REMOVAL AND INSTALLATION

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1 501-20B-1 REMOVAL AND INSTALLATION B-1 Occupant Classification Sensor Item Part Number Description Seat track assembly Special Tool(s) 8 Safety belt buckle switch electrical connector (part of Worldwide Diagnostic System 61202) (WDS) Vehicle Communication Module Seat with a Service Kit Occupant Classification (VCM) with appropriate Sensor adapters, or equivalent diagnostic tool Seat with OEM Occupant Classification Sensor Item Part Number Description Seat cushion trim cover 2 Seat cushion foam pad 3 Pin-type retainers 4 Occupant Classification Sensor (OCS) (bladder, hose with pressure sensor, electronic control unit (ECU) and wiring harness) 5 W Nuts Seat cushion pan assembly (Continued) Item Part Number Description Seat cushion trim cover 2 603B02 OCS service kit (foam pad, bladder, hose with pressure sensor, electronic control unit (ECU) and wiring harness) 3 W Nuts Seat cushion pan assembly Seat track assembly 6 Safety belt buckle switch electrical connector (part of 61202) Copyright 2004, Ford Motor Company Last updated: 07/29/2004

501-20B-2 Removal WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module.

2 501-20B-2 Removal WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. 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 scan tool is used to trigger the active command to carry out rezeroing of the OCS system. NOTE: If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered B-2 NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. All seats 1. Position the seat to access all the seat track-to-floor pan bolts. 2. Depower the supplemental restraint system (SRS). For additional information, refer to (SRS) Depowering and Repowering in the General Procedures portion of this section. 3. Remove the passenger seat. For additional information, refer to Section Remove the seat backrest. For additional information, refer to Section NOTE: Occupant classification sensor (OCS) system components (seat cushion foam pad, bladder with pressure sensor and electronic control unit) are 5. Release the seat trim cover and foam pad. calibrated to each other and are serviced as an Release the 5 J-clips and one pin-type assembly. The OCS system components are not to retainer in the RH front corner. be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, a new OCS system service kit (seat cushion foam pad, bladder with pressure sensor, electronic control unit and seat wiring harness) must be installed as an assembly. NOTE: To identify between a production OCS system and a service OCS system (OCS service kit) inspect the electronic control unit (ECU) electrical connector. A production OCS system allows the disconnect of the ECU electrical connector. A service OCS system (OCS service kit) has the ECU electrical connector glued to the ECU. It cannot and should not be disconnected or altered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.

501-20B-3 501-20B-3 6. CAUTION: Use care when separating the seat upholstery from the hook and loop strip, or the hook and loop strip can be torn from the seat cushion foam pad.

3 501-20B B-3 6. CAUTION: Use care when separating the seat upholstery from the hook and loop strip, or the hook and loop strip can be torn from the seat cushion foam pad. Separate the trim cover from the foam pad. Release the hook and loop fasteners and remove the hog rings. 9. NOTE: Note position of wire routing for installation. Disconnect the safety belt buckle switch electrical connector and release the connector retainer from the seat cushion pan. 7. NOTE: Production pressure sensor shown, service kit pressure sensor similar. Bend to release the retaining tab and remove the pressure sensor from the bracket. Seats with a production occupant classification sensor (OCS) 10. Release the 2 pin-type retainers and remove the 4 nuts and the seat track assembly. 8. Release the wire routing clip and the electrical connector retainer from the bracket.

4 501-20B-4 Seats with a service kit OCS 13. NOTE: Note position of hose routing for installation B Position aside the OCS bladder and foam pad Remove the OCS from the seat cushion pan. assembly and remove the 4 nuts (2 rear shown) Feed the hose, pressure sensor, wire harness, and the seat track assembly. electrical connector and ECU through the opening in the seat cushion pan assembly. All seats 12. NOTE: Production electronic control unit (ECU) shown, service kit ECU similar. Remove the rivets and separate the ECU from the seat cushion pan bracket.

5 501-20B B-5 Installation 2. NOTE: Make sure the ECU is properly secured to the bracket. All seats Position the ECU onto the seat cushion pan bracket and install new rivets. 1. 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 pan 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. Position the OCS to the seat cushion frame. Feed the hose, pressure sensor, wire harness, electrical connector and the ECU through the seat cushion pan assembly. 3. Bend the retaining tab back on the pressure sensor bracket.

6 501-20B-6 Seats with a service kit OCS B-6 4. Install the seat track assembly and the 4 nuts (2 rear nuts shown), and center the OCS service kit on the seat cushion pan. Tighten to 36 Nm (27 lb-ft). 7. Attach the wire routing clip to the cushion pan and electrical connector retainer to the bracket. Seats with a production OCS 5. Install the 4 nuts and the seat track assembly, and attach the 2 pin-type retainers. Tighten to 36 Nm (27 lb-ft). 8. Install the pressure sensor onto the seat cushion pan bracket, making sure the retaining tab is completely engaged. When installed correctly, an audible click will be heard and the pressure sensor will not be able to be removed from its bracket without disengaging the retaining tab. All seats 6. Connect the safety belt buckle switch electrical connector and attach the connector to the seat cushion pan.

7 501-20B B-7 9. CAUTION: Inspect the seat cushion pad and seat cushion trim cover for any foreign objects, before installing the seat cushion trim cover and 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. Align the seat cushion trim cover to the seat cushion foam pad and attach the hog rings and hook and loop fasteners. 11. Install the seat backrest. For additional information, refer to Section Install the passenger seat into the vehicle. For additional information, refer to Section Repower the SRS. Do not prove out the SRS at this time. For additional information, refer to (SRS) Depowering and Repowering in the General Procedures portion of this section. 10. Attach the seat trim cover and foam pad. Attach the 5 J-clips and one pin-type retainer in the RH front corner.

8 501-20B WARNING: Do not separate components B-8 once rezeroing of the OCS system is complete. NOTE: To rezero the OCS system using the Worldwide Diagnostic System (WDS): CAUTION: It is necessary to rezero the OCS system when a front passenger seat select the Toolbox icon cushion is disassembled, a new trim cover select Body from the menu installed or an OCS service kit is installed. A scan tool is used to trigger the active select Restraints from the menu command to carry out rezeroing of the OCS select Seat Weight Sensor ReZero system. After selecting Seat Weight Sensor ReZero, CAUTION: Make sure the seat is follow the on-screen prompts to carry out completely assembled before rezeroing. rezeroing of the OCS system. NOTE: If the first attempt to rezero the OCS CAUTION: The following precautions system is unsuccessful, a second attempt must must be taken before rezeroing the OCS be made. system. Rezero the occupant classification sensor. Make sure the OCS system components With the front passenger seat empty, use a are connected and no faults are present. diagnostic tool to trigger the active Make sure the OCS system is not at a command and rezero the OCS. temperature below 0 C (32 F) or above 45 C (113 F) when initiating the 15. NOTE: The ignition switch must be cycled rezeroing process. If the vehicle has been after rezeroing the OCS system. exposed to extreme cold or hot Cycle the ignition switch from ON to OFF. temperatures, the vehicle must be exposed and kept at a temperature within the 16. Prove out the SRS as follows: limits, 0 C to 45 C (32 F to 113 F) for a minimum of 30 minutes. Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and Make sure nothing is present on the visually monitor the air bag indicator with the passenger seat before rezeroing and air bag modules installed. The air bag indicator nothing is placed on the seat during the will light continuously for approximately 6 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: When using a NGS+ (NGS with Vehicle Communication Module (VCM) and the latest software) to rezero the OCS system: select FUNCTION TEST select SYSTEM RESET view the on-screen information then press TRIGGER The NGS+ screen will then display OCS RESET: REZERO. Press DONE (button 8) to rezero the OCS system. The NGS+ will display TEST/FUNCTION SUCCESSFUL seconds and then turn off. If an air bag 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 RCM using a scan tool.

501-20B-9 501-20B-9 17. Check the active restraint system for correct operation. For additional information, refer to Section 501-20A. 18.

9 501-20B B Check the active restraint system for correct operation. For additional information, refer to Section A. 18. 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. 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).

DISASSEMBLY AND ASSEMBLY

501-10-1 Seating 501-10-1 DISASSEMBLY AND ASSEMBLY Front Seat Cushion Special Tool(s) Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic