Ford Explorer: Supplemental Restraint System / Removal and Installation - Occupant Classification System (OCS) Sensor - Vehicles Without: Multi-Contour Seats

Special Tool(s) / General Equipment

Removal

  WARNING: The following procedure prescribes critical repair steps required for correct restraint system operation during a crash. Follow all notes and steps carefully. Failure to follow step instructions may result in incorrect operation of the restraint system and increases the risk of serious personal injury or death in a crash.

NOTICE: To prevent system failure, carry out the OCS (occupant classification system) reset when a front passenger seat cushion is disassembled, a new trim cover or heater mat is installed or an OCS (occupant classification system) service kit is installed. Use a diagnostic scan tool to carry out the OCS (occupant classification system) reset command.

NOTE: OCS (occupant classification system) components (seat cushion foam, bladder with OCSM (occupant classification system module)) are calibrated to each other and are serviced as an assembly with an OCS (occupant classification system) service kit. If a new OCS (occupant classification system) or seat cushion foam are needed, a new OCS (occupant classification system) service kit must be installed. The heater mat can be serviced separately.

NOTE: Removal steps in this procedure may contain installation details.

1.   WARNING: Before beginning any service procedure in this manual, refer to health and safety warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

   Refer to: Pyrotechnic Device Health and Safety Precautions (100-00 General Information, Description and Operation).
   

1. Remove the front passenger seat.
   Refer to: Front Seat (501-10A Front Seats, Removal and Installation).
   

1. If equipped with manual recline.
   
   1. Lift the recline handle.
      
   2. Remove the screw.
      
   3. Remove the recline handle cover.
      

1. 1. If equipped with a manual seat track.
      Remove the front seat side shield front screw.
      
   2. Remove the front seat side shield rear screw.
      

1. If equipped with a manual seat track.
   
   1. Firmly grasp the front seat side shield, lift up and out, separating the front seat side shield from the recliner bracket.
      
   2. From underneath the seat, squeeze the retainers together and pull out on the front seat side shield.
      
   3. Slide the front seat side shield forward and remove the front seat side shield.
      

1. If equipped with a power seat track.
   
   1. Lift up and out, separating the front seat side shield from the recliner bracket.
      
   2. Slide the front seat side shield forward and separate the front seat side shield from the seat.
      

1. If equipped with a power seat track.
   Disconnect the seat control switch electrical connector and remove the front seat side shield.
   

1. If equipped with a power seat track.
   Remove the screws and the front seat valance.
   

1. Release the front seat backrest panel straps.
   

1. Detach the electrical connectors, the wiring harness retainers and position the wiring harnesses aside.
   

1. If equipped with heated seat.
   Disconnect the cushion heater mat electrical connector and detach the wiring harness pin-type retainer.
   

1. 1. Disconnect the OCSM electrical connector.
      

   2. NOTICE: Using excessive force when bending the bracket tab can damage the OCS (occupant classification system) sensor housing.

      NOTE: Follow the unique instructions or graphic for this step in the installation.

      Bend the tab up. Use the General Equipment: Flat Headed Screw Driver
   3. Slide the OCSM off the bracket.
      

1. Detach the rear cushion cover retainers and position the cushion cover aside.
   

1. If equipped.
   Remove the front seat cushion blower motor.
   Refer to: Front Seat Cushion Blower Motor (501-10A Front Seats, Removal and Installation).
   

1. 1. Detach the front seat cushion cover J-clip.
      
   2. On both sides.
      Detach the front seat cushion cover J-clips.
      

1. Lift the front seat cushion foam. If the front seat cushion foam, and the OCS are adhered together, then the OCS is a service kit. If nothing is adhered together, then the OCS is OE (original equipment).
   

1. NOTE: For correct installation, note the location of the cushion heater mat wiring harness pigtail as it passes through the seat.

   If equipped with OE (original equipment) OCS, route out the front seat cushion heater mat wiring harness pigtail (if equipped) and remove the front seat cushion cover with foam as an assembly.
   

1. NOTE: Typical OE (original equipment) OCS (occupant classification system) shown, service kit similar.

   1. Detach the OCS pin-type retainers..
      
   2. Lift the OCS off the front seat track.
      

1. NOTE: Note the location of the OCS (occupant classification system) hose as it passes through the seat springs for proper installation.

   Route out the OCS hose and module from between the front seat cushion support wires and remove the OCS.
   

1. NOTE: This step is only necessary when installing a new OCS (occupant classification system).

   Position the rear portion of the front seat cushion cover from the foam.
   

1. NOTE: This step is only necessary when installing a new OCS (occupant classification system).

   NOTE: Follow the unique instructions or graphic for this step in the installation.

   
   Remove the front seat cushion cover.
   
   1. Invert the seat cushion cover.
      

   2. NOTICE: Use care when separating the seat cushion trim cover from the hook-and-loop strips or the hook-and-loop strips may be torn from the seat cushion foam pad.

      Release hook-and-loop strips.
      

   3. NOTICE: Use care when separating the seat cushion from the hook-and-arrow or the hook may be torn from the seat cushion foam pad.

      Release the hook and arrows.
      

Installation

1. NOTICE: Inspect the OCS (occupant classification system) bladder, seat cushion pan and support assembly for any foreign objects before installing the OCS (occupant classification system) to the seat cushion pan. Remove any foreign objects. Failure to follow these instructions may result in incorrect operation of the OCS (occupant classification system) and may cause system failure.

   NOTICE: Do not trap the pressure sensor hose incorrectly over the seat's suspension or spring. Route the hose so that it lays in a natural bend, and is not twisted due to being forced into an unnatural position. Failure to follow these instructions may result in component damage and/or system failure.

   To install, reverse the removal procedure.
   

1. If required.
   Install a new cushion heater mat.
   Refer to: Seat Heater Mat Installation (501-10A Front Seats, General Procedures).
   

1. Bend the OCS sensor bracket tab back.
   

1. Install the front passenger seat. Do not prove out the SRS at this time.
   Refer to: Front Seat (501-10A Front Seats, Removal and Installation).
   

1.   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: To prevent system failure, take the following precautions before carrying out the OCS (occupant classification system) reset.

   • Make sure the voltage to the OCSM (occupant classification system module) is greater than 8 volts and less than 18 volts.
   • Make sure the OCS (occupant classification system) is not below 6º C (42.8º F) or above 36º C (96.7º F) when initiating the OCS (occupant classification 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 between 6º C (42.8º F) to 36º C (96.7º F) for a minimum of 30 minutes.
   • Make sure nothing is present on the passenger seat before and during the OCS (occupant classification system) reset process.
   • Prior to carrying out the OCS (occupant classification system) reset, make sure a minimum of 8 seconds has elapsed after cycling the ignition switch on.
   Using a diagnostic scan tool, carry out the OCS reset. Cycle the ignition switch after the OCS reset.
   

1. If the first system reset attempt was successful, proceed to prove out the SRS.
   

1. If the first system reset attempt was not successful, carry out a thorough visual inspection of the OCS connector and wiring for damage, pressure sensor hose for kinks and or damage, and seat-related wiring harness and body wiring harness terminals and connectors for damage. Repair any concerns found and proceed to the next step.
   

1. Carry out a second OCS reset. Cycle the ignition switch after the OCS reset. If the second attempt is unsuccessful, install a new OCS service kit.
   

1. Prove out the SRS. Verify all airbags are installed and connected and the ignition is OFF. Wait 10 seconds then turn the ignition ON and monitor the airbag warning indicator. The airbag warning indicator illuminates continuously for approximately 6 seconds and turns off. Continue to monitor the airbag warning indicator for approximately 30 seconds, as this is the time required for the RCM to complete testing of the SRS.
   
   • If a SRS fault is present, the airbag warning indicator either fails to light, remains lit continuously or flashes. The flashing may not occur until approximately 30 seconds after the ignition has been turned from OFF to ON. If this occurs, diagnose and repair any SRS faults before proceeding with other repairs.
     
   • If, after the ignition has been turned on for 30 seconds, the airbag warning indicator remains unlit with no chime or SRS message displayed in the message center, no SRS fault is present.
     
   • If the airbag warning indicator is inoperative and a SRS fault exists, a chime sounds in a pattern of 5 sets of 5 beeps or a message displays in the message center. If this occurs, diagnose and repair the airbag warning indicator and any SRS faults before proceeding with other repairs.
     

1. Using a diagnostic scan tool, clear all Continuous Memory Diagnostic Trouble Codes (CMDTCs) from all modules.