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Occupant Classification Sensor: Installation

WARNING: This page is about a different car, the 2005 Mercury Sable and 2005 Ford Taurus. However, it is still accessible from the selected car via links, so may be relevant.

    All vehicles 

  1. Bend the retaining ear back on the occupant sensor component bracket.
    Fig 1: Bending Retaining Ear Back On Occupant Sensor Component Bracket
    G03959706Courtesy of FORD MOTOR CO.

    2. Vehicles having a service kit occupant classification sensor installed 

    WARNING: Do not separate components.
    CAUTION: 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.
    CAUTION: Failure to route the seat occupant sensor components through the correct seat cushion support opening can cause component failure.
    CAUTION: 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.
    NOTE: If the original equipment occupant classification sensor (OCS) is not being installed, install a service kit OCS using all parts in the kit.
    Fig 2: Installing Occupant Classification Sensor Assembly To Seat Cushion Frame
    G03959705Courtesy of FORD MOTOR CO.
  2. Position the occupant classification sensor assembly to the seat cushion frame
    • 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.
    3. NOTE: When installing a service part occupant classification sensor, the main seat wire harness pressure sensor electrical connector does not get used.
    Fig 3: Connecting Occupant Classification Sensor Components
    G03959708Courtesy of FORD MOTOR CO.
  3. Attach and connect the occupant classification sensor components
    1. Position the electronic control unit 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 ear 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 ear.
    3. Connect the main seat wire harness occupant classification sensor electrical connector to the service part occupant classification sensor electrical connector.
    4. Tie strap all loose wire harnesses and electrical connectors safely out of the way.
    4. 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: 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 4: Aligning Seat Cushion Trim Cover To Seat Cushion Foam Pad And Attaching Hook-And-Loop Strips
    G03959698Courtesy of FORD MOTOR CO.
  4. Align the seat cushion trim cover to the seat cushion foam pad and attach the hook-and-loop strips.

    5. Vehicles having an original equipment occupant classification sensor installed 

    CAUTION: 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.
    NOTE: 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).
    Fig 5: Installing Electronic Control Unit
    G03959710Courtesy of FORD MOTOR CO.
  5. Install the electronic control unit (ECU)
    1. Position the ECU to the bracket.
    2. Install the rivets.
    3. Connect the electrical connector.
    6. CAUTION: 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.
    CAUTION: Failure to route the seat occupant sensor components through the correct seat cushion support opening can cause component failure.
    CAUTION: While positioning the seat cushion frame and occupant sensor assembly, be careful not to damage any of the components. Failure to do so can result in component failure.
    Fig 6: Installing Occupant Classification Sensor Assembly To Seat Cushion Frame
    G03959701Courtesy of FORD MOTOR CO.
  6. Position the occupant classification sensor (OCS) assembly to the seat cushion frame.
    • Feed the pressure sensor with hose through the largest opening at the front of the seat cushion frame support assembly.
    7. CAUTION: Inspect the occupant classification sensor bladder, seat cushion frame and support assembly for any foreign objects, before installing the occupant classification sensor 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.
    Fig 7: Installing Pin-Type Retainers Holding OCS Bladder To Seat Cushion Frame
    G03959699Courtesy of FORD MOTOR CO.
  7. Install the pin-type retainers holding the OCS bladder to the seat cushion frame.
  8. Install the pressure sensor.
    1. Install the pressure sensor onto the seat cushion frame bracket, making sure the retaining ear 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 ear.
    2. Connect the electrical connector.
    Fig 8: Installing Pressure Sensor
    G03959713Courtesy of FORD MOTOR CO.
    9. 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: 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 9: Aligning Seat Cushion Trim Cover To Seat Cushion Foam Pad And Attaching Hook-And-Loop Strips
    G03959698Courtesy of FORD MOTOR CO.
  9. Align the seat cushion trim cover to the seat cushion foam pad and attach the hook-and-loop strips.
    10. CAUTION: Inspect the seat cushion pad and frame for any foreign objects before installing the seat cushion pad 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.
    Fig 10: Installing Seat Cushion Pan And OEM Occupant Classification Sensor Into Foam Pad And Trim Cover
    G03959697Courtesy of FORD MOTOR CO.
  10. Position the seat cushion pan and OEM occupant classification sensor (OCS) into the foam pad and trim cover.

    11. All vehicles 

  11. Attach the trim cover J-clips.
    Fig 11: Attaching Trim Cover J-Clips
    G03959696Courtesy of FORD MOTOR CO.
  12. Install the power seat track or manual seat track. For additional information, refer to SEATING .
  13. Install the front seat backrest. For additional information, refer to SEATING .
  14. Install the passenger seat and repower the system. Do not prove out the system at this time. For additional information, refer to SEATING .
  15. WARNING: Do not separate components.
    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: Make sure the seat is completely assembled before rezeroing.
    CAUTION: 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.
    NOTE: 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).
    NOTE: When using a New Generation STAR (NGS) Tester you must use the appropriate memory card with the latest update to carry out this function. To rezero the OCS system:
    • select "SERVICE BAY FUNCTIONS"
    • select "RCM"
    • select "SYSTEM RESET"
    • select the vehicle from the menu
    • view the on-screen information, then press "TRIGGER"

      The NGS screen will then display "OCS RESET: REZERO." Press "DONE" (button 8) to rezero the OCS system. The NGS will return to the vehicle menu once rezeroing of the OCS system is complete.

      NOTE: To rezero the OCS system using the Worldwide Diagnostic System (WDS):
    • select the "Toolbox" icon
    • select "Body" from the menu
    • select "Restraints" from the menu
    • select "Seat Weight Sensor ReZero"

    After selecting "Seat Weight Sensor ReZero", follow the on-screen prompts to carry out rezeroing of the OCS system.

    NOTE: If the first attempt to rezero the OCS system is unsuccessful, a second attempt must be made.

    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.
    16. NOTE: The ignition switch must be cycled after rezeroing the OCS system.
  16. Cycle the ignition switch from ON to OFF
  17. 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 six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either:

    • 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 five sets of five 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.

  18. Check the active restraint system for correct operation. For additional information, refer to SAFETY BELT SYSTEM .
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