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Occupant Classification Sensor - Service Kit: Removal

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.
WARNING:
  1. 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.
  2. To reduce the risk of personal injury, do not use any memory saver devices.
  3. Do not separate components.
CAUTION: It is necessary to rezero the occupant classification sensor (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.
NOTE:
  1. If a seat equipped with a SRS component is being serviced, the SRS must be depowered.
  2. 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.
  3. 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 disconnect 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.
  4. If removing an OEM OCS, refer to the appropriate procedure.
  5. The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
  6. The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
  7. Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again.

    All seats 

  1. Position the seat to access all the seat track-to-floor pan bolts and the safety belt anchor.
  2. Depower the system. For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING .
  3. Remove the passenger seat. For additional information, refer to SEATING .

    4. Seats with manual recline 

  4. Pull out and remove the recline handle.

    5. Seats with power 

  5. Remove the power seat switch knobs.

    6. All seats 

  6. Remove the rear screw, pull out on the side and front and separate the side shield.
    • Vehicles with manual seats, remove the side shield.

    7. Seats with power 

  7. Remove the power seat control switch, and remove the side shield.

    8. Seats with heat 

  8. Disconnect the heated seat electrical connector.

    9. All seats 

  9. Release all the seat cushion trim cover J-clips.
  10. Release the hook and loop strip at the rear of the seat cushion trim cover.
  11. Remove the hog rings and seat cushion trim cover.
    Fig 1: Locating Hog Rings
    G04659680Courtesy of FORD MOTOR CO.

    12. Seats with power 

    CAUTION: Do not oversize the seat cushion frame holes used to rivet the ECU in place.
    Fig 2: Identifying Electrical Connector, ECU Rivets & Pressure Sensor
    G04659681Courtesy of FORD MOTOR CO.
  12. Separate the OCS components from the seat cushion frame.
    1. Cut the tie strap.
    2. Remove the electrical tape from the service harness and pressure sensor hose.
    3. Remove the rivets with a 5 mm (3/16 in) drill and separate the ECU from the seat cushion frame bracket.
    4. Bend and release the retaining tab holding the pressure sensor in place.
    5. Slide the pressure sensor off the bracket.
    6. Release the pin-type retainer and disconnect the electrical connector.

    13. Seats with manual seat track 

    CAUTION: Do not oversize the seat cushion frame holes used to rivet the ECU in place.
    Fig 3: Identifying Electrical Connector, ECU Rivets & Pressure Sensor
    G04659682Courtesy of FORD MOTOR CO.
  13. Separate the OCS components from the seat cushion frame.
    1. Cut the tie strap.
    2. Remove the electrical tape from the service harness and pressure sensor hose.
    3. Remove the rivets with a 5 mm (3/16 in) drill and separate the ECU from the seat cushion frame bracket.
    4. Bend and release the retaining tab holding the pressure sensor in place.
    5. Slide the pressure sensor off the bracket.
    6. Release the pin-type retainer and disconnect the electrical connector.

    14. All seats 

  14. Remove the OCS from the seat cushion frame.
    • Feed the hose, pressure sensor, wire harness, electrical connector and electronic control unit through the seat cushion frame support assembly.
    Fig 4: Locating Hose, Pressure Sensor, Wire Harness, Electrical Connector & Electronic Control Unit
    G04659683Courtesy of FORD MOTOR CO.
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