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2-14
Spike suppression, in general, is accomplished by connecting a diode or resistor-diode combination across the terminals of the noisy
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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 reduces the likelihood of chafing or pinching. When this ideal routing is unattainable, the following additional
protection is needed:
Mechanical/Environmental Protection
NOTE:
This is not meant to be an all-inclusive list of methods for physically protecting the wires. There are other means of protection available that
are not listed.
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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.
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Kendall polyken fiberglass base tape (Ford specification ESB-M3G38-A) is used for engine compartment applications. This durable tape
provides protection against cut-through and abrasion commonly found in underhood applications.
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Polyken 267 is a substitute tape that may be used in lower temperature areas of the engine compartment (apron area).
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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 materials to accommodate different temperature ranges and harness sizes.
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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.
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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 temperatures 135°C (275°F) or higher.
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Tape convolute junctions with abrasion-resistant tape (Polyken 267, fiberglass).
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Scroll — Similar to convolute, but without the ridges. Scroll is used where harness rigidity is required, especially for maintaining critical
locator dimensions. Use scroll for short lengths only, as it is inflexible.
Grommets and Sealing Requirements
Any additional wiring routed through sheet metal must pass through a grommet that both seals the opening and locates the wire(s). Two-piece
grommets (rubber with plastic inserts) are recommended to facilitate installation and retention.
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Locate grommets so they are accessible for proper seating (achieved by pulling) in sheet metal holes.
Ramp grommets at the insertion end to facilitate installation and sealing.
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Be sure the direction of the hole punch is in the direction of grommet seating and the hole is burr-free.
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Make sure the grommet molding compound adheres to the harness to prevent slippage.
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Make sure the grommet will withstand the environment (temperature, splash).
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Be sure the holes are large enough to allow the installation of the harness without causing circuit damage.
Use adhesive tape on main trunks or branches with at least a 50% overlap to prevent wicking through grommets. Be certain to diaper-
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wrap the takeouts.
Wire Routing
WARNING:
Do not place electrical component attachments or ground screws adjacent to vehicle fuel tanks, fuel filler pipes, fuel lines, fuel
vapor lines or carbon canisters. Failure to follow these instructions may result in severe personal injury in the event of a collision.
Wire harness routing should conform to the following:
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Protect wires routed through holes in sheet metal or castings with a grommet whether or not conduit is used (see figure below).
Section 2: Electrical
2019 Fusion Hybrid Modifiers Guide, 8/2018
Electrical
© Copyright Ford 2018 FoMoCo
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