Attachment III - Technical Information
BATTERY CABLE HARNESS INSPECTION AND REPAIRAND PINCH BOLT TORQUE ADJUSTMENT
AFFECTED VEHICLES:
CERTAIN 2000-2001 MODEL YEAR FOCUS
BUILT FROM JANUARY 12, 2000 THROUGH MAY 31, 2001
OVERVIEW
This document details the procedures for:
^ Inspection, modification or replacement of the battery harness assembly (applies only to Focus models equipped with the ZETEC engine)
^ Inspection and possible modification of the battery tray (applies only to Focus models equipped with the ZETEC engine)
^ Torque verification on the lower ball joint pinch bolt (applies to Focus models built at the Wayne Assembly Plant with EITHER the ZETEC or SPI engine)
These procedures include various inspections and repair scenarios. A flow chart has been provided to assist in navigating through these procedures.
PLEASE NOTE THAT ONLY A VERY SMALL PERCENTAGE OF ZETEC-EQUIPPED MODELS WILL REQUIRE BATTERY CABLE HARNESS REPLACEMENT.
The illustration shows the parts kit components. These components will be referenced throughout these procedures.
INSPECTION AND REPAIR SCENARIOS FLOWCHART
INSPECTION AND BATTERY TRAY MODIFICATION
1. Check the VIN to determine the engine type and which assembly plant the vehicle was built at. The engine type is identified by the 8th digit. The assembly plant is identified by the 11th digit.
Engine Identifiers - P = 2.0L SPI
3 = 2.0L ZETEC
Assembly Plant Identifiers - W = Wayne Assembly Plant
R = Hermosillo Assembly Plant
^ If the vehicle is equipped with a SPI engine, the pinch bolt service is the only required action. Go to Step 23 of this inspection procedure.
^ If the vehicle is equipped with a ZETEC engine and built at Wayne Assembly Plant, both battery cable harness and pinch bolt services are required. Continue with Step 2.
^ If the vehicle is equipped with a ZETEC engine and built at Hermosillo Assembly Plant, the battery cable service is the only required action. Pinch bolt service is not required. Continue with Step 2.
2. Install a memory saver, then open the hood. Remove the battery cover and disconnect the battery negative cable.
3. Remove the air cleaner assembly as follows:
a) Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
b) Disconnect the positive crankcase ventilation (PCV) tube.
c) Loosen the air cleaner tube at the throttle body.
d) Remove the air cleaner assembly from the vehicle.
4. Inspect the battery cable harness routing at the battery tray. If the harness assembly is routed as shown in Figure 2, the battery tray has been modified. See Figure 2.
^ If the tray has been modified, verify the battery hold-down strap is properly positioned over the battery as shown in Figure 2 and NOT positioned on top of either battery cap. Adjust if necessary. Also, install the two (2) push pins (Item No.9) into the two vacant holes in the battery tray as shown in Figure 3. Then proceed to Step 21 to continue the inspection. If the battery tray has not been modified, continue with Step 5.
5. Disconnect the auxiliary power harness from the battery positive cable and then disconnect the battery positive cable.
6. CAUTION: The bolt for the battery hold-down strap may have a build up of rust and/or corrosion. Be sure to use Motorcraft Penetrating Oil and Lock Lubricant, part number XL-1 (E8AZ-19A501-B), or equivalent before attempting to remove the bolt. Use HAND TOOLS ONLY when removing the battery hold-down bolt or damage to the battery tray may result.
Unbolt the battery hold-down strap, position it out of the way, and then remove the battery from the vehicle.
7. Remove the smaller red auxiliary power harness from the battery tray and then remove the offset anchoring clip from the harness. Do not discard the clip at this time.
8. Install one of the two (2) supplied push pins (Item No. 9) into the auxiliary power harness anchor location.
9. Install the large diameter 229 mm (9 in) convolute tube (Item No. 2) over the auxiliary power harness and secure in place with black vinyl tape using a "candy stripe" pattern. See Figure 4.
10. NOTE: When marking the battery tray, be sure to allow for slack in the auxiliary wire harness behind the battery tray.
Place the clip removed in Step 7 against the inner right side of the battery tray. With the rear edge of the clip at least 6 mm (1/4 in) away from the rear of the battery tray and with at least 6 mm (1/4 in) of clearance between the clip and the top edge of the battery tray, mark the location of the push pin as shown in Figure 5.
11. Using a 6 mm (1/4 in) drill bit, drill a hole into the battery tray at the marked location.
12. Install the clip removed in Step 7 into the drilled hole.
13. Position the auxiliary power harness onto the installed clip, but do not attach the harness to it. Once the harness is positioned in such a manner as to allow for some slack behind the battery tray, mark the clip's position on the harness.
14. Install the new offset anchoring clip (Item No. 4) onto the marked location of the harness and secure it in place with black vinyl tape.
15. Remove and discard the original clip from the battery tray and then install the auxiliary power harness into its new position on the battery tray.
16. On the inside rear of the battery tray, measure 38 mm (1-1/2 in) down from the original battery negative cable anchoring location and mark the inside of the battery tray. See Figure 6.
17. Using a 6 mm (1/4 in) drill bit drill a hole in the battery tray at the marked location.
18. Install the remaining new push pin (Item No. 9) into the original battery negative cable anchoring location.
19. Position the battery into the vehicle.
20. CAUTION: Do not trap the battery negative cable under the strap. Be sure the hold-down strap is under the cable. Also, be sure the strap is NOT positioned on top of either battery cap. See Figure 7.
CAUTION:
Use HAND TOOLS ONLY when installing the hold-down bolt or damage to the battery tray can result.
Position the battery hold-down strap over the battery and install the bolt. Tighten the bolt to 12 Nm (106 lb-in). See Figure 7.
21. Inspect the battery cable harness to see if the positive and negative cables are in the same convolute tube. See Figure 8.
^ If the positive and negative cables are in the same tube, as indicated in Figure 8A, proceed to the Battery Cable Harness Removal procedure.
^ If the positive and negative cables are in separate convolute tubes, as indicated in Figure 8B, continue with the Step 22.
22. Perform under-hood inspection.
a) Inspect the harness and battery terminals for any signs of damage.
b) Make sure the harness does not contact any sharp edges, components, or surfaces that may damage the harness. Reposition the harness as necessary.
23. Raise and support the vehicle.
For vehicles equipped with 2.0L SPI engines, go to Step 25. Do not perform the under-vehicle inspection.
24. Perform under-vehicle inspection.
a) Inspect the harness for any signs of damage.
b) Make sure the harness does not contact any sharp edges, components, or surfaces that may damage the harness. Reposition the harness as necessary.
^ If the harness assembly shows any signs of damage as listed in Battery Cable Harness Inspection Table, the cable must be replaced. Proceed to the Battery Cable Harness Removal procedure.
^ If the harness assembly does not show any signs of damage, continue with Step 25.
25. Verify the torque on both front lower arm ball joint pinch bolts as follows. See Figure 9.
a) Using a suitable wrench with the T-50 Torx-head bit, hold the pinch bolt to keep it from turning.
b) Tighten the attaching nut to 50 Nm (37 lb-ft).
c) Repeat Steps A and B on the opposite side.
d) If the vehicle is equipped with a 2.0L SPI engine, no further service action is required. Lower the vehicle, close the hood and release the vehicle.
e) If the vehicle is equipped with a 2.0L ZETEC engine, continue with Step 26.
26. Tighten the following fasteners to their specified torque:
^ Generator positive cable nut: 8 Nm (71 lb-in).
^ Starter battery positive cable nut: 12 Nm (106 lb-in).
^ Starter solenoid nut: 6 Nm (53 lb-in).
27. Lower the vehicle.
28. Install the air cleaner assembly as follows:
a) Position the air cleaner assembly into the vehicle.
b) Tighten the air cleaner tube at the throttle body.
c) Connect the PCV tube.
d) Connect the MAP sensor electrical connector.
29. Connect the battery negative cable, then tighten the following fasteners to their specified torque:
^ Battery positive and negative post main terminal nuts: 8 Nm (71 lb-in).
^ Battery post auxiliary power and ground harness nuts: 5 Nm (44 lb-in).
^ Engine ground cable bolt: 35 Nm (26 lb-ft). See Figure 10.
30. Install the battery cover.
31. Close the hood and release the vehicle.
BATTERY CABLE HARNESS REMOVAL
1. If not already done, disconnect the auxiliary power harness from the battery positive cable and then disconnect the battery positive cable.
2. Disconnect the auxiliary ground wire from the battery negative cable.
3. Disconnect the body ground cable. See Figure 10.
4. Disconnect the starter motor solenoid electrical connector. See Figure 11.
5. Disconnect the ground cable from the transmission bell housing. See Figure 12.
6. Raise and support the vehicle.
7. Disconnect the two (2) starter motor electrical connectors.
8. Disconnect the generator electrical connector.
9. Lower the vehicle.
10. Disengage the retainer clips securing the battery cable harness at the battery tray an near the top of the transmission, then remove the harness from the vehicle.
^ If the previous inspection revealed damage to the harness, no additional inspection is required. The harness must be replaced with a new assembly. Discard the battery cable harness and proceed to the Battery Cable Harness Installation procedure.
11. Inspect the battery cable harness for any damage as listed in the Battery Cable Harness Inspection Table.
^ If the harness assembly shows any signs of damage as listed in the inspection table, the harness must be replaced. Discard the battery cable harness and proceed to the Battery Cable Harness Installation procedure.
^ If the harness assembly does not show any signs of damage as listed in the Inspection Table, it does not need to be replaced. Proceed to the Battery Cable Harness Modification procedure.
BATTERY CABLE HARNESS MODIFICATION
1. WARNING: TO AVOID PERSONAL INJURY, DO NOT USE A RAZOR KNIFE OR SIMILAR TOOL TO CUT THE CONVOLUTE TUBE FROM THE HARNESS.
CAUTION:
To prevent damage to the wire harness, use diagonal cutters, scissors, or a similar tool, to cut the convolute tube from the harness.
With the battery cable harness on a suitable work area, remove the clips from the harness. Then remove the convolute tube and the black vinyl tape (but not the black cloth tape underneath the clips) from the harness. Separate the positive and negative cables and discard the clips, convolute tube and tape. See Figure 13.
2. Install the supplied small diameter 254 mm (10 in) long convolute tube (Item No. 3) over the negative cable and secure it in place with black vinyl tape on both ends, beginning with the grounding eyelet. Once the tube is in place, wrap a layer of vinyl tape around the tube in a "candy stripe" pattern. See Figure 14.
3. Install the supplied 430 mm (17 in) long convolute tube (Item No. 1) overthe positive cable and the black starter solenoid wire. Secure the tube in place with black vinyl tape on both ends beginning 40 mm (1-1/2 in) from the starter eyelet cover. Once the tube is in place, wrap a layer of vinyl tape around the tube in a "candy stripe" pattern. If the generator wire harness anchor is missing, install the one provided in the modification kit (Item No. 5). See Figure 15.
4. Place the battery positive and negative cables side-by-side so the negative cable grounding eyelet is 140 mm (5-1/2 in) from the starter eyelet cover for vehicles equipped with an automatic transmission, or 120 mm (4-3/4 in) for vehicles equipped with a manual transmission, and is positioned in the same direction as the starter eyelet. Install the supplied tie strap (Item No. 7) 305 mm (12 in) from the starter eyelet cover to secure the two cables together. Wrap the two cables in black vinyl tape for 127 mm (5 in), starting at the negative cable eyelet.
See Figure 16.
5. Go to Battery Cable Harness Installation.
BATTERY CABLE HARNESS INSTALLATION
1. CAUTION: Make sure the battery cable harness is properly routed.
NOTE:
Be sure to use the supplied new anchoring clips when installing the harness into the vehicle.
Install the new anchoring clip (Item No. 6) into place near the top of the transmission, then position the new, or modified, battery cable harness into the vehicle. Do not secure the battery cable to the clip at this time.
2. Raise and support the vehicle.
3. Connect the generator electrical connector. Tighten the nut to 8 Nm (71 lb-in).
4. Connect the two (2) starter motor electrical connectors. Tighten the large nut to 12 Nm (106 lb-in) and the small nut to 6 Nm (53 lb-in).
5. Verify the torque on both front lower arm ball joint pinch bolts as follows. See Figure 9.
a) Using a suitable wrench with the T-50 Torx-head bit, hold the pinch bolt to keep it from turning.
b) Tighten the attaching nut to 50 Nm (37 lb-ft).
c) Repeat Steps A and B on the opposite side.
6. Lower the vehicle.
7. Connect the ground cable to the transmission bell housing. Tighten the bolt to 35 Nm (26 lb-ft). See Figure 12.
8. Secure the positive cable to the clip near the top of the transmission.
9. Connect the starter motor solenoid electrical connector.
10. Using one of the two (2) new anchoring tie straps (Item No. 8), secure the negative cable to the outside rear of the battery tray into the hole shown in Figure 17.
11. Using the remaining new anchoring tie straps (Item No. 8), secure the positive cable to the outer right side of the battery tray. Route the positive cable over the auxiliary power harness as shown in Figure 18.
12. Connect the battery positive cable and then connect the auxiliary power harness to the battery positive cable. Route the battery positive cable over the auxiliary power harness. Tighten the fasteners as follows:
a) Battery positive cable to 8 Nm (71 lb-in)
b) Auxiliary power harness to 5 Nm (44 lb-in)
13. Connect the battery negative cable and then connect the auxiliary ground wire to the battery negative cable. Tighten the fasteners as follows:
a) Battery negative cable to 8 Nm (71 lb-in)
b) Auxiliary ground wire to 5 Nm (44 lb-in)
14. Connect the body ground cable.
15. Install the air cleaner assembly as follows:
a) Position the air cleaner assembly into the vehicle.
b) Tighten the air cleaner tube at the throttle body.
c) Connect the PCV tube.
d) Connect the MAP sensor electrical connector.
16. Install the battery cover, close the hood and release the vehicle.