Attachment IV - FICM Harness Inspection
OVERVIEW
This program involves inspecting the fuel injector harness, at the fuel injection control module (FICM), for chafing caused by the harness rubbing against the intake manifold or rocker cover assembly bolt heads. If only a light amount of chafing has occurred (tape is worn through, the silver shielding and possibly the wire insulation are visible), install protective shields to prevent further damage. If more extensive chafing has occurred (copper wire strands are visible), the harness must be replaced.
INSPECTION
1. If necessary, disconnect the hot-side charge air cooler (CAC) duct (passenger side of the vehicle) from the turbocharger outlet duct cuff.
2. Inspect the FICM harness for a part number tag. If present, it will be located between two (2) of the fuel injector harness takeouts. See Figure 1.
[NEW] NOTE: The part number on the tag shows the International(R) part number for the FICM harness.
It differs from Ford Motor Company part numbers. The International� part number is a string of numbers that should end in C97. C97 will be larger than the other numbers on the harness tag.
^ If no tag is present, continue with this inspection.
^ If the tag is present but the part number ends in anything but C97, continue with this inspection.
^ If the tag is present and the part number ends in C97, no FICM harness service is required. Reinstall the CAC duct and proceed to Road Test Procedure in this Attachment IV.
3. Remove the air filter cartridge, the outlet tube and the clean air tube. See Figure 2.
4. Disconnect and clamp off the small hose from the passenger side of the degas bottle and plug hole in the bottle. See Figure 2.
5. Remove the two (2) bolts and position the degas bottle aside. See Figure 2.
6. Remove the turbocharger intake tube. See Figure 2.
7. Remove the four (4) FICM retaining bolts, then disconnect the three (3) harness connectors from the FICM and remove the FICM. See Figure 3.
8. Disconnect the two (2) rear fuel injector connectors and roll the FICM harness over to view the underside of the two (2) injector harness take-outs leading to the FICM.
9. Inspect the underside of the injector harness in the two (2) areas noted in the illustration. See Figure 4.
NOTE:
The harness is constructed of a bundle of insulated copper wires wrapped in a grounded silver-colored shield (much like heavy gauge aluminum foil), then covered with a wrapping of black vinyl tape.
^ If the harness is either NOT chafed or only lightly chafed but the copper wire strands ARE NOT visible (outer vinyl tape and possibly the silver-colored shield is worn through), the Harness Protection Kit 4C3Z-14A099-A must be installed. Proceed to FICM Harness Protection Kit Installation in this Attachment IV.
^ If extensive chafing has occurred which has exposed the copper strands, the harness must be replaced. Do not attempt to repair a chafed harness if these conditions are found. Proceed to FICM Harness Replacement in this Attachment IV.
FICM HARNESS PROTECTION KIT INSTALLATION
NOTE:
Based on when the vehicle being serviced was built, it may have some of the protection kit components, such as harness connector covers, already installed from the factory. Also, the kit includes additional parts such as rubber caps used to protect the harness from contact with studs and extra convolute that does not require installation. The kit was designed by International(R) for other service issues.
Install only the kit components necessary to fulfill the requirements of this recall.
1. Install the harness connector covers onto both FICM injector harness connectors by carefully bending the wires coming out of the connector and snapping the cover in place. See Figure 5.
2. Position and install the plastic TEE over the forward harness take-out with the narrowed end toward the rear of the vehicle. Do not latch the TEE closed at this time. See Figure 6.
3. Cut two (2) pieces of 11/16" convolute: one (1) approximately 75 mm (3 inches) long, the other about 37 mm (1.5 inches) long. See Figure 6.
4. Position the 75 mm (3 inches) section of convolute over the harness takeout from the plastic TEE to the FICM connector. See Figure 6.
5. Position the 37 mm (1.5 inches) section of convolute between the two (2) harness take-outs. See Figure 6.
6. Close the TEE around the harness and over the convolute, making sure that all four (4) latches are engaged. See Figure 6.
7. Using the supplied tape, secure the plastic TEE, both sections of convolute and the connector covers. See Figure 6.
8. Connect the injector connectors.
9. Position the FICM and connect all three (3) FICM connectors.
10. Install the FICM retainer bolts. Tighten the bolts to 13 Nm (10 lb-ft).
11. Install the turbocharger intake tube. Tighten the clamp to 4 Nm (35 lb-in). Tighten the nuts to 13 Nm (10 lb-ft).
12. Install the air filter cartridge, the outlet tube and clean air tube. Tighten the clamps to 4 Nm (35 lb-in).
13. Reposition the degas bottle and install the two (2) retaining bolts. Tighten the bolts to 10 Nm (89 lb-in).
14. Remove the plug and the clamp, and reconnect the hose to the degas bottle.
15. Check OASIS to verify there are no other Field Service Actions applicable to this vehicle prior to releasing the vehicle back to the owner.
16. Proceed to Road Test Procedure in this Attachment IV.
FICM HARNESS REPLACEMENT
NOTE:
FICM Harness Replacement must only be performed if copper strands have been exposed caused by chafing of the wires inside the harness.
REMOVAL
1. CAUTION: While removing the ground stud nut, hold the stud/intake manifold bolt from turning. If the stud/bolt is not held, the intake manifold bolt may loosen causing the ground wire to twist and eventually break.
Disengage the engine harness from the stud located at the rear of the intake manifold on the driver side of the vehicle, then remove the ground wire from the stud.
2. Disconnect the remaining two (2) fuel injectors on the driver side along with three (3) wire harness locators (two [2] located along the fuel injector manifold assembly and one located under the turbocharger). See Figure 7.
3. Remove the charge air cooler (CAC) hot air inlet duct (passenger side of the engine compartment) and the engine oil fill tube from the passenger side valve cover.
4. Disconnect the four (4) passenger-side injector connectors and the one (1) retainer located behind the alternator. Remove the harness from the vehicle by carefully pulling it from under the turbocharger towards the driver side of the vehicle. See Figure 8.
INSTALLATION
1. Route the new harness under the turbocharger and secure the retainer behind the alternator.
2. Connect the four (4) injector connectors on the passenger side of the engine.
3. Position the harness along the driver side of the engine and connect the four (4) injector connectors.
4. Secure the three (3) wire harness retainers (two [2] located along the fuel injector manifold assembly and one [1] located under the turbocharger).
5. Connect the ground wire at the intake manifold and reattach the engine harness to the stud. Hold the stud to prevent the ground wire from rotating and twisting.
6. Position the FICM and connect all three (3) FICM connectors.
7. Install the FICM retainer bolts. Tighten the bolts to 13 Nm (10 lb-ft).
8. Install the turbocharger intake tube. Tighten the clamp to 4 Nm (35 lb-in). Tighten the nuts to 13 Nm (10 lb-ft).
9. Install the air filter cartridge, the outlet tube and clean air tube. Tighten the clamps to 4 Nm (35 lb-in).
10. Reposition the degas bottle and install the two (2) retaining bolts. Tighten the bolts to 10 Nm (89 lb-in).
11. Remove the plug and the clamp, then reconnect the hose to the degas bottle.
12. Reinstall the oil fill tube to the passenger side valve cover and hand tighten.
13. 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.
Reinstall the CAC duct and tighten the Marmon clamps to 12 Nm (9 lb-ft).
14. Proceed to Road Test Procedure in this Attachment IV.
[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.