P 001_2013 Police Interceptor Wire Harness Pass Through COOL GRIND 501 001 2013

User Manual: COOL GRIND 501

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Page Count: 23

Originator: BBAS Page 1 of 23 Date Issued: 4/3/12
P-001 2013 Sedan & Utility Police Interceptor Wire Harness Pass-Through
Police
Modifier
Bulletin
2013 Sedan & Utility Police Interceptors Wire Harness Pass-Through
Models Affected
2013 Sedan & Utility Police Interceptor applications beginning Job #1 2013MY that require
addition of a wire harness to pass-through from the interior of the vehicle to the engine
compartment.
Purpose
This bulletin provides direction to route a wire harness from the interior of the vehicle to the
engine compartment.
Procedure
WARNING: Before beginning any service procedure in this section, REFER to Safety
Warnings. Failure to follow this instruction may result in serious personal injury.
Refer to suggested warnings at beginning of this publication and contact the Ford Truck
Body Builders Advisory Service as shown in the header of this bulletin.
Ensure Safety Warnings for all components/systems encountered or possibly affected
are reviewed. Following are suggestions:
Battery System Service Warnings
WARNING: Always disconnect the battery ground cable at the battery before
disconnecting the starter motor battery terminal lead. If a tool is shorted at the starter
motor battery terminal, the tool can quickly heat enough to cause a skin burn. Failure to
follow this instruction may result in serious personal injury.
WARNING: Before carrying out maintenance on the starting system, disconnect the
battery ground cable from the frame to completely isolate the starter from the dual frame-
mounted batteries. Failure to follow this instruction may result in serious personal injury.
Date: 3 April, 2012
SVE BULLETIN
SPECIAL VEHICLE ENGINEERING – BODY BUILDERS ADVISORY SERVICE
E-Mail via website: www.fleet.ford.com/truckbbas (click "Contact Us")
Toll-free: (877) 840-4338
P
-
001
Originator: BBAS Page 2 of 23 Date Issued: 4/3/12
P-001 2013 Sedan & Utility Police Interceptor Wire Harness Pass-Through
Wire Harness Pass-Through Dash Panel
Battery System Service Warnings
WARNING: Batteries contain sulfuric acid and produce explosive gases. Work in a
well-ventilated area. Do not allow the battery to come in contact with flames, sparks or
burning substances. Avoid contact with skin, eyes or clothing. Shield eyes when working
near the battery to protect against possible splashing of acid solution. In case of acid
contact with skin or eyes, flush immediately with water for a minimum of 15 minutes,
then get prompt medical attention. If acid is swallowed, call a physician immediately.
Failure to follow these instructions may result in serious personal injury.
WARNING: Always lift a plastic-cased battery with a battery carrier or with hands on
opposite corners. Excessive pressure on the battery end walls may cause acid to flow
through the vent caps, resulting in personal injury and/or damage to the vehicle or
battery.
WARNING: Do not get underneath the frame-mounted battery when disconnecting or
connecting the auxiliary battery safety straps. The battery is heavy and could fall. Failure
to follow this instruction may result in serious personal injury.
WARNING: Battery posts, terminals and related accessories contain lead and lead
components. Wash hands after handling. Failure to follow these instructions may result
in serious personal injury.
Body and Frame Service Warnings
WARNING: Always refer to MSDS when handling chemicals and wear protective
equipment as directed. Examples may include but are not limited to respirators and
chemically resistant gloves. Failure to follow these instructions may result in serious
personal injury.
WARNING: Always wear protective equipment including eye protection with side
shields, and a dust mask when sanding or grinding. Failure to follow these instructions
may result in serious personal injury.
WARNING: On vehicles equipped with Safety Canopy® options, prior to carrying out
any sectioning repairs near the roof line or sail panel areas of the vehicle, remove the
Safety Canopy® module and related components. Failure to comply may result in
accidental deployment or damage to the Safety Canopy® . Refer to Section 501-20
Supplemental Restraint System. Failure to follow these instructions may result in serious
injury to technician or vehicle occupant(s).
Originator: BBAS Page 3 of 23 Date Issued: 4/3/12
P-001 2013 Sedan & Utility Police Interceptor Wire Harness Pass-Through
Wire Harness Pass-Through Dash Panel
Body and Frame Service Warnings
WARNING: Do not cut or grind body side components within 50 mm (1.9685 in) of
restraint anchoring points. Welding within 50 mm (1.9685 in) of restraint anchoring points
may result in incorrect operation of restraint devices. For additional restraints anchoring
location information, refer to Section 501-20 Safety Belt System and Section 501-20
Supplemental Restraint System. Failure to follow these instructions may result in serious
injury to vehicle occupant(s).
WARNING: If a vehicle has been in a crash, inspect the RCM and the impact sensor (if
equipped) mounting areas for deformation. If damaged, restore the mounting areas to the
original production configuration. A new RCM and sensors must be installed whether or
not the air bags have deployed. Failure to follow these instructions may result in serious
personal injury or death in a crash.
Engine Cooling System Service Warnings
WARNING: Always allow the engine to cool before opening the cooling system. Do
not unscrew the coolant pressure relief cap when the engine is operating or the cooling
system is hot. The cooling system is under pressure; steam and hot liquid can come out
forcefully when the cap is loosened slightly. Failure to follow these instructions may
result in serious personal injury.
General Service Warnings
WARNING: Never get underneath a vehicle that is supported only by a jack. The jack
could unintentionally lower. Always support vehicle with floor stands. Failure to follow
these instructions may result in serious personal injury.
WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this
instruction may result in serious personal injury.
WARNING: Do not apply heat or flame to the shock absorber or strut tube. The shock
absorber and strut tube are gas pressurized and could explode if heated. Failure to
follow this instruction may result in serious personal injury.
WARNING: Carefully read cautionary information on product label. For EMERGENCY
MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft
products call: 1-800-959-3673. For additional information, consult the product MSDS, if
available. Failure to follow these instructions may result in serious personal injury.
Originator: BBAS Page 4 of 23 Date Issued: 4/3/12
P-001 2013 Sedan & Utility Police Interceptor Wire Harness Pass-Through
WARNING: Use tools, not fingers, to hold flagnuts. Flagnuts may slip or spin
unexpectedly when removing fasteners. Failure to follow this instruction may result in
injured fingers.
Wire Harness Pass-Through Dash Panel
General Service Warnings
WARNING: Keep solvents away from ignition sources. Solvents may be flammable
and can ignite or explode if not handled correctly. Failure to follow this instruction may
result in serious personal injury.
WARNING: Place a shop towel between the hands and the exterior mirror glass for
protection in case of glass breakage during mirror service. Failure to follow this
instruction may result in serious personal injury.
WARNING: Use only a type-D fire extinguisher to extinguish magnesium fires. Never
attempt to use a type-A, -B, -C extinguisher, or water, as these items are ineffective and
may accelerate a magnesium fire. Failure to follow these instructions may result in
serious personal injury.
WARNING: Only raise the vehicle when positioned on a hard, level surface.
Attempting to raise the vehicle on an uneven or soft surface may result in vehicle
slipping or falling from the jack or jackstand. Failure to follow this instruction may result
in serious personal injury.
WARNING: Identify the correct jacking points by locating the triangle stamped into
the uni-body sheet metal or vehicle frame. Raising a vehicle in any other location may
result in vehicle shifting or falling. Failure to follow this instruction may result in serious
personal injury.
WARNING: Install only FCC-approved radio transmitting equipment. See your
authorized radio dealer for the correct transmitter. Use of incorrect transmitting
equipment may cause the vehicle to malfunction or stall, resulting in loss of power brake
and power steering assist. Failure to follow these instructions may result in serious
personal injury to vehicle occupant(s).
WARNING: Vehicle may have multiple drive wheels. Do not use engine to power the
driveline unless all drive wheels are elevated off the ground. Drive wheels in contact with
ground could cause unexpected vehicle movement. Failure to follow this instruction may
result in serious personal injury.
WARNING: Do not operate the engine with the hood open until the fan blade has been
examined for possible cracks and separation. A damaged fan can separate during
operation. Failure to follow this instruction may result in serious personal injury.
Originator: BBAS Page 5 of 23 Date Issued: 4/3/12
P-001 2013 Sedan & Utility Police Interceptor Wire Harness Pass-Through
WARNING: Do not stand in line with or near the engine cooling fan blade when
revving the engine. A damaged fan can separate during operation. Failure to follow this
instruction may result in serious personal injury.
Wire Harness Pass-Through Dash Panel
General Service Warnings
WARNING: When jacking or lifting the vehicle, block all wheels remaining on the
ground. Set the parking brake if the rear wheels will remain on the ground. These actions
help prevent unintended vehicle movement. Failure to follow these instructions may
result in serious personal injury.
WARNING: Turn OFF the ignition switch for a minimum of 5 minutes before removing
high-voltage cables. High-voltage cables and wiring are orange in color. The nominal
HVTB is 330 V DC. Failure to follow these instructions may result in serious personal
injury or death.
WARNING: Vehicles with engine auto start-stop technology may start automatically
with the ignition on. Make sure the ignition is off when servicing or working in close
proximity to rotating engine parts. Failure to follow this instruction could result in
serious personal injury.
WARNING: Wear high-voltage insulated safety gloves and a face shield when working
with high-voltage batteries or cables. The high-voltage insulated safety gloves should be
of the appropriate safety and protection rating. Inspect the gloves before use and always
wear them with the leather outer glove. Any hole in the rubber insulating glove is a
potential entry point for high-voltage. Failure to follow these instructions may result in
serious personal injury or death.
WARNING: Depower the HVTB before carrying out any removal or installation
procedures affecting the high-voltage battery system. Failure to follow this instruction
may result in serious personal injury or death.
WARNING: Secure the torque converter in the transmission during removal or
installation. The torque converter is heavy and may result in injury if it falls out of the
transmission. Failure to follow this instruction may result in serious personal injury.
WARNING: When using compressed air, never let air pressure exceed 172.4 kPa (25
psi) and always wear safety glasses. Compressed air may cause foreign material or parts
to become airborne. Failure to follow this instruction may result in serious personal
injury.
Originator: BBAS Page 6 of 23 Date Issued: 4/3/12
P-001 2013 Sedan & Utility Police Interceptor Wire Harness Pass-Through
Wire Harness Pass-Through Dash Panel
General Service Warnings (continued)
WARNING: Wear protective gloves when handling components or parts that have
pointed or sharp edges. Failure to follow this instruction may result in serious personal
injury.
WARNING: Turn off (disable) the power running boards (if equipped) before jacking,
lifting or placing any object under the vehicle.Never place your hand between the power
running board and the vehicle. Extended power running boards will retract when doors
are closed. Failure to follow these instructions may result in serious personal injury.
WARNING: Disconnect the window regulator motor connector before working inside
the vehicle doors. Service actions inside the door (such as door latch, handle or lock
cylinder service) or operating the RKE fob may activate the windows on vehicles
equipped with global open/close. Serious injury to hands or arms may occur if a window
motor is activated during service. Failure to follow these instructions may result in
serious personal injury.
Safety Restraints Service Warnings
WARNING: Never disassemble or tamper with seat belt deployable components, including
pretensioners, load limiters and inflators. Never back probe deployable device electrical connectors.
Tampering or back probing may cause an accidental deployment and result in personal injury or
death.
WARNING: Never probe the electrical connectors on air bag, Safety Canopy® or side air
curtain modules. Failure to follow this instruction may result in the accidental deployment of these
modules, which increases the risk of serious personal injury or death.
WARNING: Never put any type of fastener or tie strap around any part of a Safety Canopy®
module, side air curtain module or interior trim panel. This will prevent the Safety Canopy® or side
air curtain module from deploying correctly. Failure to follow this instruction may increase the risk
of serious personal injury or death in a crash.
WARNING: Always tighten the fasteners of the RCM and impact sensor (if equipped) to the
specified torque. Failure to do so may result in incorrect restraint system operation, which increases
the risk of personal injury or death in a crash.
WARNING: Always carry or place a live Safety Canopy® , or side air curtain module, with the
module and tear seam pointed away from your body. Failure to follow this instruction may result in
serious personal injury or death in the event of an accidental deployment.
Originator: BBAS Page 7 of 23 Date Issued: 4/3/12
P-001 2013 Sedan & Utility Police Interceptor Wire Harness Pass-Through
Safety Restraints Service Warnings (continued)
WARNING: Always deplete the backup power supply before repairing or installing any new
front or side air bag SRS component and before servicing, removing, installing, adjusting or
striking components near the front or side impact sensors or the RCM. Nearby components include
doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the
Description and Operation portion of Section 501-20 for location of the RCM and impact sensor(s).
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1
minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow
these instructions may result in serious personal injury or death in the event of an accidental
deployment.
WARNING: Always carry or place a live air bag module with the air bag and deployment
door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with
the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result
in serious personal injury in the event of an accidental deployment.
Safety Restraints Service Warnings (continued)
WARNING: Do not paint any air bag module trim covers or deployment doors. Paint may
cause the air bag to deploy incorrectly. Failure to follow this instruction may increase the risk of
serious personal injury or death in a crash.
Prior to beginning work, ensure you inspect the area in which you will be working for any
components and/or systems that will be encountered and determine the safety
procedures required to work in that and adjacent areas.
Verify that the most recent safety and removal and installation procedures are identified
and implemented.
Originator: BBAS Page 8 of 23 Date Issued: 4/3/12
P-001 2013 Sedan & Utility Police Interceptor Wire Harness Pass-Through
Wire Harness Pass-Through Dash Panel
Sedan Interceptor
Remove glove compartment from passenger side instrument panel
1. Open glove box
2. Disconnect glove box damper (item 4)
3. Depress tabs on both sides of glove box and rotate glove compartment assembly
downward
4. Open the glove compartment door, disengage the glove compartment down stops
and remove the glove compartment door.
Originator: BBAS Page 9 of 23 Date Issued: 4/3/12
P-001 2013 Sedan & Utility Police Interceptor Wire Harness Pass-Through
Wire Harness Pass-Through Dash Panel
Sedan Interceptor
Remove interior trim panels as necessary for access
View with glove compartment assembly removed
Locate flooring retention points and pull back flooring on top of wheel well in passenger
side area of front row seat.
Locate grommet (22 mm / 0.866 in. diameter) on top of wheel well (see photo above).
Wire should be covered with a material that meets worst case environmental requires
experienced along its routing (i.e., convolute. etc.) minimum of 125oC.
Remove and cut grommet to allow wire harness to pass through.
Grommet
Originator: BBAS Page 10 of 23 Date Issued: 4/3/12
P-001 2013 Sedan & Utility Police Interceptor Wire Harness Pass-Through
Wire Harness Pass-Through Dash Panel
Sedan Interceptor
Note:
If a larger hole is required for wire harness pass-thru
• Remove grommet
• Enlarge existing grommet hole to desired diameter
• De-bur edges of enlarged hole to prevent chafing/cutting damage to wire
Harness
• Obtain new grommet to fit size of wire pass-through hole
• Cut open grommet just enough to allow harness to pass through
• Use sealant that meets performance characteristics for environment that
the vehicle will experience
Pass wire through grommet and re-install grommet.
Retain wiring passing behind glove compartment towards bottom of center stack so that
it will not interfere with opening/closing of glove compartment. Determine and
implement retention points and locations to secure wiring/harness.
Originator: BBAS Page 11 of 23 Date Issued: 4/3/12
P-001 2013 Sedan & Utility Police Interceptor Wire Harness Pass-Through
Wire Harness Pass-Through Dash Panel
Sedan Interceptor
Route wiring through grommet (see photo below)
The wire passing downward through the grommet, will enter into the passenger side
wheel well.
Wire passing
through grommet
Originator: BBAS Page 12 of 23 Date Issued: 4/3/12
P-001 2013 Sedan & Utility Police Interceptor Wire Harness Pass-Through
Wire Harness Pass-Through Dash Panel
Sedan Interceptor
Turn the steering wheel to simulate a full left hand turn and provide access to passenger
side wheel well area.
From outside the passenger side of front wheel area, remove fasteners retaining inner
wheel well liner to provide view of wire harness entering wheel well and opening to
engine compartment.
Wire with convolute enter wheel well and routed toward engine compartment opening.
(see photo below)
Add wire harness retention fastener/clamp at entry point to wheel well and along routing
pathway to ensure proper retention to avoid contact with moving components/systems
and protection from heat.
Use drip loop after entry into wheel well area.
Wire with
convolute passing
from wheel well
into engine
Originator: BBAS Page 13 of 23 Date Issued: 4/3/12
P-001 2013 Sedan & Utility Police Interceptor Wire Harness Pass-Through
Wire Harness Pass-Through Dash Panel
Sedan Interceptor
View of wire with convolute entering engine compartment near passenger side shock
tower and engine mount.
Wire harness
enterin engine
comparment
Originator: BBAS Page 14 of 23 Date Issued: 4/3/12
P-001 2013 Sedan & Utility Police Interceptor Wire Harness Pass-Through
Wire Harness Pass-Through Dash Panel
Sedan Interceptor
Ensure wire harness is retained without slack and in a position that will not have any
contact with shock absorber travel and/or engine roll.
View of fastener location inside engine compartment.
Follow OEM wiring to desired location in upper engine compartment to ensure no
contact with moving components.
Do not route wire harness to lower engine compartment near exhaust manifolds and/or
turbochargers.
Replace flooring and fasteners to OEM installed position.
Replace trim panels to OEM install position.
Replace glove box in reverse order of removal process.
Retention point
upon entering
engine
compartment
Originator: BBAS Page 15 of 23 Date Issued: 4/3/12
P-001 2013 Sedan & Utility Police Interceptor Wire Harness Pass-Through
Wire Harness Pass-Through Dash Panel
Utility Interceptor
Utility Interceptor
Remove glove compartment from passenger side instrument panel.
WARNING: Before beginning any service procedure in this section, REFER to Safety
Warnings. Failure to follow this instruction may result in serious personal injury.
Refer to suggested warnings at beginning of this publication and contact the Ford Truck
Body Builders Advisory Service as shown in the header of this bulletin.
Failure to follow this instruction may result in serious personal injury.
Removal
1. Remove the RH instrument panel side trim panel.
• Pull outward to release the 4 retaining clips.
Originator: BBAS Page 16 of 23 Date Issued: 4/3/12
P-001 2013 Sedan & Utility Police Interceptor Wire Harness Pass-Through
Wire Harness Pass-Through Dash Panel
Utility Interceptor
2. Detach the glove compartment dampener string from the glove compartment bin.
Originator: BBAS Page 17 of 23 Date Issued: 4/3/12
P-001 2013 Sedan & Utility Police Interceptor Wire Harness Pass-Through
Wire Harness Pass-Through Dash Panel
Utility Interceptor
3. If equipped with a passenger side knee bolster air bag disconnect the battery. REFER to
Battery Disconnect.
4. If equipped, remove the passenger side knee bolster air bag.
a. Disconnect the electrical connector.
• Tighten to 10 Nm (89 lb-in).
Originator: BBAS Page 18 of 23 Date Issued: 4/3/12
P-001 2013 Sedan & Utility Police Interceptor Wire Harness Pass-Through
Wire Harness Pass-Through Dash Panel
Utility Interceptor
5. NOTE:
LH side shown, RH side similar.
Remove the 2 glove compartment hinge pins.
6. Open the glove compartment door, disengage the glove compartment down stops and
remove the glove compartment door.
Originator: BBAS Page 19 of 23 Date Issued: 4/3/12
P-001 2013 Sedan & Utility Police Interceptor Wire Harness Pass-Through
Wire Harness Pass-Through Dash Panel
Utility Interceptor
Wire Harness Pass-Through
Remove interior trim panels as necessary for access
Photo with glove compartment assembly and knee air bag removed
Grommet
Originator: BBAS Page 20 of 23 Date Issued: 4/3/12
P-001 2013 Sedan & Utility Police Interceptor Wire Harness Pass-Through
Wire Harness Pass-Through Dash Panel
Utility Interceptor
Locate flooring retention points and pull back flooring on top of wheel well in passenger
side of front row seat.
Locate grommet (22 mm / 0.866 in. diameter) on top of wheel well (see photo above).
Remove and cut grommet to allow wire harness to pass through.
Pass wire through grommet and re-install grommet.
Wire should be covered with a material that meets worst case environmental requires
experienced along its routing (i.e., convolute. etc.) minimum of 125oC.
Retain wiring passing behind glove compartment towards bottom of center stack so that
it will not interfere with opening/closing of glove compartment. Determine and
implement retention points and locations to secure wiring/harness.
Route wiring through grommet (see photo below)
The wire passing downward through the grommet, will enter into the passenger side
wheel well.
Wire passing
through grommet
Originator: BBAS Page 21 of 23 Date Issued: 4/3/12
P-001 2013 Sedan & Utility Police Interceptor Wire Harness Pass-Through
Wire Harness Pass-Through Dash Panel
Utility Interceptor
Turn the steering wheel to simulate a full left hand turn and provide access to passenger
side wheel well area.
From outside the passenger side of front wheel area, remove fasteners retaining inner
wheel well liner to provide view of wire harness entering wheel well and opening to
engine compartment.
Wire with convolute enter wheel well and routed toward engine compartment opening.
(see photo below)
Add wire harness retention fastener/clamp at entry point to wheel well and along routing
pathway to ensure proper retention to avoid contact with moving components/systems
and protection from heat.
Use drip loop after entry into wheel well area.
Wire with
convolute passing
from wheel well
into engine
Originator: BBAS Page 22 of 23 Date Issued: 4/3/12
P-001 2013 Sedan & Utility Police Interceptor Wire Harness Pass-Through
Wire Harness Pass-Through Dash Panel
Utility Interceptor
View of wire with convolute entering engine compartment near passenger side shock
tower and engine mount.
Wire harness
enterin engine
comparment
Originator: BBAS Page 23 of 23 Date Issued: 4/3/12
P-001 2013 Sedan & Utility Police Interceptor Wire Harness Pass-Through
Wire Harness Pass-Through Dash Panel
Utility Interceptor
Ensure wire harness is retained without slack and in a position that will not have any
contact with shock absorber travel and/or engine roll.
View of fastener location inside engine compartment.
Follow OEM wiring to desired location in upper engine compartment to ensure no
contact with moving components.
Do not route wire harness to lower engine compartment near exhaust manifolds and/or
turbochargers.
Replace flooring and fasteners to OEM installed position.
Replace trim panels to OEM install position.
Replace glove box in reverse order of removal process.
If you have any questions, please contact the Ford Truck Body Builders Advisory Service
as shown in the header of this bulletin.
Retention point
upon entering
engine
compartment

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