FocusEU2018_cel005.pdf

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Focus MK4 EU rev:2018
*
Repair Procedures
5-1
Troubleshooting wiring harness and connector hidden concerns
The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns.
The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration.
Non Safety Restraint System Repairs
Several components, such as PCM and ABS modules, may utilize gold plated terminals in their
connections to the wiring harness. Replace all gold plated terminals with either a gold plated terminal or a "universal" service kit
with a plating of silver or tin with grease already applied.
IMPORTANT NOTICE REGARDING SAFETY RESTRAINT SYSTEMS:
Restraint system terminals must not be removed or repaired
Restraint terminals are not to be repaired/replaced with individual pins/terminals.
Ford no longer requires replacement of the affected harness if a restraint connector or terminal requires service.
Wiring Pigtail Kits designed specifically for the deployable components (for example, Airbags or Seatbelt Pretensioners)
of the restraint harness should be used. Available Wiring Pigtail Kits can be identified in the wiring connector face view.
replace with the service connector pigtails. Failure to follow this instruction may result in incorrect operation of the vehicle safety
restraint, which increases the risk of serious personal injury or death in a crash.
WARNING:
Do not repair or service restraint component connector terminals. If restraint connector terminals need repair,
Focus MK4 EU rev:2018
*
Repair Procedures
5-2
Terminal not properly seated
7
1
6
5
2
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire
at the end of the connector.
3
4
Focus MK4 EU rev:2018
*
Repair Procedures
5-3
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
1
2
4
3
4
Partially mated connectors
2
3
4
1
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked
position; pull on the connector to verify the lock.
7
6
5
Focus MK4 EU rev:2018
*
Repair Procedures
5-4
Deformed (enlarged) female terminals
1
2
1
2
1 = Enlarged
2 = Normal
Any probe entering the terminal may enlarge the contact
spring opening creating an intermittent signal.
Insert the correct mating terminal (Location A) from the
service kit and feel for a loose
fit.
A
A
A
A
Electrical short inside the harness
3
1
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of
another circuit.
4 = Grounding foil
2
4
Focus MK4 EU rev:2018
*
Repair Procedures
5-5
Recommended splicing method 1 - Solder (For 14 AWG/1.9mm and Smaller Diameter Wire Only )
Note: Cut and splice one circuit at a time noting the original wire to connector pin locations.
This will avoid miss-connections.
1. Disconnect battery
ground cable.
2. Strip wires to
appropriate length.
19.5 mm
(¾ in)
12.7 mm
(�½ in)
25.4 mm
(1 in)
49.9 mm
(2 in)
6. Evenly position
heat shrink tubing
over wire repair.
NOTE:
Overlap
tubing on both wires.
19.5 mm
(¾ in)
12.7 mm
(�½ in)
3. Install heat shrink tubing.
4. Twist wires together.
5. Solder wires together.
NOTE:
Use rosin core
mildly-activated (RMA)
solder. Do not use acid
core solder.
NOTE:
Use Motorcraft
heat shrinkable
tubes:
Part # WT-56815
for 14-16 AWG
Part # WT-56814
for 18-22 AWG
7. Use shielded heat
gun to heat the
repaired area until
adhesive
flows
out of both ends
of heat shrink tubing.
NOTE:
On smaller
wires, use pliers to
gently squeeze the
ends of the heat shrink
sleeve (while heat
shrink is still warm)
to ensure a tight
fit
and
close any air gaps
8. Reconnect battery
ground cable.

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