LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2011 >> Transit Connect Van Cargo >> Repair and Diagnosis >> Restraints >> Air Bag, SRS >> Supplemental Restraint System >> Removal And Installation >> Occupant Classification Sensor >> Installation

Occupant Classification Sensor: Installation

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 carrying out the System Reset. 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. 
    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. 
    Fig 1: Locating OCS System And Seat Wiring Through
    G06293928Courtesy of FORD MOTOR CO.
  1. Install the OCS  bladder and foam.
    • Route the OCS  system components and seat wiring through the opening in the suspension spring.
    • Position the OCS  bladder to the cushion half pan and install the 2 pin-type retainers.
  2. Bend the locking tab back on the pressure sensor bracket and install the pressure sensor onto the bracket making sure the locking tab is completely engaged.
    • Check the pressure sensor bracket mounting for tightness. If the bracket is loose, install a new rivet to tighten the bracket.
    Fig 2: Locating Pressure Sensor Bracket Locking Tab
    G06293930Courtesy of FORD MOTOR CO.
  3. Attach the 2 pin-type retainers and OCS  bladder to the cushion half pan.
  4. Attach the pressure sensor hose clip to the suspension spring.
    Fig 3: Locating Pressure Sensor Hose Clip
    G06293798Courtesy of FORD MOTOR CO.
  5. Install the OCSM  and 2 screws.
    Fig 4: Locating OCSM Screws
    G06293927Courtesy of FORD MOTOR CO.
  6. Install the brown safety belt buckle electrical connector and yellow side air bag connector to the seat electrical bulkhead connector.
    Fig 5: Locating Brown Safety Belt Buckle Electrical Connector And Yellow Side Air Bag Connector
    G06293793Courtesy of FORD MOTOR CO.
  7. Install the wire harness.
    • Install the wire harness and retainers to the seat track.
    • Attach the seat electrical bulkhead connector to the seat track.
  8. Install the cushion cover and all hog rings to the foam pad.
  9. Fasten all cushion cover J-clips.
  10. Install the inboard side shield and screw.
    • Attach the safety belt buckle wire harness.
  11. Install the outboard side shield and screw.
  12. If equipped, install the height adjust handle.
  13. Install the recliner handle and screw.
  14. Install the passenger seat. For additional information, refer to the Removal and Installation portion of SEAT SYSTEM article.
    15. NOTE: To prevent system failure, it is necessary to carry out the Occupant Classification System (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover is installed or an OCS  system service kit is installed. A scan tool is used to carry out the OCS  system reset.
  15. 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  system DTCs must be diagnosed and repaired before carrying out the OCS  system reset.
    16. 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 carrying out the System Reset. 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. 
    NOTE: To prevent system failure, the following precautions must be taken before carrying out the Occupant Classification System (OCS) system reset:
    • Make sure the voltage to the Occupant Classification System Module (OCSM) is above 8 volts and less than 18 volts.
    • Make sure the OCS  system is not at a temperature below 6°C (42°F) or above 36°C (97°F) when initiating the OCS  system 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  system 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  system reset.
  16. Carry out the Occupant Classification System (OCS) system reset.
  17. If the first system reset attempt was unsuccessful, carry out a thorough inspection of the following and repair any concerns found.
    • OCS  system 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
  18. Carry out a second OCS  system reset. If unsuccessful, install a new OCS  system service kit.
  19. Prove out the Supplemental Restraint System (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 CMDTCs  .

    20. NOTE: A prepaid return postcard is provided with a new OCS  system service kit. The serial number for the new part and the Vehicle Identification Number (VIN) must be recorded and sent to Ford Motor Company.
  20. If a new OCS  system service kit was installed, fill out the necessary information on the OCS  system traceability card and return it along with the complete inoperative OCS  system to Ford Motor Company.
    • When returning the inoperative OCS  system, include: foam pad, bladder, OCSM  , pressure sensor, hose, electrical connectors and wire harness (OCS  system service kit OCS  only).
scientia non olet · About LEMON Manuals