Occupant Classification Sensor - Service Kit: Installation

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.

NOTE: To prevent system failure, it is necessary to carry out the OCCUPANT CLASSIFICATION SYSTEM (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.

NOTE: 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 System (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.

Bend the retaining tab back on the pressure sensor component bracket.

Fig 1: Bending Retaining Tab Back On Pressure Sensor Component Bracket
Courtesy of FORD MOTOR CO.

NOTE: Inspect the Occupant Classification System (OCS) bladder, seat cushion pan and support assembly for any foreign objects before installing the OCS to the seat cushion pan. If any foreign objects are found, remove them. Failure to follow these instructions may result in incorrect operation of the OCS system and may cause system failure.

NOTE: Route the Occupant Classification System (OCS) components through the correct seat cushion support opening. Failure to follow these instructions may result in component damage and/or system failure.

NOTE: While positioning the seat cushion pan and Occupant Classification System (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.

Fig 2: Locating OCS Service Kit Components

Courtesy of FORD MOTOR CO.

Feed the OCS service kit components (hose, pressure sensor, OCSM, wire harness and connectors) through the correct seat cushion pan opening.

NOTE: When installing an OCS 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.

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 OCSM into the seat cushion pan bracket.
  - The OCSM must be correctly positioned and securely fastened in place. Failure to do so can set a DTC in the RCM.
3. Install the rivets.
  
  Fig 3: Identifying Pressure Sensor, Seat Cushion Pan Bracket And Rivets
  Courtesy of FORD MOTOR CO.
Attach the seat cushion trim cover J-clips to the seat cushion pan.

Fig 4: Locating Seat Cushion Trim Cover J-Clips
Courtesy of FORD MOTOR CO.

Position the seat cushion and pan assembly to the seat track.
- To aid in installation, recline the seat.
Install the 4 seat track-to-cushion frame bolts.
- Tighten to 25 Nm (18 lb-ft).

NOTE: Do not tie-strap any wiring to the OCS bladder and pressure sensor hose.

Connect the electrical connector(s) and wiring clips in the following sequence.
1. Connect the seat wire harness OCS electrical connector to the service part OCS electrical connector.
2. Install the 2 wiring clips on the wiring harness to the cushion pan.
3. 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 2 cushion heater mat electrical connectors.
4. Tie-strap the unused seat wire harness pressure sensor electrical connector safely.
5. Tie-strap all loose wire harnesses and electrical connectors safely.
Install the front passenger seat and repower the SRS. For additional information, refer to SEATING article. Do not prove out the SRS within the seat installation procedure. Proceed to the next step after seat installation and repowering the SRS to carry out the system reset procedure.

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.

NOTE: To prevent system failure, the following precautions must be taken before carrying out the OCCUPANT CLASSIFICATION SYSTEM (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 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.

Carry out the OCS system reset.
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/or damage
- Seat-related wiring harness and body wiring harness terminals and connectors for damage

NOTE: The ignition switch must be cycled after the OCS system reset.

Carry out a second OCS system reset. If the second attempt is unsuccessful, install a new OCS system service kit.
Prove out the SRS as follows:
Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back 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 present, the air bag warning indicator will:
- 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 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 RCM and OCSM DTCs using a scan tool.

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.

Fill out the necessary information on the OCS traceability card and return it along with the complete inoperative OCS to Ford Motor Company.
- When returning the inoperative OCS, include the following: seat cushion foam pad, bladder, OCSM, pressure sensor (transducer), hose, electrical connectors and wire harness (service part OCS only).
  
  Fig 5: Locating Occupant Classification Sensor Serial Number
  Courtesy of FORD MOTOR CO.