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Occupant Classification Sensor - Service Kit: Installation

WARNING: This page is about a different car, the 2008 Mercury Mariner and 2008 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.
    2. Fig 1: Pressure Sensor Component Bracket Retaining Tab
    GF0024006Courtesy of FORD MOTOR CO.
    NOTE: Inspect the Occupant Classification Sensor (OCS) bladder, seat cushion pan and support assembly for any foreign objects before installing the OCS to the seat cushion pan. If any foreign objects are found, remove them. Failure to follow these instructions may result in incorrect operation of the OCS system and may cause system failure.
    NOTE: Route the seat Occupant Classification Sensor (OCS) components through the correct seat cushion support opening. Failure to follow these instructions may result in component damage and/or system failure.
    NOTE: While positioning the seat cushion pan and Occupant Classification Sensor (OCS) assembly, be careful not to damage any of the components. Failure to follow these instructions may result in component damage and/or system failure.
  2. Feed the OCS service kit components (hose, pressure sensor, OCSM, wire harness and connectors) through the seat cushion pan opening.
    3. Fig 2: OCS Components
    GF0024011Courtesy of FORD MOTOR CO.
    NOTE: When installing an OCS service kit, the seat wire harness pressure sensor electrical connector is not used.
    NOTE: 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 OCSM into the seat cushion pan bracket.
      • The OCSM must be correctly positioned and securely fastened in place. Failure to do so can set a DTC in the RCM.
    3. Install the rivets.
    4. Fig 3: ECU In Seat Cushion Pan Bracket
    GF0024012Courtesy of FORD MOTOR CO.
  4. Attach the seat cushion trim cover J-clips to the seat cushion pan.
    5. Fig 4: Seat Cushion Trim Cover J-Clips
    GF0024013Courtesy of FORD MOTOR CO.
    NOTE: While positioning the seat cushion pan and Occupant Classification Sensor (OCS) assembly, be careful not to damage any of the components. Failure to follow these instructions may result in component damage and/or system 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 Nm (133 lb-in).
    7. NOTE: Do not tie strap any wiring to the OCS bladder and pressure sensor hose.
  7. Connect the electrical connector(s) and wiring clips in the following sequence.
    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.
  8. Install the front passenger seat into the vehicle. For additional information, refer to SEATING article.
  9. Repower the SRS. Do not  prove out the SRS at this time. Refer to Supplemental Restraint System (SRS) Depowering and Repowering .
    10. WARNING: Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash.
    NOTE: Make sure the seat is completely assembled before carrying out the Occupant Classification Sensor (OCS) System Reset active command. Failure to follow these instructions may result in incorrect operation of the OCS system and may cause system failure.
    NOTE: To prevent system failure, the following precautions must be taken before carrying out the Occupant Classification Sensor (OCS) system reset:
    • Make sure the voltage to the Occupant Classification System Module (OCSM) is above 8 volts and less than 18 volts.
    • Make sure the OCS system is not at a temperature below 6°C (42°F) or above 36°C (97°F) when initiating the OCS system reset 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, 6°C to 36°C (42°F to 97°F) for a minimum of 30 minutes.
    • Make sure nothing is present on the passenger seat before carrying out the OCS system reset and nothing is placed on the seat during the process.
    • Make sure a minimum 8-second time period has passed after cycling the ignition switch ON before the carrying out the OCS system reset process.
    NOTE: If the first attempt to carry out the OCS system reset is unsuccessful, a second attempt must be made. If the second attempt is unsuccessful, install a new OCS system service kit.
  10. Carry out the OCS system reset.
    • Carry out the OCS system reset.
    11. NOTE: The ignition must be cycled after the OCS system reset.
  11. Prove out the SRS as follows:

    Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will:

    - fail to light.

    - remain lit continuously.

    - flash at a 5 Hz rate (RCM not configured).

    The air bag warning indicator might not light until approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning 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 warning indicator and any SRS fault discovered must be diagnosed and repaired.

    Clear all RCM andOCSM DTCs using a scan tool.

    12. 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.
  12. Fill out the necessary information on the OCS traceability card and return it along with the complete inoperative OCS to Ford Motor Company.
    • When returning the inoperative OCS, include the following: seat cushion foam pad, bladder, OCSM, pressure sensor (transducer), hose, electrical connectors and wire harness (service part OCS only).
    13. Fig 5: Occupant Classification Sensor Verification Form
    G04586575Courtesy of FORD MOTOR CO.
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