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Old 06-21-2012, 11:28 PM   #1
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Fog Light Installation - S Model (with Pics)

I decided to put this in a new thread so its easier to find in a search, and to reduce confusion..

This is going to be a multi part install, since I am still waiting for some of the stuff to get here yet.

First an overview of how these things work...

The fog lights in our cars is controlled by the Body Control Module via an internal non-servicable relay. The headlight switch has only 3 wires, power, ground and LIN (data connection to body control module to tell it what mode to run in.) Once the body control module recieves the instructions (for lack of a better word) as to what the driver wishes for lighting, it will energize relays for the parking lights, headlights, high/low beams, and fog lights. as needed.

As a result, the majority of the system is already in place along with all the wiring except for the optional fog harness that connects the fog lamps to the main BCM harness. Ford bundles this harness in with the parking sensor wiring for cars equipped with Park Assist. and it's part number is 15K867 if you were to order the official Ford Part. Well since we don't have park assist on a S model... we have no need for the additional wiring (and cost of it). So we are going to build our own stripped down version here.

Now that we got that out of the way... On to the good part....

PART 1... Building The Fog Light Harness

1. Parts You will Need:

Connector C144 (connection to Main Harness)
Molex MX150 Series 16 way male Connector P/N 33482-1601 (1 pc)
Molex MX150 Series 1.5mm Male Terminal P/N 33000-0002 (4 pcs)
Molex MX150 Series Cavity Sealing Plug P/N 34345-0001 (12 pcs)

Connectors C152 and C162 (connects each fog lamp)
Packard/Delphi MetriPack 280 Female Connector P/N 12124819 (2 pcs)
Packard/Delphi MetriPack 280 Secondary Lock P/N 12020807 (2 pcs)
Packard/Delphi Metripack 280 Female Terminal P/N 12077411 (4 pcs)
Packard Delphi Cable Seal - Green P/N 15324982 (4 pcs)

Black Electrical Tape
Nylon Split Loom Conduit.. 3/8" Diam. (10 FT)
18 Gauge Brown Automotive Wire (10 FT)
18 Gauge Black Automotive Wire (10 FT)

Nylon Zip Ties (6" preferred) (6 pcs)

2. Tools Required

Tape Measure (metric if possible)
Wire Cutters
Wire Strippers
Needle Nose Pliers
Yellow Paint Marker
Gray Paint Marker
Soldering Iron/Solder
Beer.. (optional)

Cut 1 black and 1 Brown wire 75 inches Long or 1900mm Long strip each end 7/32" (or) about 5mm.

Cut 1 Black and 1 Brown wire 8 inches Long or 205mm Long and strip each end 7/32" (or 5mm)

Next.. Take the Yellow Paint marker and paint a stripe on the short black wire

Do the same with the Gray Marker on the Long Black wire.

(Note.. I couldnt find Brown Wire around here so i used white and spray painted it brown so it matches the Ford Wiring Diagram)...

Once your wires are cut and stripped.. and you have put the stripe on them, we are ready to put the terminals on... If you've never put these on before.. order a few extras for practice since they are stupidly cheap.. and its easy to mess up the terminal especially your first time or so doing it.

For the Delphi Packard Terminals...

First slip the green seal over the wire as shown..

like this...

Then apply the terminal with needle nose by pinching the wings of the terminal closed over the wire strands (do the same with the seal crimp.) BE CAREFUL NOT TO distort the socket part of the terminal and keep your crimp as small as possible.. (there is a tool to do this with but it is way more than i want to pay for..)

Then solder the crimp area.. use only as much solder as is needed to secure the terminal to the wire and DON'T get any in the socket part... Once the wire brush turns silver.. STOP!

For the Molex Terminals... they are done the same way, just without a cable seal...

Completed Molex terminal..

Once all your terminals are on and soldered.. You are ready to begin assemblying the harness...

Starting with the Molex Connector.. The Top of the connector is the side with the part number on it... Looking at the side you insert the wires into, the top row from left to right goes. 8 7 6 5 4 3 2 1
bottom row left to right goes, 16 15 14 13 12 11 10 9
Short Brown - Position 9
Short Black/Yellow - Position 10
Long Black/Gray - Position 11
Long Brown - Position 12
The remaining positions will get cavity plugs.. line the notch in the connector hole with the notch on the fat end of the plug.. skinny end goes in first.

Once they are in they should look like this

... More To come...

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