Interceptor 2007 rev C

Interceptor 2007 rev C
2007 POLICE
PREP PACKAGES
OWNER’S MANUAL
•
(65A)
BASE POLICE PREP
•
(68P)
COMPLETE POLICE
PREP PACKAGE
(Includes 65A components)
•
(65W)
VISIBILITY PACKAGE
(Includes 68P)
•
(65N)
BASE VISIBILTY PACKAGE
(Includes 65A )
•
(65U)
READY FOR THE ROAD
PACKAGE (See separate manual)
Review ow ner’s manual prior to package use.
Revision: A
Part Number: 144417
TABLE OF CONTENTS
Option Content 65A and 65N Packages……………………………………………………
Option Content 68P and 65W Packages…………………….……………………………..
Option Content 65U Package **NEW**…………………………………………………….
About Crown North America…………………………………..……………………………..
Police Prep and Visibility Packages…………………………..…………………………….
Base Police Prep Package (65A) …………………………..………………………….….
Strobe Bulbs……………………………………..………………………………...
Console Wiring…………………………………………………………………….
Engine Compartment Wiring…………………………………..…………………
Trunk Wiring………………………..……………………………………………...
Headlight Flasher (Wig-Wag)……………………………………………………
Complete Police Prep Package …………………………..………………………...…….
Console Mounting Platform (65N), (68P), and (65U)……….………………...
Center Wiring Conduit………………………………………..…………………..
Hidden Manual Rear Door Lock Plungers (68P)…………...………………….
Trunk Air Circulation Fan (68P), and (65U)………………...………………….
Permanent Rubber Tie-Down Strap (68P), and (65U)…….………………….
Dual Trunk Storage Boxes (68P), and (65U)……………….………………….
Rear Communications Service Tray (68P), and (65U)……..………………...
Visibility Packages …………………………………………..…………………………….
Strobe Power Unit ………………………………………………………………..
Flashing Rear Deck LED Lights (65W), (65N), and (65U)…………………...
Switch Control Panel (65N), and (65W)…………………….………………….
Schematics………………………………………………….………………….……….……
Key to Wire Color Codes……………………………………...…………………
Ford Engine Compartment Fuse Block……………………..………………….
Power Connection Placement…………………………………………………...
Power Circuits Placement (65A), and (68P)………………..………………….
Power Circuits Placement (65N), (65W) and (65W)……….………………….
Spare Circuit Placement……………………………………...………………….
Ground Circuits Placement…………………………………..…………………..
Strobe Power Supply Assembly (65N), (65W) and (65W)……………………
Console Pin outs (65W) and (65U)………………..…………………………….
Alternating Headlight Flasher Circuit………………………...………………….
Horn/Siren Relay Amplifier Circuit (Amplifier at Console)….…………………
Horn/Siren Relay Amplifier Circuit (Amplifier in Trunk)……..………………...
Glove Box Power Distribution Center……………………….…………………..
Trunk Power Distribution Center…………………..…………………………….
Lighting Relay Center (8-Relay Panel) (65N), (65W), and 65U)……………..
Removal of Police Prep Packages………………………………………………………….
General Guidelines……….…………..……………………………………………………….
Technical Service Numbers…………………………………..……………………………...
3
4
5
6
7
8
8
9
10
11
12
13
13
14
15
16
17
18
19
21
21
22
23
24
24
25
26
27
30
32
34
36
38
39
40
41
42
43
44
45
46
52
SPECIAL NOTE:
Although the total current capacity of the harness on the following pages
states that the harness is capable of handling over 350 AMPS of fused
power, it is recommended that total vehicle loads to the 2007 Crown Victoria
Police Interceptor be limited to 110 AMPS, at idle, to support alternator/
battery capacity. Electrical loads above this level may degrade battery/
starting capacity.
2
OPTION CONTENT 65A and 65N Packages
2007 Ford Police Interceptor Equipment Packages
Base
Package
(65A)
3
OPTION CONTENT 68P and 65W Packages
2007 Ford Police Interceptor Equipment Packages
4
OPTION CONTENT 65U Package
2007 Ford Police Interceptor Equipment Packages
5
ABOUT CROWN NORTH AMERICA
Crown has been in the business of manufacturing and installing
commercial vehicle products for nearly 30 years. Crown currently
has two plants in Canada and five plants within the United States,
which together have delivered over 100,000 vehicles to commercial
service providers.
Crown has been a Tier 1 supplier to Ford Motor Company since
1968. A significant element of Crown’s success is due to the ability
to perform quick, high quality vehicle outfitting. This allows the vehicles to be entered into service use in a timely manner. High quality is
supported by QS9000 standards. Manufacturing and assembling
process controls assure that every Crown up-fitted vehicle meets and
exceeds customer expectations.
6
POLICE PREP AND VISIBILITY PACKAGES
The Ready for the Road Package (65U), Base Police Prep Package
(65A), Base Visibility Package (65N), Complete Police Prep Package
(68P), and Visibility Package (65W), are fully compliant with the United
States Federal Motor Vehicle and Canadian Motor Vehicle Safety
Standards.
The Ready for the Road Package (65U), Base Police Prep Package
(65A), Base Visibility Package (65N), Complete Police Prep Package
(68P), and Visibility Package (65W) have undergone many tests as
individual components and as completed assemblies. The components
have been subjected to temperatures ranging from minus 40 to over 175
degrees Fahrenheit. All moving components, such as latches, tray
slides, and switches have been put through tens of thousands of cycles.
All packages, including the new Ready for the Road Package have been
installed within a vehicle and subjected to an accelerated durability test
that simulates 300,000 miles of use over various terrain and environmental conditions.
The electrical systems must meet the most stringent requirements. All
circuits have been load tested and certified. All power circuits have
ground wires provided, which are grounded to Ford approved chassis
grounds. All terminations have been power crimped.
Use of the police specific wiring greatly reduces the risk of vehicle
electrical system damage and can greatly increase the durability of other
vehicle electrical components. The Ford warranty for the original electrical components is preserved and available for full-term warranty coverage, except where noted for siren speaker and strobe bulbs.
7
BASE POLICE PREP PACKAGE (65A)
The Police Prep Packages are designed to promote speedy preparation of police vehicles
for “in-service use”. The wiring harness in the Police Prep Packages supplies a police specific electrical system that is designed to provide easy access for fused power and ground
circuits at the glove box, console area and trunk.
Please note: The Base Police Package (65A) and Complete Prep Package (68P)do
not come equipped with a strobe power supply. The Base Police Package and Complete Prep Package come equipped with six (6) shielded strobe cables, four (4) corner strobes and is ready for the installation of a customer supplied strobe power supply. The Base Visibility Package (65N), Base Visibility Option (65W) or Ready for the
Road Package (65W) come equipped with a six (6) head Strobe power supply with
front shut down capability.
8
BASE POLICE PREP PACKAGE (65A)
GLOVE BOX POWER DISTRIBUTION CENTER
Power sources - (color coded) See page 42.
Grounds - (Black) See pages 34-35
CONSOLE AREA
Extra wires to trunk & engine compartment. pages 32 and 33.
Headlight activation (page 39), Speed Signal and Battery Saver Circuit.
Three additional 50Amp Battery and Ground circuits, pages 28 and 29
Horn ring transfer circuit, and 2 spare circuits to Radiator, pages 40 and 41
9
BASE POLICE PREP PACKAGE (65A)
FORD ENGINE COMPARTMENT FUSE BLOCK.
See page 25.
WIRES FOR SIREN AT RADIATOR,
ROUTED TO CONSOLE AND TRUNK—
(color coded) see pages 40 and 41.
Grill Strobe Connectors
SPARE WIRES LOCATED ON PASSENGER SIDE WHEEL
HOUSE, ROUTED TO CONSOLE AREA (color coded) see page 39.
10
BASE POLICE PREP PACKAGE (65A)
TRUNK WIRING IDENTIFICATION
Strobe Power
Supply Leads
(For use with
65W, 65N and
65U packages)
See page 36
Red Connectors—Strobes
cables to tail
lights, front
marker lights
and grill lights
See page 36.
Trunk
Power Distribution
Center - see
page 43
Ground wires
for Power Distribution Center. - (color
coded) See
pages 34 and
35.
White Conn.
YE/LG wires
to horn ring see pages
40 and 41.
Spare wires
(color coded)
· 2 to radiator
· 4 to console
see pages 32
and 33.
50 Amp
communications circuit
- see pages
28 and 29
Power wires
from trunk
Power
distribution
Center
See page 43
11
BASE POLICE PREP PACKAGE (65A)
Alternating Headlight Flasher
An alternating headlight flasher module is included with each package
which allows for the headlight high beams alternate. To activate the
headlight flasher in the Base Police Package (65A) and the Complete
Prep Package (68P), use the LG/YE circuit available at the console. This
wire should be connected to a B+ switch box. The Base Visibility Packages (65N) , Visibility Option (65W) and Ready for the Road (65U),
supplies a switch control panel at the console mounting platform that
allows for the control of the headlight flasher and other Visibility Package components at the fingertips of the driver.
Caution: Alternating headlight flashers must be used only on high
beam to meet FMVSS and CMVSS standards. Please see the Ford
Police Modifiers guide when connecting any flasher module to rear
lights of the vehicle. Some jurisdiction have requirements that state
that the headlight flasher must not operate with headlights on. The
Prep Package harness system has a provision built into it to allow for
this function. See schematic on page 39.
12
COMPLETE POLICE PREP PACKAGE
Console Mounting Platform
Available with (65N), (68P) and (65U)
The console mounting platform is designed to firmly support police
consoles and equipment. The console mounting platform is made of
heavy gauge steel and aluminum and is predrilled and tapped with
¼-20 threaded holes for easy mounting. Components should be
torqued to 11.5 Nm.. Slots are provided for routing of electrical wiring and cables.
13
COMPLETE POLICE PREP PACKAGE (68P)
Center Wiring Conduit
The center wiring conduit allows for the routing of wires from the
console to the rear communications service tray with only the removal
of the rear seat cushion.
Note: The conduit system depicted here will be modified for vehicles
equipped with the Fire Suppression System.
For these units, both the seat cushion and seat back will have to be
removed. The nylon conduit will need to be opened, have the wires
inserted and then be closed.
14
COMPLETE POLICE PREP PACKAGE
Hidden Manual Rear Door Lock Plunger (68P) & (65U)
The Complete Police Prep Package (68P) reworks the rear doors of the
vehicle so that the lock stem has been removed from the standard
position and relocated to the front edge of the rear doors. This ensures
that only an officer has access to the plunger of the lock.
The power lock and power window connectors are taped to the
harness within the rear doors. Disconnecting the white connectors in
the door panel has disabled automated locks. They may be reconnected if normal power operation is desired.
With option 68P and 65U , the rear windows have also been reworked
to be inoperative from either the front or rear switches. If it is desirable to have the rear windows operational from the front switches,
dealers should order FORD option 948
15
COMPLETE POLICE PREP PACKAGE
Trunk Air Circulation Fan (68P) and (65U)
The trunk air circulation fan pulls air from the passenger compartment
and exhausts through the trunk, which in turn helps to stabilize the
environment and climate of the trunk for electrical, mechanical, and
chemical equipment that have been situated in the trunk. The fan has
the added benefit of positive airflow through the trunk area, which
helps to minimize contamination of dust and water in the trunk
compartment when the lid is closed.
The trunk fan is grounded to the vehicle body to support EMC compliance with electronic equipment.
16
COMPLETE POLICE PREP PACKAGE
Permanent Rubber Tie-Down Strap (68P) and (65U)
The Complete Police Prep Package (68P) provides a permanent rubber
tie-down strap for securing the trunk lid when transporting large,
irregular items.
Note: When not in use, secure the tie-down strap to the inside of the
trunk lid. Prior to vehicle operation, make sure that the tied down
strap is secured.
17
COMPLETE POLICE PREP PACKAGE (68P)
Dual Trunk Storage Boxes
Caution: Be sure the jack is secured to the storage box to prevent
damage to any items within the trunk.
The two storage boxes are designed to house small equipment that
should not be loose in the trunk. The boxes have clear polycarbonate
covers for easy identification of their contents. The clear cover
should be cleaned with non-abrasive cleaners.
Caution: Be sure that both storage boxes are fully latched prior to
vehicle operation.
18
COMPLETE POLICE PREP PACKAGE (68P) and (65U)
Rear Communications Service Tray
The rear communications service tray is mounted on heavy-duty slides to
provide easy access for equipment mounting, equipment servicing, and
the spare tire. With the tray in its closed position it will help provide
protection from any loose items and elements of the weather.
Caution: Follow instructions for tire mounting to ensure proper retention of spare tire. This can prevent damage to the tray and the vehicle
trunk interior.
REAR COMMUNICATIONS SERVICE TRAY
SHOWN WITH SPARE TIRE MOUNTED
19
COMPLETE POLICE PREP PACKAGE (68P) and (65U)
Rear Communications Service Tray Latching
Caution: Be sure that both side latches are secured and in second
locked position prior to vehicle operation. Improper latching may damage components and vehicle.
20
OPENING THE LATCH
OPEN LATCH
POSITION 1 LATCH CLOSURE
POSITION 2 LATCH CLOSED
VISIBILITY PACKAGES (65W), (65N), and (65U)
Strobe Power Unit
Where the Complete Police Prep Package provides a platform for departmental specific add-ons, the Visibility Packages are a collection of some
of the most popular emergency lighting add-ons packaged together.
The Visibility Packages includes a strobe power unit which is required to
flash the four strobe bulbs in the vehicle as well as two capped cables
located in the grill/radiator area. The supplied power supply has front
shut down capability. There are control wires in the trunk for connection
to a B+ switching device.
Note: The Visibility Package provides secondary lighting as defined by
SAE Standards J1318 and J845. The four-corner strobe system is calibrated to maintain compliance to FMVSS-CMVSS 108, governing tail,
stop, turn, and marker light intent and operation. The end user should
select primary lighting as defined by SAE J1318 and J2495 to ensure
proper identification of the emergency vehicle.
***See Page 36 Prior to Servicing***
21
VISIBILITY PACKAGE (65W), (65N), and (65U)
Flashing Rear Deck LED Lights
The Base Visibility Package (65N) and Visibility Option (65W) also
supplies the user with two flashing high intensity LED lights mounted
to the rear parcel shelf. These flashing lights come standard as one
blue high intensity LED on the passenger side and one red high intensity LED on the driver side of the high-mount third brake light.
Note: A Switch Control Panel is provided to control operation of the
flashing rear deck LED lights. This switch panel triggers relays
through a ground activation circuit which is not a power source to the
LED lights.
22
VISIBILITY PACKAGE (65W) & (65N)
Switch Control Panel
The functions of the 4-Position Slide Switch on the Switch Control Panel
are defined as follows:
Position 1:
Position 2:
Position 3:
Position 4:
FOUR Corner Strobes, Alternating High Beams plus Lighting
Relay Center function 1*
TWO Rear Corner Strobes, (front shut down) Flashing
High Intensity LED plus Lighting Relay Center function 2*
TWO Rear Corner Strobes, (front shut down) Flashing
High Intensity LED plus Lighting Relay Center function 3*
FOUR Corner Strobes, Alternating High Beams, Flashing High
Intensity LED plus Lighting Relay Center function 4*
The four red switches next to the slide switch are provided for control of
light bar take-downs or other accessories not included in the Visibility
Packages, (customer installed).
*For further light bar information, see page 44
23
SCHEMATICS
This SCHEMATICS section serves to illustrate the location of the various
fuses, wires, and relays.
KEY TO WIRE COLOR CODES
BL – blue
BK – black
BN – brown
DB – dark blue
DG – dark green
GN – green
GY – gray
LB – light blue
LG – light green
Note:
NA – natural
OR – orange
PK – pink
PU – purple
RD – red
SR – silver
TN – tan
WH – white
YE – yellow
On dual color notation, the first color is for the wire and the
second color is for the tracer (stripe).
Format: Main wire color / Tracer (stripe) color.
In-line fuse (10 AMP) located beneath glove box provided to
protect ignition signal circuit.
24
SCHEMATICS
Ford Engine Compartment Fuse Block
Fuse
Wire
Color
Function 1
Function 2
Load
111
TN/YE
Radio
(Blunt cut at console)
Radio
(Blunt cut in trunk)
50 Amp
112
PK
Ignition Power
Siren Amplifier (65U)
40 Amp
113
RD/YE
Console
Trunk Pigtail (65A & 68P)
Lighting Relay Center *
(65W, 65N, & 65U)
50 Amp
114
RD/BL
Trunk Pigtail (65A & 68P)
Lighting Relay Center *
(65W, 65N, & 65U)
50 Amp
115
RD
Trunk Pigtail (65A & 68P)
Lighting Relay Center *
(65W, 65N, & 65U)
50 Amp
116
TN
Glove Box PDB
50 Amp
117
LG
Blunt cut at Console
50 Amp
118
RD/WH
Trunk PDB
50 Amp
Inline
PK
In-line fuse located beneath
glove box in separate holder
Provided to protect ignition
signal circuit
Police Power Relay
Used to switch ignition power
on fuse 112
302
10 Amp
* - See page 44
25
SCHEMATICS
Power Connection Placement
Note: All connectors
viewed from wire end.
26
SCHEMATICS
Power Connection Placement
Pin
Gauge
Color
Function
1
5
6
10
10
10
RD/YE
RD/WH
RD
Fused Power (Fuse 1-113)
Fused Power (Fuse 1-118)
Fused Power (Fuse 1-115)
Pin
Gauge
Color
Function
1
4
7
12
10
10
16
10
TN
TN
PK
TN
Fused Power (Fuse 1-116)
Fused Power (Fuse 1-116)
Ignition Signal (Fuse 10Amp Inline)
Fused Power (Fuse 1-116)
Pin
Gauge
Color
4
10
LG
Fused Power (Fuse 1-117)
6
10
TN/YE
Ignition Power (Fuse 1-111)
7
12
PK
Fused Power (Fuse 1-112)
9
10
TN
Fused Power (Fuse 1-116)
11
10
RD/LB
Fused Power (Fuse 1-114)
Function
Pin
Gauge
Color
Function
1
4
7
12
10
16
10
10
RD/WH
PK
RD/WH
RD/WH
Fused Power (Fuse 1-118)
Ignition Signal (Fuse 10 Amp Inline)
Fused Power (Fuse F1-118)
Fused Power (Fuse 1-118)
Pin
Gauge
Color
Function
1
2
10
10
PK
RD/LB
Ignition Power
Fused Power (Fuse F1-114)
3
4
16
16
RD/BK
BN
Siren Speaker (65U PKG)
Siren Speaker (65U PKG)
Pin
Gauge
Color
Function
1
4
10
10
RD/YE
RD
Secondary Power
Primary Power
12
16
PK
Ignition Signal
27
SCHEMATICS
Power Circuit Placement (65A and 68P)
28
SCHEMATICS
Power Circuit Placement (65A and 68P)
29
SCHEMATICS
Power Circuit Placement (65N, 65W and 65U)
Engine Compartment
30
Interior
SCHEMATICS
Power Circuit Placement (65N, 65W and 65U)
Trunk
31
SCHEMATICS
Spare Circuit Placement
32
SCHEMATICS
Spare Circuit Placement
33
SCHEMATICS
Ground Circuit Placement
34
SCHEMATICS
Ground Circuit Placement
35
SCHEMATICS
Strobe Power Supply Assembly (65N, 65W, 65U)
Note: All connectors
viewed from wire end.
36
SCHEMATICS
Strobe Power Supply Assembly
WARNING: The strobe power supply is a high voltage
device. Do not touch or remove the strobe lamp assembly
while unit is in operation. Wait at least 10 minutes after shutting off power before continuing diagnostic. Failure to follow
these instructions may result in personal injury.
Correct Wiring Color Codes for Ford Product
2007 (7W7T-15A599)
2006 (6W7J-15A599)
2005 (5W7J-15A599)
2004 (4W7J-15A599)
C
White Housing
1W7J-15C594-AA
Strobe
B
A
BK
C
BK
WH
B
WH
RD
A
RD
Visibility Pacakge
Strobe Power
Supply (Federal
RD Signal Strobe
Module
3
2
WH
BK
1
Female Amp
Connector
2003 Phase 2 (3W7J-15A599)
C
White Housing
1W7J-15C594-AA
Strobe
B
A
Visibility Pacakge
Strobe Power
Supply (Federal
1
RD Signal Strobe
Module
Male Amp
BK
C
BK
3
WH
B
WH
2
RD
A
RD
BK
WH
Connector
2003 Phase 1 (1W7J-15A599)
C
White Housing
1W7J-15C594-AA
Strobe
B
A
BK
C
WH
B
RD
A
WH
3
BK
2
RD
1
Visibility Pacakge
Strobe Power
Supply (Federal
RD Signal Strobe
Module
WH
BK
Male Amp
Connector
NOTE: Federal Signal modules other than the 2004-2007 Ford supplied module, Federal Signal Silver Series and the Federal Signal
Ricochet model should use the 2003 Phase 2 configuration and re-pin
as shown. Other Industry standard configured modules should use the
2004-2006 wiring pin-out. See module Manufacturer’s instructions for
exact color configurations. Correct color configurations are key to
Strobe bulb longevity.
Note: All connectors
viewed from wire end.
37
SCHEMATICS
Console Pin outs (located under ashtray)
(Available only in 65W and 65N Packages)
1
2
3
4
5
6
7
8
Vehicle Connector
Vehicle Connector
Terminal Gauge Color
N/A
End
Power Distribution Center,
Glove Box
Power Distribution Center,
Trunk
Not Used
16
BK
Ground
N/A
Not Used
Not Used
6
16
OR/YE
Pin 7
Back Lighting
7
16
OR/YE
Back Lighting
8
16
PK
Pin 6
Under Instrument Panel at
Glove Box
16
1
DB/OR
16
2
DG/PU
3
4
5
1
2
3
4
5
6
7
8
Function
Headlight Flasher and Strobes
Strobes and High Intensity LED
Deck Lights
Not Used
Power Distribution
Ignition Feed
Auxiliary Plug
Auxiliary Connector to 8-Relay Center in Trunk
Terminal Gauge Color
End
Function
1
16
PU/LG
Slide Switch 1
Light 1
2
16
PU/LG
Slide Switch 2
Light 2
3
16
PU/YE
Slide Switch 3
Light 3
4
16
PU
Slide Switch 4
Light 4
5
16
OR/RD
Toggle 1
Take Down
6
16
BK/OR
Toggle 2
Auxiliary
7
16
WH
Toggle 3
Left Alley
8
16
GY/BK
Toggle4
Right Alley
Caution: Do not reverse connectors when installing in switch box.
Note: These connectors are for use only in the visibility packages
65W and 65N. Otherwise, these connectors are capped and should
Note: All connectors
remain capped as delivered.
viewed from wire end.
38
SCHEMATICS
Alternating Headlight Flasher Circuit
39
SCHEMATICS
Horn / Siren Relay Circuit (Amplifier at Console)
40
SCHEMATICS
Horn / Siren Relay Circuit (Amplifier in Trunk)
41
SCHEMATICS
Glove box Power Distribution Center
Note: All connectors
viewed from wire end.
42
SCHEMATICS
Trunk Power Distribution Center
43
SCHEMATICS
8-Relay Panel (65N), (65W)
44
REMOVAL OF POLICE PREP PACKAGES
Note: When retiring a police vehicle, it is the owner’s
responsibility to remove any police-related apparatus
that is not intended for civilian use. The Police Prep
Packages contain a vehicle harness which does not
need to be removed, only disabled by removing fuses
111, 112, 113, 114, 115, 116, 117, and 118 in the engine compartment. All strobe bulbs need to be disconnected from the strobe power supply. The Visibility
Package contains two rear parcel shelf mounted LED
lights and a rear communications service tray
mounted strobe power unit which should be removed.
45
GENERAL GUIDELINES
General Guidelines
• Circuit protection (fuses) must be
provided for all wiring. The fuse
rating should not exceed either
the rated wiring current capacity or
the total current requirements for
all the add-on components
on the circuit. Fuses should be
installed as close to the point of
tapped power as possible.
• All revisions to the electrical
system should be documented
and placed with the vehicle owner
guide. All revisions or additions to
wiring should be color coded and/
or labeled.
• Protective covering should be
provided in all areas that could be
damaged during normal
equipment installations.
• Vehicles stored on site should
have the negative battery cable
disconnected to reduce the
possibility of draining the battery
by lights or other equipment.
• Control panels attached to the
instrument panel should not
protrude into the driver and
passenger air bag deployment
zones. For additional information,
refer to Section 4: Installation
Considerations in this guide.
• Switches and gauges should not
be installed in the driver or
passenger knee impact areas.
• All Ford gauges, lights, and
switches must be inspected for
correct operation after instrument
panel work is performed.
• All wiring relocated or removed
while wor k ing behind t he
instrument panel must be secured
properly to prevent chafing,
squeaks and rattles.
• Provide adequate retention for
wiring harnesses so that they are
clear of bolts, corners, edges,
etc., which could abrade the wires
during normal vehicle operation.
• Anticipate misrouted wiring
situations and protect all wiring
from penetration by screws and
raw edges.
• Weather-seal all electrical
connectors exposed to the
elements.
• Do not use quick splice
connectors or wire nuts.
• Connections should be easily
accessible for assembly and
service.
• Mak e sur e subm er sible
connectors do not lose their seals
under extreme assembly
conditions,
such as bending wires 90 degrees
immediately after the connector.
• Whenever using connectors, use
a socket (female) connector on the
electrical source side and a plug
(male) connector on the electrical
load side to reduce the possibility
GENERAL GUIDELINES
of a shor t cir cuit when
disconnected.
• Air bag restraint systems must
remain intact as received from
Ford Motor Company. Before
modifications are done to the
vehicle, the system must be
disarmed by following the
instructions provided in the
current Crown Victoria Workshop
Manual.
• Adherence to the above
guidelines is not to be construed
as approval by Ford Motor
Company of any specific revisions
or additions to the vehicle’s
original electrical system.
Wire Insulation
• Polyvinyl Chloride (PVC) rated
at 90°C (199°F) is the standard
wire insulation that is acceptable
for inside body use but is not
acceptable for underhood/
underbody wiring.
• Hypalon insulation should be
used on links only (Ford
Specification ESB-M1L54-A).
• Cross-linked Polyethylene
(XPLPE or SXL) rated at 135°C
(275°F) is the required insulation
for underhood/underbody
applications (Ford Specification
ESB-M1L123-A).
• GXL can be used as an
alternate wire (Ford Specification
ESB-M7L85B) as long as the
concentricity specifications are
met. To provide a water-resistant
seal in conjunction with crimp
connectors, a Duraseal crimp
connector is recommended since
it is designed to account for
outside wire diameter that is
smaller than the present SXL
wire.
Splices and Repairs
For quality splicing and to reduce
potential problems, the following
guidelines are recommended:
• Stagger the splices within a
harness to reduce increased
harness diameter. Splice only on
straight areas as installed, not on
bends.
• Strip wire ends making sure that
individual conductor strands are
not damaged.
• When soldering, make sure an
adequate mechanical joint exists
before applying solder. Use only
resin-core solder. Acid-core
solder should not be used since it
may result in corrosion.
• For crimp joints, use butt-type
metal barrel fasteners and the
proper tool at the appropriate
setting for the wire size (such as
Motorcraft crimp tool S-9796)
specifically designed for this type
of work.
GENERAL GUIDELINES
• Make sure splice joints are
adequately sealed and insulated.
In an outside environment, use
Duraseal butt connectors or
equivalent. A durable substitute
splice joint can be achieved by
using a bare metal barrel,
crimping, flow-soldering and
covering with shrink tubing (see
figure). Quality electrical tape can
be used inside the vehicle but is
not recommended for an outside
environment.
• Be sure that the new wire is not a
lesser gauge than its original
mating wire.
Recommended
splicing method
1. Disconnect the battery
2. Strip wires to appropriate length
.
3. Install heat shrink tubing.
4. Twist wires together.
Note: Use resin-core mildlyactivated (RMA) solder. Do not
use acid-core solder.
GENERAL GUIDELINES
5. Solder wires together.
Note: Wait for solder to cool before
moving wires.
6. Bend Wire 1 back in a straight
line.
Note: Overlap tubing on both wires.
7. Evenly position heat shrink
tubing over wire repair.
8. Use heat gun to heat the
repaired area until adhesive flows
out of both ends of heat shrink
tubing.
Ford Part Number
Part Name
Class
E6FZ-14488-A
BUTT CONNECTOR
GAUGE: 18-22, COLOR:RED
C
E6FZ-14488-B
BUTT CONNECTOR
GAUGE: 14-16, COLOR:BLUE
C
E6FZ-14488-C
BUTT CONNECTOR
GAUGE: 10-12, COLOR:YELLOW
C
GENERAL GUIDELINES
Heat Shrinkable Tubing (Heat
Shrink) (Ford Specification ESBM99D56-A2) Heat shrinkable tubing
is available in various diameters for
different splice sizes and
configurations. When shrunk, it
forms a small, flexible hermetic
seal. Other methods (tape, PVC
mold, etc.) do not provide a
hermetic seal and are not
recommended. Splice balancing is
critical with heat shrink insulation. If
the splice is extremely unbalanced
(more circuits on one side than the
other), heat shrink insulation will not
provide a proper seal. Evaluate
the use of double terminals instead
of splices where practical in these
situations.
Wire Protection Requirements
General Notes:
• Anticipate problems and design
accordingly. Try to anticipate what
could go wrong and modify
your designs to address any
adverse impact.
• Review all connector applications
and electrical systems to determine
the need for solder, grease,
weat her -r esist ant or sealed
connectors. Make sure components
and wire insulation are
compatible with greased connectors
(important for long term durability).
• Make sure that drip loops or other
means are provided to prevent
water leakage into the vehicle
through wiring assemblies that pass
through the dash panel.
• Use greased or sealed connectors
in floor pan troughs which are
subject to moisture coming through
the carpeting.
• Use XLPE insulation for
uncovered runs that exceed 305
mm (12 inches).
Electrical Protection
• Properly route wires away from
noise-generating wires or
components. However, if routing
near noisy wires or plugging into
noisy components is unavoidable,
additional protection must be
designed into the harness.
• Shielding — Electro Magnetic
Interference (EMI) — Consider
shielding if you must route close to
high-current or noisy circuits. Use
shielded wire and ground one side.
Seal all splices in wire assemblies
that use bare coaxial shielding
(braid or tape) for EMI suppression,
and insulate or tape over all
shielding ends that terminate near
any open connectors. This prevents
splice and terminal shorts to the
shielding. Minimize the length of
conductors which extend beyond
the shield. Failure to do this
reduces the effectiveness of the
shield.
• Spike suppression, in general, is
GENERAL GUIDELINES
accomplished by connecting a
diode or resistor-diode
combination across the terminals
of the noisy component. The diode
should be sufficiently close to the
component (both electrically and
physically) so that inductive spikes
are clamped off. Make sure the
diode is connected with the proper
polarity. Proper routing and
retention will reduce the likelihood
of chafing, pinching, etc. When
this ideal routing is unattainable,
the following additional protection
is needed:
Mechanical/Environmental
Protection
Tape — Tape is the most basic
means of protection. It contains
the wires in a loose bundle and
provides limited environmental
protection. It does not protect
against chafing and pinching.
— Kendall Polyken Fiberglass
Base Tape (Ford Specification
ESB-M3G38-A) is used for engine
compartment applications. This
durable tape provides against cutthrough and abrasion commonly
found in underhood applications.
— Polyken 267 is a substitute tape
that may be used in lower
temperature areas of the engine
compartment (apron area).
Convolute - Use convolute for all
underhood/underbody applications
or when increased temperature,
abrasion or pinch resistance is
required. Convoluted tubing
comes in different diameters and
m at er ials t o accomm odat e
different temperature ranges and
harness sizes.
— Use polyethylene convolute
when abrasion is the only
consideration; this convolute is
adequate up to 96°C (205°F)
maximum. Use nylon convolute
when underhood/underbody or
abrasion and temperature are
considerations; nylon convolute is
adequate up to 177°C (350°F)
maximum.
— On all engine-mounted wiring or
bend points. Use vinyl tape on the
outside of the convolute to prevent
wiring from looping out. This tape
must be able to withstand high
temperatures 135°C (275°F) or
over.
— Tape convolute junctions with a
brasion-resistant tape (Polyken
267, fiberglass, etc.).
Ford Motor Company warrants the Police Interceptor Preparation
Packages under the Ford New Vehicle Warranty.
All Ford Product Warranty Service is provided through the Ford Dealer
Organization. Please contact your dealer for warranty service assistance.
While certain components may be sourced through recognized vendors,
those vendors are not Ford Product Warranty Service Centers.
Crown North America
Technical Assistance, Customer Service and Sales
1 (866) 402-6838
www.crown-na.com
Assistance with Ford equipment not installed by Crown
Ford Fleet
Technical Assistance
1 (800) 34-FLEET
www.fleet.ford.com
48
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