2002 Engine Bay Wiring Harness installation | Ford Thunderbird forum club group 1955-2005 models
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2002 Engine Bay Wiring Harness installation

  • Thread starter Thread starter Redbird 02
  • Start date Start date
R
Reaction score
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Thunderbird Year
2002
Due to an electrical fire caused by a faulty installation of an electric cooling fan, I am required to replace the Engine Bay Wiring Harness and Fuse/Relay box in my 2002. This harness runs from the fuse/relay box under the hood behind the passenger headlight, out in front of the radiator, then splits and runs around the car in both directions, up into the fenders above the liners, then into the engine bay and through the firewall into the cabin on each side of the car. I have obtained a complete and intact fuse box and wiring harness from a salvage 2002. After carefully inspecting all the wires coming from the fuse box, I find 4 wires that are different colors than the ones which came out of my car. They are associated with the following relays:

Mini Relay #2 - WIPER PARK - Old wire BLK with WHITE stripes - New Wire BLK with RED stripes. (Smallest Wire)
Mini Relay #4 - HEATED WIPER PARK - Old wire BLK with RED stripes - New wire BLK with BLUE stripes (Smallest wire)
Mini Relay #8 - A/C CLUTCH - Old wire BLK with BLUE stripes - New wire BLK with RED stripes (smallest wire)
Standard Relay #11 - WIPERS - Old wire RED with WHITE stripes - New wire RED with BLUE Stripes. This wire is slightly larger than the others,

Should I be concerned with this? (I am not even sure what a Heated Wiper Park relay does). Maybe just plug it in and see if everything works?
Two things to note...
1. My car was built in April 2001, the first month of production, #0197. Maybe they changed the wire colors at some point during the production year.
2. There was a sticker on the new Box..."B"
A1.jpgB1.jpg

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Hi 'REDBIRD', so sorry to hear about your issue with the installation of the cooling fan.
I'm curious, as I'm sure other members of this forum are interested in what happened. Can you enlighten us?
Nobody wants to have this happen to our 'baby birds', however, if you choose not to share, I/we can understand.
 
The fire was started by too small a wire used to power the fan. It looks like it got so hot it ignited the plastic fill funnel on the windshield washer reservoir, which provided fuel to burn the outside wires of the wiring harness.
 
Due to an electrical fire caused by a faulty installation of an electric cooling fan, I am required to replace the Engine Bay Wiring Harness and Fuse/Relay box in my 2002. This harness runs from the fuse/relay box under the hood behind the passenger headlight, out in front of the radiator, then splits and runs around the car in both directions, up into the fenders above the liners, then into the engine bay and through the firewall into the cabin on each side of the car. I have obtained a complete and intact fuse box and wiring harness from a salvage 2002. After carefully inspecting all the wires coming from the fuse box, I find 4 wires that are different colors than the ones which came out of my car. They are associated with the following relays:

Mini Relay #2 - WIPER PARK - Old wire BLK with WHITE stripes - New Wire BLK with RED stripes. (Smallest Wire)
Mini Relay #4 - HEATED WIPER PARK - Old wire BLK with RED stripes - New wire BLK with BLUE stripes (Smallest wire)
Mini Relay #8 - A/C CLUTCH - Old wire BLK with BLUE stripes - New wire BLK with RED stripes (smallest wire)
Standard Relay #11 - WIPERS - Old wire RED with WHITE stripes - New wire RED with BLUE Stripes. This wire is slightly larger than the others,

Should I be concerned with this? (I am not even sure what a Heated Wiper Park relay does). Maybe just plug it in and see if everything works?
Two things to note...
1. My car was built in April 2001, the first month of production, #0197. Maybe they changed the wire colors at some point during the production year.
2. There was a sticker on the new Box..."B"
View attachment 33082View attachment 33083
If the wires are going to the correct position on the connectors it’s good to go.
 
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