Originator: Stephen I. Dains/sdains
Page 21 of 29
Date Issued: 2-16-04
guidebookcommon spring 2004.doc
DateRevised: 5/27/2004
E1109
CONNECTORS
Quick splice (pinch through) connectors or wirenuts areunacceptable for under hoodand
under body applications or for splicinganywhere into theOEMwires.
•
Quick splice connectors are strongly discouragedanywhereon the vehicle.
•
Groundingof the secondunit body to the frame shouldbemade inat least two locations
using flexible straps of substantial gauge.
•
Donot ground thebody to the transmissionor transmission crossmember. Donot ground
the transmission to the frameof the vehicle.
•
All bare low voltage connectors shouldbe covered to reduce the chanceof shorts during
vehicle servicing.
•
All addedelectrical connectors and connections shouldprovideadequate current carrying
capability tomeet the circuit current requirements.
•
All wire splices shouldbeeither twisted, solderedand sealed, or crimpedusing theproper
size crimp connector tomatch thewires being joined.
•
All electrical connections exposed tohostileenvironments shouldbeproperly sealedwith
either sealable crimp connectors or heat shrinkable tubing. Sealedbutt connectors are
available fromFordComponent Sales:
FordPart Number
Part Name
E6FZ-14488-A
18-22gauge connector, red
E6FZ-14488-B
14-16gauge connector, blue
E6FZ-14488-C
10-12gauge connector, yellow
Aheat shrink tool for wire splices, that includes a torch, is available fromRotunda. Rotunda
TorchNumber 107-R0305 ismadebyWright Tool Company, 1738MaplelawnBoulevard, Troy,
Michigan48099 (telephone: 1-800-783-9826).
E1110
Connectors shouldbeprotectedduring themanufacturingprocess toensuremetal chips or
other debris arenot introduced into the connectorswhich result in short circuits or warning light
illumination.
E1111
WIREROUTINGANDPROTECTION
All additional under hoodandunderbodywiring shouldbeprotectedwithhigh temperature
(minimum125
°
C) nylon convoluted tubing.
•
All wiring shouldbe routedand securedneatly to avoidany functional or visual issues.
Under hoodandunderbodywire routings shouldbe clear of sharpedges (¾ inches
minimum) anddirect sources of heat (4 inchesminimum). Wiring located in thepassenger
compartment shouldbe routedaway fromhigh temperatureareas over themuffler or
catalyst. Addedheat shieldingnear exhaust componentsmay beneeded.
E1112
Wires routedover, through, or near sharpedgesmust use rubber edgeguards, grommets, or
convoluted tubing.
•
Convoluted tubingused in thepassenger compartmentmay beof lower temperature rating
if kept separate from thehigh temperature rated convoluteandbothare clearly labeled.
•
Wiring shouldnot be routed over theexhaust system.
•
Addedwiring shouldbe located toavoid, or securedaway from, rotatingparts like cooling
fans, enginebelts, transmission shift controls, andbrakeandaccelerator pedals. Wiring in
theengine compartment shall provideat least 1½-inch clearance to theengine toallow for
engine roll.
•
Any addedwiring shouldnot contact thebrake lines or fuel lines.
•
Addedelectrical circuits shouldbeprotected by a fuseor circuit breaker, labeled, and
positioned to facilitate servicing. Fuses and circuit breakers located in theengine
compartment are tobe sealed tominimize corrosion.
•
All wiring shouldbeprotected from fastener damageduring thebuildprocess and from
abrasionby any unfriendly surface.
