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Occupant Classification Sensor - Service Kit: Installation

WARNING: This page is about a different car, the 2006 Mercury Montego, 2006 Ford Freestyle, and 2006 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.

    Seats with heat 

  1. Seats receiving a new OCS service kit, install the new cushion heated seat element onto the new cushion foam pad.

    All seats 

  2. Bend the retaining tab back on the pressure sensor bracket.
    Fig 1: Bending Retaining Tab Back On Pressure Sensor Bracket
    G04659684Courtesy of FORD MOTOR CO.
    3. WARNING: Do not separate components.
    CAUTION:
    1. Inspect the occupant classification sensor assembly, seat cushion frame and support assembly for any foreign objects, before installing the occupant classification sensor 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.
    2. Failure to route the seat occupant sensor components through the correct seat cushion support opening can cause component failure.
    3. While positioning the seat cushion frame and occupant classification sensor assembly, be careful not to damage any of the components. Failure to do so can result in component failure.
  3. Position the OCS assembly to the seat cushion frame.
    • Slide the pushpin clip retainer onto the double header connector.
    • Connect the double header connector to the 18-way connector on the service kit harness.
    • Using a service occupant classification sensor, feed the electronic control unit, 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 and install the OCS bladder pin-type retainers.
      Fig 2: Locating Hose, Pressure Sensor, Wire Harness, Electrical Connector & Electronic Control Unit
      G04659685Courtesy of FORD MOTOR CO.

    4. Seats with manual seat track 

    NOTE:
    1. When installing a new occupant classification sensor, the main seat wire harness pressure sensor electrical connector is not used.
    2. The ECU must be correctly positioned and securely riveted in place. Failure to do so can set a diagnostic trouble code (DTC) in the restraints control module.
    Fig 3: Identifying OCS Attachment Components
    G04659686Courtesy of FORD MOTOR CO.
  4. 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 tab is completely engaged.
      • Make sure the pressure sensor hose is routed correctly and is not kinked during installation.
      • 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.
    3. Connect the main seat wire harness OCS electrical connector to the service kit OCS electrical connector, and then attach the connector pin-type retainer to the seat track bracket.
    4. Tie strap the wire harness and electrical connector safely aside.
    5. Using electrical tape, tape the service kit wire harness to the pressure sensor hose.
      • Do not tie strap the service kit wire harness to the pressure sensor hose.

    5. Seats with power 

    NOTE:
    1. When installing a new occupant classification sensor, the main seat wire harness pressure sensor electrical connector is not used.
    2. The ECU must be correctly positioned and securely riveted in place. Failure to do so can set a diagnostic trouble code (DTC) in the restraints control module.
    Fig 4: Identifying OCS Attachment Components
    G04659687Courtesy of FORD MOTOR CO.
  5. 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 tab is completely engaged.
      • Make sure the pressure sensor hose is routed correctly and is not kinked during installation.
      • 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.
    3. Connect the main seat wire harness OCS electrical connector to the service kit OCS electrical connector, and then attach the connector pin-type retainer to the seat track bracket.
    4. Tie strap the wire harness and electrical connector safely out of the way.
    5. Using electrical tape, tape the service kit wire harness to the pressure sensor hose.
      • Do not tie strap the service kit wire harness to the pressure sensor hose.

    6. All seats 

    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.
    Fig 5: Locating Hog Rings
    G04659688Courtesy of FORD MOTOR CO.
  6. Align the seat cushion trim cover to the seat cushion foam pad and attach the hog rings.
  7. Attach the hook and loop strip at the rear of the seat cushion trim cover.
  8. Attach all the seat cushion trim cover J-clips.

    9. Seats with heat 

  9. Connect the heated seat electrical connector.

    10. Seats with power 

  10. Install the power seat control switch to the side shield.

    11. All seats 

  11. Install the side shield and rear screw.

    12. Seats with power 

  12. Install the power seat switch knobs.

    13. Seats with manual recline 

  13. Install the recline handle.

    14. All seats 

  14. Install the passenger seat. For additional information, refer to SEATING .
  15. Repower the SRS. Do not prove out the SRS at this time.  For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING .
    16. WARNING: Do not separate components.
    CAUTION:
    1. 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.
    2. Make sure the seat is completely assembled before rezeroing.
    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.
  16. 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 eight second time period has passed after cycling the ignition switch ON before the rezeroing process.

    Rezero the occupant classification sensor.

    • With the front passenger seat empty, use a diagnostic tool to trigger the active command and rezero the OCS.
    17. NOTE: The ignition switch must be cycled after rezeroing the OCS system.
  17. Cycle the ignition switch from ON to OFF.
  18. 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 six 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 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 RCM using a diagnostic tool.

  19. Check the active restraint system for correct operation. For additional information, refer to SAFETY BELT SYSTEM .
    20. 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.
    Fig 6: Service Kit Assembly - Passenger Occupant Classification Sensor Verification
    G04586575Courtesy of FORD MOTOR CO.
  20. 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).
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