Ford Fusion: General Information / Wire Terminal Inspection and Removal. General Procedures
Disconnect
-
WARNING:
Before beginning any service procedure in this
section, refer to Health and Safety Precautions in section 100-00
General Information. Failure to follow this instruction may result in
serious personal injury.
Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
NOTE:
To avoid wiring pin (terminal) damage, Rotunda Flex Probes
NUD105-R025D or Terminal Probe Kit 29-011A must be used to connect test
equipment or jumper wires to pins (terminals).
-
Male to female pin (terminal) fit is critical for correct connection and durability.
-
Pin (terminal) fit may be checked by using the
mating pin (terminal) to test for normal separation force (a damaged pin
or terminal will have very low separation force from the mating pin or
terminal).
-
Correctly checking the separation force of small
pins (terminals) may require removal of the connector terminal
guide/retainer if it adds drag to the pin (terminal) insertion or
removal.
-
For more detail on the replacement of damaged connectors or pins (terminals) refer to the video below.
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Click here to view a video version of this procedure.
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NOTE:
The connector hard-shell information, which is
measured in millimeters is the distance from the front face of the
connector to the engagement point on the terminal release tang. Mark the
listed distance on the terminal removal tool prior to removing the
terminal.
NOTE:
The dimensions of the connector hard-shell and the
connector terminals release tang are listed above the corresponding
graphics.
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Audio Front Control Module (ACM), Body Control Module (BCM) and Instrument Panel Cluster (IPC) Electrical Connector
Callout
|
Connector
|
1
|
External terminal release tang
|
2
|
Electrical connector locking tab
|
-
Audio Front Control Module (ACM), Front Controls Interface
Module (FCIM), Gateway Module A (GWM), and Heating, Ventilation and Air
Conditioning (HVAC) Control Module Electrical Connector
Callout
|
Connector
|
1
|
Distance to release tang -
0.2953
in (
7.5
mm) (inner terminal) -
0.4646
in (
11.8
mm) (outer terminal)
|
2
|
Terminal width size -
0.0244
in (
.62
mm) (inner terminal) -
0.1102
in (
2.8
mm) (outer terminal)
|
-
Body Control Module (BCM) Electrical Connector
Callout
|
Connector
|
1
|
Terminal width size -
0.1102
in (
2.8
mm) (inner terminal) -
0.2480
in (
6.3
mm) (outer terminal)
|
2
|
Distance to release tang -
0.1260
in (
3.2
mm) (inner terminal) -
0.1575
in (
4
mm) (outer terminal)
|
3
|
Terminal width size -
0.0591
in (
1.5
mm)
|
4
|
Distance to release tang -
0.3780
in (
9.6
mm) (lower terminal)
|
-
Body Control Module (BCM) Electrical Connector
Callout
|
Connector
|
1
|
Terminal width size -
0.0591
in (
1.5
mm) (inner terminal) -
0.1102
in (
2.8
mm) (outer terminal)
|
2
|
Distance to release tang -
0.3780
in (
9.6
mm) (inner terminal)
|
3
|
Distance to release tang -
0.1575
in (
4
mm)
|
4
|
Distance to release tang -
0.1575
in (
4
mm)
|
5
|
Terminal width size -
0.2480
in (
6.3
mm)
|
-
Body Harness In-line Electrical Connector
Callout
|
Connector
|
1
|
Distance to release tang -
0.3346
in (
8.5
mm)
|
2
|
Terminal width size -
0.1102
in (
2.8
mm)
|
3
|
Terminal width size -
0.0591
in (
1.5
mm)
|
4
|
Distance to release tang -
0.3858
in (
9.8
mm) (inner)
|
-
Body Harness In-line Electrical Connector
Callout
|
Connector
|
1
|
Distance to release tang -
0.3543
in (
9
mm)
|
2
|
Terminal width size -
0.0591
in (
1.5
mm) (inner terminal) -
0.1102
in (
2.8
mm) (outer terminal)
|
3
|
Terminal width size -
0.2480
in (
6.3
mm)
|
4
|
Distance to release tang -
0.3543
in (
9
mm)
|
-
Body Harness In-line and Seat Harness Electrical Connector
Callout
|
Connector
|
1
|
Distance to release tang -
0.4331
in (
11
mm)
|
2
|
Terminal width size -
0.0591
in (
1.5
mm)
|
3
|
Terminal width size -
0.0591
in (
1.5
mm)
|
4
|
Distance to release tang -
0.4331
in (
11
mm)
|
-
Body Harness In-line and Seat Module Electrical Connector
Callout
|
Connector
|
1
|
Terminal width size -
0.0591
in (
1.5
mm)
|
2
|
Distance to release tang -
0.3937
in (
10
mm)
|
Master DTC Index
ABS Module
REFER to: Anti-Lock Brake System (ABS) and Stability Control (206-09 Anti-Lock Brake System (ABS) and Stability Control, Diagnosis and Testing)...
Other information:
Removal
NOTE:
Removal steps in this procedure may contain installation details.
With the vehicle in NEUTRAL, position it on a hoist.
Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
NOTE:
RH height sensor assembly shown, LH similar.
Disconnect the front suspension height sensor electrical connector.
..
Note: Do not exceed the trailer
weight for your vehicle
configuration listed in the chart
below.
Note: Make sure to take into
consideration trailer frontal area.
Do not exceed 12 feet2 (1.11 meters2)
for 1.5L GTDI and 2.5L TiVCT or 20
feet2 (1.86 meters2) for 2.0L GTDI.
Note: For high altitude operation,
reduce the gross combined weight
by 2% per 1,000 ft (300 m)
starting at the 1,000 ft..