Occupant Classification Sensor

Special Tool(s)

Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Original Equipment (OE) Occupant Classification System (OCS)

Occupant Classification System (OCS) Service Kit

Removal

NOTICE: To prevent system failure, it is necessary to carry out the Occupant Classification System (OCS) reset when a front passenger seat cushion is disassembled, a new cover installed or an OCS service kit is installed. A scan tool is used to carry out the OCS reset.

NOTICE: Do not install a new heater mat on a front passenger seat cushion. Install a new Occupant Classification System (OCS) service kit. Failure to follow this instruction can cause incorrect OCS operation.

NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON.

NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer.

1. Remove the front passenger seat. For additional information, refer to Section 501-10 .

2. Remove the seat backrest. For additional information, refer to Section 501-10 .

3. NOTE: Power seat shown, manual similar.

   Disengage the OCS hose from the retainer.

4. If equipped, disconnect the cushion heater mat electrical connector.

5. NOTICE: Using excessive force when bending the bracket tab can damage the OCS sensor housing.

   NOTE: Power seat shown, manual similar.

   Insert a flat head screw driver or other appropriate tool between the bracket and OCS pressure sensor. Pry the bracket retainer tab down.

6. Slide the pressure sensor off the bracket and disconnect the electrical connector.

7. Disengage the cushion cover retainers from the cushion frame.
   • For an OE OCS remove the cushion cover and foam pad from the cushion frame.

8. Remove the 2 pin-type retainers attaching the OCS bladder to the seat cushion pan.

9. Feed the hose and pressure sensor out of the opening in the cushion frame and remove the OCS .

10. Detach the hook-and-loop strips, remove the hog rings and the cushion cover.

Installation

1. If equipped, adhere an new cushion heater mat to the cushion foam pad.

2. Attach the cushion cover to the cushion foam pad.
   • Install the hog rings and attach the hook-and-loop strips.

3.  WARNING: Occupant Classification System (OCS) parts are calibrated as an assembly and must only be replaced in the configuration they are sold. Never separate parts of an assembly. Failure to follow this instruction may result in incorrect operation of the OCS and increases the risk of serious personal injury or death in a crash.

    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 using System Reset to rezero the seat weight. Failure to follow these instructions may result in incorrect operation of the occupant classification system (OCS) and increases the risk of serious personal injury or death in a crash.

   NOTICE: Failure to correctly route the Occupant Classification System (OCS) components may cause component failure and incorrect operation of the OCS .

   Position the OCS hose and pressure sensor between the seat cushion wire support springs shown.

4. Position the OCS bladder and install the 2 pin-type retainers to the seat cushion frame.

5. Check the OCS hose routing.
   1. Make sure the hose is routed correctly over the seat spring.
   2. Do not route the hose under the seat spring.

6. Bend the tab back on the bracket.

7. Install the pressure sensor onto the bracket, making sure the tab is completely engaged.
   • Connect the electrical connector.

8. Attach the OCS hose to the retainer.

9. If equipped, connect the cushion heater mat electrical connector.

10. Attach all J-clips to the cushion frame.

11. Install the seat backrest. For additional information, refer to Section 501-10 .

12. Install the seat. Do not prove out the SRS at this time. For additional information, refer to Section 501-10 .

13. Make sure no Occupant Classification System Module (OCSM) DTCs are present. If DTC C1941 has been stored in OCSM memory, it will clear upon a successful system reset. All other OCS DTCs must be diagnosed and repaired before carrying out the OCS reset.

14.  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 using System Reset to rezero the seat weight. Failure to follow these instructions may result in incorrect operation of the occupant classification system (OCS) and increases the risk of serious personal injury or death in a crash.

    NOTICE: To prevent system failure, the following precautions must be taken before carrying out the Occupant Classification System (OCS) reset:

    • Make sure the voltage to the OCS sensor is above 8 volts and less than 18 volts.
    • Make sure the OCS is not at a temperature below 6°C (42°F) or above 36°C (97°F) when initiating the OCS reset. 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 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 ON before carrying out the OCS reset.
    Carry out the OCS reset.

15. If the first system reset attempt was unsuccessful, carry out a thorough inspection of the following and repair any concerns found.
    • OCS connector and wiring for damage
    • Pressure sensor hose for kinks and/or damage
    • Seat-related wiring harness and body wiring harness terminals and connectors for damage

16. Carry out a second OCS reset. If unsuccessful, install a new OCS service kit.

17. Prove out the SRS as follows:
    Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition ON and 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 detected, the air bag warning indicator will:
    - fail to light.
    - remain lit continuously.
    - flash.
    The flashing might not occur until approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This is the time required to complete 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 and OCSM Continuous Memory Diagnostic Trouble Codes (CMDTCs).

18. NOTE: A prepaid return postcard is provided with a new OCS service kit. The serial number for the new part and the Vehicle Identification Number (VIN) must be recorded and sent to Ford Motor Company.

    If a new OCS service kit was installed, 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: foam pad, bladder, hose, and pressure sensor ( OCS service kit only).