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Occupant Classification Sensor: Removal

WARNING: This page is about a different car, the 2006 Mercury Grand Marquis and 2006 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not separate the components.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury.
WARNING: To reduce the risk of personal injury, do not use any memory saver devices.
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: If only installing a new front passenger seat cushion trim cover, the occupant classification sensor must be rezeroed.
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: Occupant classification sensor (OCS) system components (seat cushion foam pad, bladder with pressure sensor and electronic control unit) 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 and electronic control unit) must be installed as an assembly.
NOTE: To identify between a production OCS system and a service OCS system (OCS service kit), inspect the electronic control unit (ECU) electrical connector. A production OCS system allows the disconnection of the ECU electrical connector  . A service OCS system (OCS service kit) has the ECU electrical connector glued to the ECU, it cannot and should not be disconnected or altered. An OCS system service kit also has an in-line 18-pin connector between the OCS ECU and the seat wiring harness.
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) service kit and a new heated seat element must be installed.
NOTE: If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered  .
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer.

    All seats 

  1. Position the front passenger seat to access the fasteners.
  2. Depower the system. For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING  in the General Procedures portion of this article.
  3. Remove the front passenger seat. For additional information, refer to SEATING .
  4. Remove the front seat backrest. For additional information, refer to SEATING .
  5. Remove the seat track. For additional information, refer to SEATING .

    6. Heated seats 

  6. Disconnect the cushion heated seat element electrical connector.

    7. Seats with manual recline 

  7. Remove the seat backrest recliner handle.

    8. Seats with power lumbar 

  8. Release the tabs at the front and back to separate the power lumbar switch and bezel from the seat cushion pan.
  9. Disconnect the electrical connector and remove the power lumbar switch.

    10. All seats 

  10. Release the remaining seat cushion trim cover J-clips.
    11. CAUTION: If replacing only the front passenger seat cushion trim cover, the occupant classification sensor must be rezeroed.
    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: Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam.
    Fig 1: Separating Hook And Loop Strips
    G04586563Courtesy of FORD MOTOR CO.
  11. Separate the hook and loop strips. Position the seat cushion trim cover aside.
  12. Bend the retaining tab holding the pressure sensor in place down and aside.
    Fig 2: Bending Retaining Tab Holding Pressure Sensor
    G04586564Courtesy of FORD MOTOR CO.

    13. Seats with an original equipment OCS 

  13. Remove the seat cushion pad from the seat cushion frame.
  14. If necessary, remove the 2 pin-type retainers and the mat, otherwise position the mat aside.
  15. Remove the ECU and separate the pressure sensor from the ECU bracket.
    1. Release the pressure sensor hose.
    2. Disconnect the electrical connector and slide the pressure sensor off the bracket.
      3. CAUTION: Do not oversize the seat cushion frame holes used to rivet the ECU in place.
    3. Using a 5 mm (3/16 inch) drill, remove the 3 rivets.
    4. Remove the ECU bracket.
    5. Disconnect and remove the ECU.
      Fig 3: Disconnecting ECU
      G04586565Courtesy of FORD MOTOR CO.
  16. Remove the pin-type retainers holding the occupant classification sensor bladder to the seat cushion pan.
    17. NOTE: Make note of the opening that the pressure sensor and hose are being fed through on the seat cushion support assembly for installation purposes.
  17. Separate the occupant classification sensor bladder and pressure sensor from the seat cushion frame.
    • Feed the pressure sensor and hose through the seat cushion support assembly.
      Fig 4: Separating Occupant Classification Sensor Bladder And Pressure Sensor From Seat Cushion Frame
      G04586566Courtesy of FORD MOTOR CO.

    18. Seats with an OCS service kit 

  18. Separate the OCS components from the seat cushion frame.
    1. Release the pressure sensor hose.
    2. Slide the pressure sensor off the bracket.
    3. Cut the tie straps.
      4. CAUTION: Do not oversize the seat cushion frame holes used to rivet the ECU in place.
    4. Using a 5 mm (3/16 inch) drill, remove the 3 rivets.
    5. Remove the ECU bracket.
    6. Disconnect the service part OCS electrical connector.
      Fig 5: Disconnecting Service Part OCS Electrical Connector
      G04586567Courtesy of FORD MOTOR CO.
    19. NOTE: Make note of the opening that the OCS components are being fed through on the seat cushion support assembly for installation purposes.
  19. Remove the OCS from the seat cushion frame.
    • Feed the hose, pressure sensor, wire harness, electrical connector and ECU through the seat cushion frame support assembly.
      Fig 6: Removing OCS From Seat Cushion Frame
      G04586568Courtesy of FORD MOTOR CO.
  20. If necessary, remove the 2 pin-type retainers and the mat.
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