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Occupant Classification Sensor: Installation

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

    All seats 

  1. Bend the pressure sensor bracket retaining ear back, so it will engage upon assembly.
    Fig 1: Locating Pressure Sensor Bracket Retaining Ear
    G03881284Courtesy of FORD MOTOR CO.

    2. Vehicles with heated seats 

    NOTE: The heated seat element on the front passenger seat cushion is not serviceable separately. If a new heated seat element is needed on the front passenger seat cushion a new occupant classification sensor (OCS) service kit and a new heated seat element must be installed.
  2. Attach the heated seat cushion element to the cushion foam pad.

    3. Seats with the original equipment OCS installed 

    CAUTION: Failure to route the seat occupant classification sensor components through the correct seat cushion support opening can cause component failure.
    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.
    Fig 2: Positioning OCS Assembly To Seat Cushion Frame
    G03881285Courtesy of FORD MOTOR CO.
  3. Position the 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 as noted during removal.
    4. 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 3: Installing Pin-Type Retainers Holding OCS Bladder To Seat Cushion Frame
    G03881280Courtesy of FORD MOTOR CO.
  4. Install the pin-type retainers holding the OCS bladder to the seat cushion frame.
  5. If the mat was removed, position the mat over the bladder and install pin-type retainers. Otherwise, position the mat over the bladder.
  6. Attach and connect the OCS components.
    1. Position the electronic control unit (ECU) to the seat cushion frame and connect the electrical connector.
    2. Install the rivets to hold the ECU in place.
    3. Position the ECU bracket through the opening in the front of the seat cushion frame.
    4. Install the ECU bracket rivet.
    5. Install the pressure sensor onto the seat cushion frame bracket, making sure the retaining ear is completely engaged.
      • Connect the pressure sensor electrical connector.
    6. Attach the pressure sensor hose.
    Fig 4: Attaching & Connecting OCS Components
    G03881287Courtesy of FORD MOTOR CO.
    7. CAUTION: Inspect the seat cushion pad and frame for any foreign objects before installing the seat cushion frame 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 5: Installing Seat Cushion Pad To Seat Cushion Frame
    G03881278Courtesy of FORD MOTOR CO.
  7. Install the seat cushion pad to the seat cushion frame.

    8. Seats with an OCS service kit installed 

    WARNING: Do not separate components.
    CAUTION: Inspect the OCS 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 classification sensor components through the correct seat cushion support opening can cause component failure.
    NOTE: If the original equipment OCS is not being installed, install a service kit OCS using all parts in the kit.
    Fig 6: Positioning Seat Cushion Pad And Bladder To Seat Cushion Frame
    G03881283Courtesy of FORD MOTOR CO.
  8. Position the OCS assembly to the seat cushion frame.
    • Using a service OCS, feed the electronic control unit (ECU), electrical connector, wire harness, pressure sensor, and hose through the largest opening at the front of the seat cushion frame support assembly as noted during removal.
      • Position the seat cushion pad and bladder to the seat cushion frame.
    9. NOTE: When installing a service part OCS, the main seat wire harness pressure sensor electrical connector does not get used.
    Fig 7: Attaching OCS Components
    G03881290Courtesy of FORD MOTOR CO.
  9. Attach and connect the OCS components.
    1. Position the ECU onto the seat cushion frame and install the two rivets.
    2. Position the ECU bracket through the opening in the front of the seat cushion frame.
    3. Install the ECU bracket rivet.
    4. Install the pressure sensor onto the seat cushion frame bracket, making sure the retaining ear is completely engaged.
    5. Attach the pressure sensor hose.
    6. Connect the main seat wire harness OCS electrical connector to the service part OCS electrical connector.
    7. Tie strap all loose wire harnesses and electrical connectors safely out of the way.

    10. All seats 

    CAUTION: Inspect the seat cushion pad and seat cushion trim cover for any foreign objects, before installing the seat 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 8: Aligning Seat Cushion Trim Cover To Seat Cushion Pad
    G03881276Courtesy of FORD MOTOR CO.
  10. Align the seat cushion trim cover to the seat cushion pad and fasten the hook and loop strips.
  11. Position the trim cover, attach the J-clips as shown, feed the power lumbar switch (if equipped) pigtail through the seat cushion pan opening and connect the electrical connector.
    Fig 9: Attaching J-Clips
    G03881275Courtesy of FORD MOTOR CO.

    12. Seats with power lumbar 

  12. Attach the power lumbar switch and bezel to the seat.
    • Connect the power lumbar switch electrical connector, if not done already.
    Fig 10: Attaching Power Lumbar Switch And Bezel To Seat
    G03880363Courtesy of FORD MOTOR CO.

    13. Seats with manual recline 

  13. Install the seat backrest recliner handle.
    Fig 11: Installing Seat Backrest Recliner Handle
    G03880385Courtesy of FORD MOTOR CO.

    14. Heated seats 

  14. Connect the cushion heated seat element electrical connector.
    Fig 12: Connecting Cushion Heated Seat Element Electrical Connector
    G03880459Courtesy of FORD MOTOR CO.

    15. All seats 

  15. Install the seat track. For additional information, refer to SEATING .
  16. Install the front seat backrest. For additional information, refer to SEATING .
  17. Install the front seat. For additional information, refer to SEATING .
  18. Repower the system. Do not prove out the system at this time  . For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING .
  19. 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 an NGS+ (NGS with Vehicle Communication Module (VCM) and the latest software update) to rezero the OCS system:
    • select "ACTIVE COMMAND MODES"
    • select "SYSTEM SELECTABLE CALIBRATION"
    • view the on-screen information, then press "TRIGGER"

    The NGS+ will display "TEST/FUNCTION COMPLETED" once rezeroing of the OCS system is complete.

    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.
    20. NOTE: The ignition switch must be cycled after rezeroing the OCS system.
  20. Cycle the ignition switch from ON to OFF.
  21. Prove out the (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 (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.

  22. Check the active restraint system for correct operation. For additional information, refer to SAFETY BELT SYSTEM .
    23. 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.
    Fig 13: Occupant Classification Sensor Verification Form
    G04586575Courtesy of FORD MOTOR CO.
  23. 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).
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