LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2006 >> Focus ZX5 SE, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 186 (Seat System) >> Disassembly And Assembly >> Seat Cushion - Passenger >> Assembly

Seat Cushion - Passenger: Assembly

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

    Heated seats 

  1. Seats receiving a new OCS service kit, install the new cushion heated seat element onto the new cushion foam pad.

    2. All seats 

  2. Position the cushion trim cover to the cushion foam pad and install the hog rings.
    Fig 1: Locating Hog Rings For Seat Cushion Trim Cover
    G03988965Courtesy of FORD MOTOR CO.
  3. Install the seat wire harness.

    4. Seats with manual recline 

  4. Position the manual seat backrest adjuster and drive the 2 large roll pins into the cushion pan and through the front manual seat backrest adjuster eyelets.

    5. Seats with power recline 

  5. Position the power seat backrest adjuster to the cushion pan and install the 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
  6. Drive the 2 large roll pins into the cushion pan and through the front power seat backrest adjuster eyelets.
  7. Connect the power seat backrest adjuster electrical connector.

    8. Heated seats 

  8. Slide the heated seat module onto the bracket, making sure it is locked in place. Connect the heated seat module electrical connector.

    9. Seats with an OCS service kit 

    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 (OE) occupant classification sensor (OCS) is not being installed, install a service kit OCS using all parts in the kit.
  9. 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.
      Fig 2: Positioning Seat Cushion Pad And Bladder To Seat Cushion Frame
      G03988978Courtesy of FORD MOTOR CO.
  10. Install the ECU.
    1. Position the ECU and install the rivets.
    2. Connect the electrical connector.
      • The ECU must be correctly positioned and securely riveted in place. Failure to do so can set a diagnostic trouble code (DTC) in the restraints control module (RCM).
        Fig 3: Positioning ECU And Install Rivets
        G03988979Courtesy of FORD MOTOR CO.

    11. Power seats with an OCS service kit 

  11. Tie strap the unused pressure sensor electrical connector to the seat wiring harness.
    Fig 4: Identifying Power Seats With An OCS Service Kit
    G03988973Courtesy of FORD MOTOR CO.

    12. Seats with an OE OCS 

  12. Install the ECU and rivets to the cushion frame bracket.
    • The ECU must be correctly positioned and securely riveted in place. Failure to do so can set a diagnostic trouble code (DTC) in the restraints control module (RCM).
      Fig 5: Installing ECU And Rivets To Cushion Frame Bracket
      G03988974Courtesy of FORD MOTOR CO.
  13. Connect the ECU electrical connector.
    Fig 6: Connecting ECU Electrical Connector
    G03988971Courtesy of FORD MOTOR CO.
    14. WARNING: Do not separate components.
    CAUTION: Inspect the occupant classification sensor bladder, 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.
  14. Position the OCS bladder to the cushion frame.
    • Feed the pressure sensor and hose through the center opening in the cushion frame wires.
      Fig 7: Inspecting Occupant Classification Sensor Bladder
      G03988970Courtesy of FORD MOTOR CO.
  15. Install the OCS bladder pin-type retainers.
    Fig 8: Installing OCS Bladder Pin-Type Retainers
    G03988969Courtesy of FORD MOTOR CO.

    All seats 

    16. NOTE: Make sure the pressure sensor is correctly installed and retained to the seat track bracket and the pressure sensor hose is not kinked during installation.
  16. Install the seat track. For additional information, refer to SEAT TRACK - FRONT .
  17. Install the front seat backrest. For additional information, refer to SEAT BACKREST - FRONT .
  18. Install the seat. For additional information, refer to SEAT - FRONT .
  19. Repower the SRS. Do not prove out the SRS at this time.  For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures portion of SUPPLEMENTAL RESTRAINT SYSTEM .
    20. 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 is 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 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.
  20. Rezero the occupant classification sensor.
    • With the front passenger seat empty, use a diagnostic tool to trigger the active command and rezero the OCS.
    21. NOTE: The ignition switch must be cycled after rezeroing the OCS system.
  21. Cycle the ignition switch from ON to OFF.
  22. 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.

    23. NOTE: When installing a new OCS service kit, 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.
  23. If a new OCS was installed, fill out the necessary information on the OCS traceability card and return it along with the complete inoperative occupant classification sensor to Ford Motor Company.
    • When returning the inoperative OCS, include: seat cushion foam pad, bladder, electronic control unit, pressure sensor (transducer), hose, electrical connectors and wire harness (service part OCS only).
      Fig 9: Installing New OCS Service Kit
      G04586575Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals