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Occupant Classification Sensor - Service Kit: Installation

NOTE: If installing an OCS service kit, refer to OCCUPANT CLASSIFICATION SENSOR - SERVICE KIT .

    All seats 

  1. Bend the retaining tab back on the pressure sensor component bracket.
    Fig 1: Locating Retaining Tab
    G04663926Courtesy of FORD MOTOR CO.
    CAUTION: Inspect the seat cushion foam pad and pan for any foreign material before installing the seat cushion foam pad 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: Failure to route the seat occupant classification sensor components through the correct seat cushion support opening can cause safety system failure.
    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.
  2. Feed the OCS service kit components (hose, pressure sensor, ECU, wire harness and connectors) through the seat cushion pan opening.
    Fig 2: Locating OCS Service Kit Components
    G04663927Courtesy of FORD MOTOR CO.
    CAUTION: Inspect the seat cushion foam pad and pan for any foreign material before installing the seat cushion foam pad 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.
  3. Using hog rings, attach the seat cushion trim cover to the seat cushion foam pad.
  4. Position the seat cushion foam pad with the OCS bladder to the seat cushion pan and set in place.
    CAUTION: Inspect the seat cushion foam pad and seat cushion trim cover for any foreign material, before installing the seat cushion trim cover to the seat cushion foam pad. 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.
  5. Attach the seat cushion trim cover J-clips to the seat cushion pan.
    Fig 3: Locating Seat Cushion Trim Cover J-Clips
    G04663928Courtesy of FORD MOTOR CO.

    6. Power seats 

  6. Connect the heated seat cushion electrical connector (if equipped).

    7. All seats 

    NOTE: When installing an occupant classification sensor service kit, the seat wire harness pressure sensor electrical connector is not used.
    NOTE: Make sure the pressure sensor hose is not kinked during installation.
    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.
  7. Install the OCS components to the seat cushion pan.
    1. 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.
    2. Slide the electronic control unit (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 diagnostic trouble code (DTC) in the restraints control module (RCM).
    3. Install the rivets.
    4. Connect the main seat wire harness occupant classification sensor electrical connector.
    5. Tie-strap the unused main seat wire harness pressure sensor electrical connector safely aside.
    6. Tie-strap all loose wire harnesses and electrical connectors aside.
      Fig 4: Identifying OCS Components
      G04663929Courtesy of FORD MOTOR CO.
  8. Position the seat cushion and pan assembly to the seat track.
  9. Install the 4 cushion pan-to-seat track bolts.
    • Tighten to 25 Nm (18 lb-ft).
  10. Install all wire harnesses and connect all electrical connectors to the seat pan (if equipped).

    11. Power seats 

  11. Install the backrest assembly.
    • If equipped, install the seat backrest assembly while feeding the climate control seat duct and wiring in through the seat cushion trim cover.
  12. Install the 4 backrest-to-seat track bolts.
    • Tighten to 58 Nm (43 lb-ft).
  13. Connect the climate control duct and the backrest thermal electrical device electrical connector (if equipped).
    Fig 5: Locating Backrest Thermal Electrical Device Electrical Connector
    G04663930Courtesy of FORD MOTOR CO.
  14. Connect the 2 seat backrest heated seat element electrical connectors (if equipped).
  15. Attach the seat cushion rear trim cover J-clip.

    16. Seats with side air bags 

  16. Route the air bag module wire harness and electrical connector and attach to the seat riser and cushion pan.
  17. Connect the seat side air bag module electrical connector.

    18. Power seats 

  18. Install the LH side shield and 3 screws.
  19. Connect the power seat switch electrical connector.
  20. Install the RH side shield and 3 screws.
  21. Install the recliner handle.
  22. Install the passenger seat and repower the system. Do not prove out the system at this time.  For additional information, refer to SEATING .
    • Make sure the safety belts and buckles are accessible to the occupants after installation.

    23. Manual seats 

  23. Repower the SRS. Do not prove out the system at this time. Refer to SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING  in this article.
    • Make sure the safety belts and buckles are accessible to the occupants after installation.

    24. All seats 

    WARNING: Do not separate components.
    CAUTION: It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A diagnostic tool is used to trigger the active command to carry out rezeroing of the OCS system.
    CAUTION: Make sure the seat is completely assembled before rezeroing.
    CAUTION: The following precautions must be taken before rezeroing the OCS system:
    • 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 rezeroing and nothing is placed on the seat during the rezeroing process.
    • Make sure a minimum 8-second time period has passed after cycling the ignition switch ON before the rezeroing process.
    NOTE: For best results in rezeroing, the OCS system should be at or near room temperature, 10°C to 29°C (50°F to 85°F).
    NOTE: If the first attempt to rezero the OCS system is unsuccessful, a second attempt must be made.
    NOTE: The ignition switch must be cycled after rezeroing the OCS system.
  24. Rezero the OCS.
    • With the front passenger seat empty, use a diagnostic tool to trigger the active command and rezero the OCS.
  25. Cycle the ignition switch from ON to OFF.
  26. Prove out the supplemental restraint system (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 supplemental restraint system (SRS) fault is present, the air bag indicator will:

    • fail to light.
    • remain lit continuously.
    • flash.

    The flashing might not occur 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 restraints control module (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 indicator and any SRS fault discovered must be diagnosed and repaired.

    Clear all continuous DTCs from the restraints control module using a diagnostic tool.

    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 Ford Motor Company.
  27. Fill out the necessary information on the occupant classification sensor traceability card and return it along with the complete inoperative occupant classification sensor to Ford Motor Company.
    • When returning the inoperative occupant classification sensor, include the following seat cushion foam pad, bladder, electronic control unit, pressure sensor (transducer), hose, electrical connectors and wire harness (service part occupant classification sensor only).
      Fig 6: Identifying Occupant Classification Sensor Traceability Card
      G04663931Courtesy of FORD MOTOR CO.
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