Replacing damaged FICM connectors...A HOW-TO with pics - Ford Powerstroke Diesel Forum
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Old 01-07-2012, 06:28 PM Fanatic

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Replacing damaged FICM connectors...A HOW-TO with pics

Replacement FICM connectors:
1456315-6 (AP0018)
1456315-2 (AP0019)
1456316-1 (AP0020)

1. Remove the injector harness from the engine.

2. If your harness has the 90 degree wire protection at the base of the connector, carefully remove all of the tape from the wires about 2-3 inches back from the connector. This will allow for easier pin removal later on.

3. The 90 degree wire protection is fastened to the main connector with four clips. Depress the clips and remove it from the connector.

4. Inside the connector the wires are held in place by a clip that snaps at the base of each pin. The clip has to be released so the outer portion of the connector can be removed. Looking at the face of the connector, the top row of pins are numbered 1 -8 from right to left. Using an appropriate sized screwdriver, press in the the white plastic retaining clip on the 1 pin side of the connector. You will hear a click when it is released.

5. At the connector base, there are two more clips that need to be released. Using a small screwdriver, insert it into the small holes on the short sides of the connector to release connector cover. Very little pressure is needed here.

6. The cover can now be carefully pulled from the base of the connector and removed. The inner white plastic retaining clip that was released in step 4 will most likely be removed along with the cover in this step. I put it back on for this picture.

7. The pins are now held in place by some very fragile one way barbs which are pinched in at the pin base. Each barb clips the wire pin from the top and bottom. The openings at the side of the barb will allow the wire pins to gently slip through. The circled area shows an unused barb in the middle row with a good view of the side openings. I used a small screwdriver to CAREFULLY wiggle each pin while lightly pushing them beyond the barbs. Do not push the pins all the way out. We only want to remove the barbed plastic retainer in this step. This will give you the opportunity to transfer the pins to the new connector without having to keep track of all of the wires. This is where removing the additional tape from the base of the connector at the beginning will give you the needed room to back out the wires from the base without totally removing them.

8. Grab your new connector base and orient it the same way as the damaged connector base. Remove your first row of wires and place them one by one into the new base. Repeat the same step with the second row.

9. Once the pins are transferred to the new connector, only push them in far enough so the one way barbed retainer can be placed over them. We only want the tips of the pins to be just above the barbs. Now grab the new connector cover and place it face down with number 1 pin hole on the right (arrow in pic). The white retaining clip needs to be placed inside the cover with the extended tab towards the left (8 pin side) and the raised tab (pic) fits into the cover and away from the pins. Slide the retaining clip to the left inside the cover so the holes are fully open.

10. The new connector cover can now be placed over the pins and onto bottom half. Take your time. Once you feel that all of the pin tips have passed beyond the clip and have started into the connector holes, the connector cover should easily snap into place. Each wire now has to be 100% inserted into the connector so they seat beyond the one way barbs. Make sure the pins all are full inserted to the numbered face of the connector cover. The white retaining clip will not snap into place. Once all wire pins are fully seated and visible at the numbered connector face, the internal white retaining clip tab should be pushed in from 8 pin side of the connector and snapped into place.
11. Replace the 90 degree wire protection at the base, and tape it back up.

Here are two views of the connector assembly.

Last edited by fixxxer-upper; 01-08-2012 at 06:16 PM.
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Old 01-08-2012, 12:17 PM Fanatic

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I updated the write up for some added clarification.

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