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Occupant Classification Sensor - Service Kit: Installation

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
  1. Bend the retaining tab back on the pressure sensor component bracket.
    Fig 1: Bending Retaining Tab Back On Pressure Sensor Component Bracket
    G04622813Courtesy of FORD MOTOR CO.
    2. CAUTION:
    1. Inspect the occupant classification sensor assembly, seat cushion pan and support assembly for any foreign objects before installing the occupant classification sensor assembly to the seat cushion pan. 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.
    2. Failure to route the seat occupant classification sensor components through the correct seat cushion support opening can cause component failure.
    3. 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.
    Fig 2: Locating OCS Seat Cushion Pan
    G04622814Courtesy of FORD MOTOR CO.
  2. Feed the OCS service kit components (hose, pressure sensor, ECU, wire harness, and connectors) through the seat cushion pan opening.
    3. NOTE:
    1. When installing a service part occupant classification sensor, the seat wire harness pressure sensor electrical connector is not used.
    2. Make sure the pressure sensor hose is not kinked during installation.
  3. 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.
      Fig 3: Identifying Electronic Control Unit (ECU) Into Seat Cushion Pan Bracket
      G04622815Courtesy of FORD MOTOR CO.
  4. Attach the seat cushion trim cover J-clips to the seat cushion pan.
    Fig 4: Locating Seat Cushion Trim Cover J-Clips To Seat Cushion Pan
    G04622816Courtesy of FORD MOTOR CO.
    5. 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.
  5. Position the seat cushion and pan assembly to the seat track.
    • To aid in installation, recline the seat.
  6. Install the 4 seat cushion bolts retaining the seat cushion to the seat track.
    • Tighten to 15 N.m (11 lb-ft).
    7. NOTE:
    1. Do not tie strap any wiring to the OCS bladder and pressure sensor hose.
    2. The seat wiring harness will be reused.
  7. Connect the electrical connector(s) and wiring clips.
    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 element electrical connectors.
    4. Tie strap the unused seat wire harness pressure sensor electrical connector safely aside.
    5. Tie strap all loose wire harnesses and electrical connectors safely aside.
      Fig 5: Identifying Electrical Connectors And Wiring Clips
      G04622817Courtesy of FORD MOTOR CO.
  8. Install the passenger seat into the vehicle. For additional information, refer to SEATING .
  9. Repower the system. Do not prove out the system at this time  . For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING .
    10. CAUTION:
    1. Make sure the seat is completely assembled before rezeroing.
    2. 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:
    1. 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).
    2. If the first attempt to rezero the OCS system is unsuccessful, a second attempt must be made.
    3. The ignition switch must be cycled after rezeroing the OCS system.
  10. Rezero the occupant classification sensor.
    • With the front passenger seat empty, use a diagnostic tool to trigger the active command and rezero the occupant classification sensor.
  11. 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.

    12. 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.
  12. 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 Inoperative Occupant Classification Sensor Verification Form
      G04622818Courtesy of FORD MOTOR CO.
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