Occupant Classification Sensor: Installation

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

CAUTION: While positioning the seat cushion pan and occupant classification sensor assembly, be careful not to damage any of the components. Failure to do so can result in component failure.

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: Occupant classification sensor (OCS) system components (seat cushion frame, seat cushion foam pad, bladder with pressure sensor, seat wiring harness 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 cushion foam pad are needed, a new OCS system service kit (seat cushion frame, seat cushion foam pad, bladder with pressure sensor, seat wiring harness and electronic control unit) must be installed as an assembly.

CAUTION: Inspect the seat cushion foam pad and seat cushion trim cover for any foreign objects before installing the seat cushion trim cover to the seat cushion foam 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 1: Installing Hog Rings

Courtesy of FORD MOTOR CO.

Install the seat cushion trim cover.
- Install hog rings to attach the seat cushion trim cover to the seat cushion foam pad of the OCS assembly at all locations from where they were removed.
At the front outboard side of the seat cushion frame, attach the 2 clips.

Fig 2: Attaching Clips
Courtesy of FORD MOTOR CO.
Attach the seat cushion trim cover J-clips to the seat cushion frame.
- Do not attach the RH rear J-clip at this time, so as to route the belt tension sensor wire harness between the trim cover and seat cushion frame later in the procedure.
- If equipped, do not attach the LH rear J-clip at this time so as to route the lumbar cable between the trim cover and seat cushion frame later in the procedure.
  
  Fig 3: Attaching Seat Cushion Trim Cover J-Clips To Seat Cushion Frame
  Courtesy of FORD MOTOR CO.

NOTE: Make sure the trim cover J-clips (left unattached for purposes of routing the belt tension sensor wire harness or lumbar cable) are accessible after the seat cushion assembly has been positioned to the seat track.

Install the seat cushion assembly to the seat track.
- Position the safety belt buckle through the seat cushion strap.
- Tighten to 25 Nm (18 lb-ft).
If equipped, connect the backrest heated seat element electrical connector and attach any wire harness retainers to the seat cushion frame.
If equipped, connect the power seat motor electrical connector and attach any wire harness retainers to the seat cushion frame.

NOTE: If equipped with manual lumbar, make sure this wire harness is routed above the manual lumbar cable.

Connect the safety belt buckle pretensioner and safety belt buckle switch electrical connectors and attach the wire harness retainer to the seat track.
On vehicles with SIR seats, connect the BTS electrical connector.
- Route the wire harness, connect the electrical connector and attach the J-clip.
Fig 4: Connecting Electrical Connector And Attaching J-Clip
Courtesy of FORD MOTOR CO.
If equipped, connect the lumbar cable.
- Route the cable and attach the J-clip.
Fig 5: Connecting Lumbar Cable
Courtesy of FORD MOTOR CO.
Install the passenger seat into the vehicle and repower the system. Do not prove out the supplemental restraint system at this time. For additional information, REFER to SEATING .
- Make sure the safety belts and buckles are accessible to the occupants after installation.
- Verify the safety belt retractor operates without excessive effort or binding.

WARNING: Do not separate components.

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

Re-zero 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.

NOTE: The ignition switch must be cycled after rezeroing the OCS system.

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 6 seconds and then turn off. If an air bag supplemental restraint system 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 restraints control module using a diagnostic tool.

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.

When installing a new OCS service kit, fill out the necessary information on the OCS service kit traceability card and return it along with the complete inoperative OCS system to Ford Motor Company.
- When returning the inoperative OCS system, include the following: seat cushion foam pad, seat cushion frame, bladder, electronic control unit, pressure sensor (transducer), hose, electrical connectors and wire harness.