Attachment III - Sensor Connector Replacement
OVERVIEW
This program involves replacing the injector control pressure (ICP) sensor connector assembly. The harness connector is replaced utilizing the Rotunda Wire Splice Tool Kit 164-R5903.
NOTE:
The ICP sensor is located in the right (passenger side) valve cover near the front of the engine. For access to replace the ICP sensor harness connector, the generator must be removed. On vehicles with dual generators, the upper generator must be removed for access.
GENERATOR REMOVAL
1. Disconnect the dual batteries.
2. Position the cowl harness aside as follows. See Figure 1.
a) Remove the bolt and position the manifold absolute pressure (MAP) sensor aside.
b) Remove the ground strap bolt.
c) Remove the power steering reservoir bolts and position the reservoir aside.
d) Remove the cowl panel harness retaining bolts and position the harness aside.
3. Remove the charge air cooler (CAC) tube bracket by removing the left- and right-side stud nuts and the bracket screws. See Figure 2.
4. Remove the CAC tube.
5. Rotate the accessory drive belt tensioner clockwise and remove the drive belt from the generator pulley.
6. Remove the transmission fluid level indicator tube bracket nut from the generator and position the tube aside.
7. Remove the generator as follows. See Figure 3.
a) Position the rubber cover aside and disconnect the B+ electrical connector.
b) Disconnect the generator electrical connector.
c) Remove the generator mounting bolts (two [2] stud bolts and the one [1] hex-head bolt).
d) Remove the generator from the vehicle.
8. Proceed to Sensor Connector Replacement in this Attachment III.
SENSOR CONNECTOR REPLACEMENT
NOTE:
All splices are to be made using tools provided in the Rotunda Wire Splice Tool Kit 164-R5903. The repair kit contains the connector and pigtail, butt splice connectors and heat shrink tubing.
1. Disconnect the ICP sensor. See Figure 4.
2. Remove the tape from the vehicle harness back to the original take-out location.
3. CAUTION: The replacement connector has only one (1) color wire, so location identification is crucial for a proper repair.
Identify each wire leading to the connector (Vref, Ground and Signal). Note the locations of each wire relative to the connector face view provided. Place the identification tags at least a few inches away from the connector. See Figure 5.
4. Cut the wires about 25 mm (1 inch) behind the connector on the vehicle harness MAKING SURE TO LEAVE THE IDENTIFYING TAGS ON THE HARNESS and retain the old connector for reference. See Figure 5.
5. Strip about 7 mm (1/4 inch) of insulation from the wires on the new pigtail.
6. Using the crimp tool provided in the Rotunda Tool Kit, install the buff splice connectors provided in the service kit onto the replacement connector pigtail.
7. Strip about 7 mm (1/4 inch) of insulation from the wires on the vehicle harness.
8. Position the heat shrink over the wires on the new connector.
9. Matching the wires on the pigtail to the identifying tags on the vehicle harness, crimp the new butt connectors to the vehicle harness. Lightly tug on the wires to make sure you have a good, tight splice.
10. Position the heat shrink tubing over the butt splice connectors, then using the provided Flameless Heat Gun and deflector, heat the tubes on the vehicle harness until they shrink and adhesive flows from the ends, indicating a water-tight seal.
11. Fold the repaired harness to mirror the original harness length and tape the harness.
12. Install a length of convolute over the spliced section of harness and secure with tape.
13. Apply electrical grease to the face of the connector, forcing a small amount into all three (3) terminals.
[NEW]14. NOTE: The new connector is equipped with a new weather seal. Before connecting the ICP sensor, make sure the original weather seal is not stuck on the sensor. If the original weather seal is left in place, it will impair connector attachment.
Connect the connector to the ICP sensor.
15. Reinstall the generator. Refer to the procedure provided in this Attachment III.
GENERATOR INSTALLATION
1. NOTE: Be sure to install the engine-to-body ground strap under the front stud bolt.
Position the generator and install the mounting bolts. Tighten all to 47 Nm (35 lb-ft).
2. Connect the generator electrical connector, the B+ electrical connector and reposition the rubber boot cover.
3. Install the drive belt.
4. NOTE: Using Motorcraft Metal Brake Parts Cleaner PM-4, thoroughly clean the CAC outlet port and turbocharger inlet port of any oil residue or dirt that would interfere with an air-tight seal.
Install the CAC tube. Tighten the clamps to 12 Nm (9 lb-ft).
5. Install the CAC tube bracket.
^ Tighten the stud bolts to 25 Nm (18 lb-ft).
^ Tighten the screws to 2 Nm (18 lb-in).
6. Position and install the cowl wire harness as follows:
^ Tighten the wire harness bolts to 2 Nm (18 lb-in).
^ Position the power steering reservoir and install the bolts. Tighten to 8 Nm (71 lb-in).
^ Install the ground strap and tighten the bolt to 8 Nm (71 lb-in).
^ Install the MAP sensor and tighten the bolts to 5 Nm (44 lb-in).
7. Connect the battery terminals.
8. Check OASIS to verify there are no other Field Service Actions applicable to this vehicle prior to releasing the vehicle back to the owner.
9. Proceed to Road Test Procedure in this Attachment III.
[NEW] ROAD TEST PROCEDURE
Refer to the Road Test Procedure in Emission Recall 05E15. This road test is to be performed only once per vehicle and only after all applicable recall and service programs have been completed.