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Occupant Classification Sensor: Installation

All seats 

  1. Bend the retaining tab back on the pressure sensor bracket.
    2. Fig 1: Bending Retaining Ear Back On Occupant Sensor Component Bracket
    GF0019533Courtesy of FORD MOTOR CO.

    Seats with a service kit OCS 

    WARNING: Do not separate components.
    CAUTION: Inspect the OCS assembly, seat cushion frame and support assembly for any foreign objects, before installing the OCS assembly to the seat cushion frame. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment.
    CAUTION: Failure to route the seat occupant sensor components through the correct seat cushion support opening can cause component 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.
    NOTE: If the original equipment OCS is not being installed, install a service kit OCS using all parts in the kit.
  2. Position the OCS assembly to the seat cushion frame.
    • Using a service OCS, feed the ECU, electrical connector, wire harness, pressure sensor and hose through the largest opening at the front of the seat cushion frame support assembly.
      • Position the seat cushion pad and bladder to the seat cushion frame.
    3. Fig 2: Locating Occupant Classification Sensor Assembly On Seat Cushion Frame
    GF0019532Courtesy of FORD MOTOR CO.
    NOTE: When installing a service part OCS, the main seat wire harness pressure sensor electrical connector does not get used.
  3. Attach and connect the OCS components.
    1. Position the ECU onto the seat cushion frame bracket and install new rivets.
    2. Install the pressure sensor onto the seat cushion frame bracket, making sure the retaining ear 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 ear.
    3. Connect the main seat wire harness OCS electrical connector to the service part OCS electrical connector.
    4. Tie strap all loose wire harnesses and electrical connectors safely aside.
    4. Fig 3: Identifying Seat Wire Harness OCS Electrical Connector
    GF0019534Courtesy of FORD MOTOR CO.
    CAUTION: It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed 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: 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 do so may result in personal injury, in the event of an air bag deployment.
  4. Align the seat cushion trim cover to the seat cushion foam pad and attach the hook-and-loop strips.
    5. Fig 4: Identifying Seat Cushion Trim Cover
    GF0019527Courtesy of FORD MOTOR CO.

    Seats with a production OCS 

    CAUTION: While positioning the seat cushion frame and OCS assembly, be careful not to damage any of the components. Failure to do so can result in component failure.
    NOTE: The ECU must be correctly positioned and securely fastened in place. Failure to do so can set a diagnostic trouble code (DTC) in the RCM.
  5. Install the ECU.
    1. Position the ECU to the bracket.
    2. Install the rivets.
    3. Connect the electrical connector.
    6. Fig 5: Identifying ECU, Rivets And Electrical Connector
    GF0019535Courtesy of FORD MOTOR CO.
    CAUTION: Inspect the OCS assembly, seat cushion frame and support assembly for any foreign objects before installing the OCS assembly to the seat cushion frame. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment.
    CAUTION: Failure to route the OCS components through the correct seat cushion support opening can cause component failure.
    CAUTION: While positioning the seat cushion frame and OCS assembly, be careful not to damage any of the components. Failure to do so can result in component failure.
  6. Position the OCS assembly to the seat cushion frame.
    • Feed the pressure sensor with hose through the largest opening at the front of the seat cushion frame support assembly.
    7. Fig 6: Positioning The OCS Assembly To Seat Cushion Frame
    GF0019529Courtesy of FORD MOTOR CO.
    CAUTION: Inspect the OCS bladder, seat cushion frame and support assembly for any foreign objects, before installing the OCS to the seat cushion frame. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment.
  7. Install the pin-type retainers holding the OCS bladder to the seat cushion frame.
  8. Install the pressure sensor.
    1. Install the pressure sensor onto the seat cushion frame bracket, making sure the retaining ear 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 ear.
    2. Connect the electrical connector.
    9. Fig 7: Identifying Pressure Sensor Electrical Connector
    GF0019536Courtesy of FORD MOTOR CO.
    CAUTION: It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed 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: 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 do so may result in personal injury, in the event of an air bag deployment.
  9. Align the seat cushion trim cover to the seat cushion foam pad and attach the hook-and-loop strips.
    10. Fig 8: Identifying Seat Cushion Trim Cover
    GF0019527Courtesy of FORD MOTOR CO.
    CAUTION: Inspect the seat cushion pad and frame for any foreign objects before installing the seat cushion pad to the seat cushion frame. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment.
  10. Position the seat cushion pan and OEM OCS into the foam pad and trim cover.

    11. All seats 

  11. Attach the trim cover J-clips.
    12. Fig 9: Locating Trim Cover J-Clips
    GF0019526Courtesy of FORD MOTOR CO.
  12. Install the power seat track or manual seat track. For additional information, refer to SEATING article.
  13. Install the seat backrest. For additional information, refer to SEATING article.
  14. Install the passenger seat and repower the system. Do not prove out the system at this time.  For additional information, refer to SEATING article.
    15. 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 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.
  15. Rezero the occupant classification sensor.
    • With the front passenger seat empty, use a diagnostic tool to trigger the active command and rezero the OCS.
    16. NOTE: The ignition switch must be cycled after rezeroing the OCS system.
  16. Cycle the ignition switch from ON to OFF.
  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.

    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 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 RCM using a diagnostic tool.

  18. Check the active restraint system for correct operation. For additional information, refer to SAFETY BELT SYSTEM article.
    19. NOTE: When installing a new OCS, a prepaid return postcard is provided with the new OCS. The serial number for the new part and the vehicle identification number (VIN) must be recorded and sent to Ford Motor Company.
  19. If a new OCS was installed, fill out the necessary information on the OCS traceability card and return it along with the complete inoperative occupant classification sensor to Ford Motor Company.
    • When returning the inoperative OCS include: seat cushion foam pad, bladder, electronic control unit, pressure sensor (transducer), hose, electrical connectors and wire harness (service part OCS only).
    20. Fig 10: Occupant Classification Sensor Verification Form
    G04586575Courtesy of FORD MOTOR CO.
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