crash.

NOTICE: 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 volts and less than 18 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. 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 ON before carrying out the OCS system reset.


Carry out the Occupant Classification Sensor (OCS) system reset.

17. If the first system reset attempt was unsuccessful, carry out a thorough inspection of the following and repair any concerns found.
- OCS system connector and wiring for damage

- Pressure sensor hose for kinks and/or damage

- Seat-related wiring harness and body wiring harness terminals and connectors for damage

18. Carry out a second OCS system reset. If unsuccessful, install a new OCS system service kit.

19. Prove out the Supplemental Restraint System (SRS) as follows:
Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition ON and 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 detected, the air bag warning indicator will:
- fail to light.
- remain lit continuously.
- flash.
The flashing might not occur until approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This is the time required to complete 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 RCM and OCSM CMDTCs.

20. 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: foam pad, bladder, OCSM, pressure sensor, hose, electrical connectors and wire harness ( OCS system service kit OCS only).

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