Installation-FULL 2016

INSTALLATION IS VERY EASY and We Guide You Step By Step!

1. Lay the Cat Safeguard harness out along the passenger side of your engine compartment and fish it behind the truck's fuse panel and down to the underside of your truck;

2. Unplug the truck's factory electrical connection to the hood switch. 

3. Connect the Cat Safeguard T-harness to the hood switch and to the electrical connection that you just unplugged from the hood switch;

3. Set the Cat Safeguard modules into place and plug them together;

4. Connect the Cat Safeguard "brain" module to the Cat Safeguard harness;

5. Make the connections to your truck's electrical system.

That's About It!

IT TAKES ABOUT AN HOUR! 

>>>>>>>>>>> BUT BEFORE YOU BEGIN <<<<<<<<<<<

Installation of the Cat Safeguard Catalytic Converter Theft Deterrent System should require less than an hour.  The important thing is to understand what you're trying to do before you actually start to do it.  That's why it's important to read and understand the instructions FIRST. 

WE' RE HERE TO HELP YOU IF YOU GET STUCK

To begin, although the instructions that follow may appear to be complicated they are actually very straightforward--just take them one line at a time. 

Once you being reading them, you'll find that the instructions simply consist of the following major steps:

SECTION 1:  SAFETY PRECAUTIONS

This section simply tells you to make sure your vehicle is stable and that you should wear appropriate clothing and eyewear to prevent injury.

SECTION 2:  DISCONNECTIING THE NEGATIVE BATTERY TERMINAL

This section tells you how to disconnect the vehicle's negative battery terminal

SECTION  3: THE CAT SAFEGUARD WIRING HARNESS

This section familiarizes you with the main Cat Safeguard wiring harness and shows you how to stretch the harness out along the passenger side of the engine compartment from front to back, with one end of the harness across the very front of the vehicle, and the other end extending down to the underside of the vehicle. 

SECTION 4:  THE HOOD LATCH ASSEMBLY AND HOOD AJAR SWITCH

This section shows you how to connect the front end of the Cat Safeguard harness to the Hood Ajar (Hood Latch) switch.  It's very easy to do and there are videos to show you how to do it.

SECTION 5:  INSTALLING THE ANTENNA AND ROUTING THE CABLING

This section shows you how to install the antenna and route the wiring

SECTION 6:  INSTALLING THE CAT SAFEGUARD MAIN MODULE AND SENSORS

This section shows where and how to place the Cat Safeguard Main Module under your vehicle.  It attaches to the vehicle with a strong magnet--there is nothing to unbolt, and it will not move.

The section then tells you where and how to install the sensor assemblies, and how to route and secure the wiring.

And the last (well, almost the last) part of this section shows you how to plug everything together to complete the assembly.

STEP 7:  BATTERY JUNCTION BOX (AKA FUSE BOX) CONNECTIONS

This section shows you how to connect the Cat Safeguard into your vehicle's electrical system.  It's very straightforward.

SECTION 8:   RECONNECTING THE VEHICLE BATTERY GROUND WIRE

This section shows you how to reconnect the battery ground wire, which will provide power to the system.

SECTION 9:  FUNCTIONAL TESTS

This section describes how to verify proper operation.

SECTION 10:  FINAL ASSEMBLY STEPS

This section wraps everything up.

THAT'S ALL THERE IS TO IT--IT SHOULD REQUIRE LESS THAN AN HOUR TO INSTALL THE SYSTEM

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

BEFORE YOU BEGIN

THE INSTALLATION INSTRUCTION SHOWN HERE ILLUSTRATES A TYPICAL INSTALLATION--NOT NECESSARILY THE INSTALLATION FOR YOUR PARTICULAR VEHICLE.  THIS IS SHOWN HERE TO GIVE YOU AN IDEA OF WHAT'S INVOLVED.

THE ONLY DIFFERENCE BETWEEN CAT SAFEGUARD ALARM MODELS ARE THE ELECTRICAL CONNECTIONS BETWEEN TRUCK MODEL YEARS AND THE SOFTWARE INSTALLED IN THE CAT SAFEGUARD SYSTEM

YOU WILL BE PROVIDED WITH INSTALLATION INSTRUCTIONS FOR YOUR SPECIFIC VEHICLE

DO NOT USE THIS INSTRUCTION FOR INSTALLATION ON YOUR VEHICLE!

Installation of the Cat Safeguard Catalytic Converter Theft Deterrent System is extremely straightforward.

Each system comes with everything needed to install it--the only things that you need to provide other than common hand tools is a soldering iron or wood burner tool, a rivet tool (available for around $10 at your big box store) and a small tube of caulk-preferable black:

You will use the soldering iron to create two small divots in your vehicle's Battery Junction Box (located in the rear passenger side of the engine compartment) in order to allow the Cat Safeguard wires to connect into your vehicle's electrical system. 

The caulk will be used to provide a watertight seal where the wires go into the Battery Junction Box.

And the hand rivet tool will be used to secure two steel shield plates below each catalytic converter in order to provide additional protection from would-be thieves.

The Cat Safeguard Electronic Catalytic Converter Theft Deterrent System consist of the following major components:

a) Power and Vehicle Interface Harness

b) Main Processing Module

c) Two Sensor Assemblies

d) A cellular antenna and cable

e) All hardware required to complete the installation 

Installation involves the following sections:

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SECTION 1:  SAFETY PRECAUTIONS

WARNING!

****************************************************************************************SECTION 2:  DISCONNECTING THE NEGATIVE BATTERY TERMINAL

Raise your vehicle's hood and disconnect the ground (negative) connection at your vehicle's battery. 

The NEGATIVE battery terminal is shown in the photo immediately below  Notice that the POSITIVE terminal (immediately above the negative one) generally has a red wire and terminal cover as delivered from the factory--yours may be different depending on whether or not your positive wire may have been replaced at some time in the past:

Figure 2-1 (Above): Locating the negative battery terminal

****************************************************************************************SECTION 3: THE POWER AND VEHICLE INTERFACE HARNESS PART 1

Familiarize yourself with the ends of the Power and Vehicle Interface Harness--one end will have a single FIVE-PIN connector, while the other end will have the connections necessary to interface with your vehicle's electrical system and alarm circuitry in the engine compartment.  The end with the five-pin connector is the end that you will start with and route along the passenger side and then under your vehicle between the passenger side fender well and the firewall.  Refer to Figure 3-1.

Figure 3-1 (Above): Identifying the five pin connector on the end of the Power and Vehicle Interface Cable.  Note the coiled cable in the background of the photo.

3a. Lay the coiled Power and Vehicle Interface cable on the radiator shroud above the passenger side headlight.

3b. Lay a light source (a flashlight or a trouble light) under the vehicle just behind the tire-- You should be able to see light shining up through the gap between the rear of the plastic fender well and the firewall.  Refer to Figure 3-2.

Figure 3-2 (Above): Identifying the Firewall and Locating the Gap Directly Beneath It

3c. Fish the five-pin connector end (Figure 3-2 above) of the CAT SAFEGUARD Power and Vehicle Interface Harness along the passenger side of the engine compartment toward the firewall. 

Ensure that the harness passes below the hood support strut and past the windshield washer fluid bottle (Figure 3-3).

Figure 3-3 (Above): Routing the Power and Vehicle Interface Cable Past The Windshield Washer Bottle

3d. Route the cable alongside the Battery Junction Box (the fuse box) and down through this gap--it will dangle above the ground and you will be able to see it hanging down beneath the vehicle.  Refer to Figure 3-4.

Figure 3-4 (Above): Routing the Power and Vehicle Interface Cable

3d. From under the vehicle on the passenger side gently pull on the cable until you've pulled approximately three feet of the harness under the vehicle.

3e. Back in the engine compartment route the other end of the Power and Vehicle Interface Harness along the passenger side fenderwell toward the front left corner of the vehicle.

If you've done it correctly you should come upon a ground lug on the harness...(Figure 3-5).

Figure 3-5 (Above): The Power and Vehicle Interface Cable Ground Lug

...that is right next to the Battery Junction Box.  There will also be two wires with fuses in them that are there as well.  Don't do anything with them yet.

Then continue on around to the front corner of the engine compartment.

At this point you will have routed the harness up almost to the passenger side headlight.  The next step is to get the end of the Power and Vehicle Interface Harness over to the hood latch assembly--which is behind the vehicle's grill:

3f. You will now notice a plastic shroud that covers the radiator and a/c condenser, and which surrounds the hood latch opening.  You will need to remove four of the fasteners that secure the passenger side end of the plastic shroud--they are easily removed.  Each fastener is a two-piece assembly and consists of a "fastener body" that is inserted through the shroud and down into the engine compartment metal, and a "stud" that goes down through the "fastener body" to secure it in place: 

You will want to remove the four fasteners that secure the passenger side end of the shroud so that you can get under it.  The fasteners can be removed by gently inserting the tip of a medium size flat blade screwdriver

                                  (WARNING: DON'T USE A KNIFE BLADE!)

into the slot that is along the perimeter of the fastener "stud".  Do this carefully--it's very easy to flip them up into the air and down into the engine compartment, so be careful.  Refer to Figures 3-6 and 3-7.

Figure 3-6 (Above): Shroud Fasteners Part 1

Once the stud has been lifted (but not actually removed from the fastener body) you can pry the fastener body up to remove it.  Again, don't allow it to flip up into the air--they are easily lost. 

Figure 3-7 (Above): Shroud Fasteners Part 2

3g. Repeat step 3f. for the remaining three fasteners.  With the four passenger side studs removed the plastic shroud can be lifted far enough to allow access to the area immediately forward of the radiator and a/c condenser.

WARNING:

THE FOLLOWING STEPS REQUIRE WORKING IN CLOSE PROXIMITY TO THE A/C CONDENSER.  THE A/C CONDENSER CONTAINS HIGH-PRESSURE REFRIGERANT.  THE CONDENSER IS EXTREMELY FRAGILE AND IS EASILY PUNCTURED.   

CAT SAFEGUARD ACCEPTS NO RESPONSIBILITY IF YOU PUNCTURE YOUR A/C CONDENSER!

YOU ONLY HAVE TWO EYES--BE SAFE, WEAR GLOVES AND FULL EYE PROTECTION!!

****************************************************************************************SECTION 4:  THE HOOD LATCH ASSEMBLY AND HOOD AJAR SWITCH

Before proceeding further take a look at the end of the harness: You will see a bridle consisting of two connectors: one male, and one female (the female connector is the larger of the two).  Refer to Figure 4-1.

Figure 4-1 (Above): Hood Latch Assembly Connections

The first step is to disconnect the factory harness from the hood latch assembly and then insert the CAT SAFEGUARD harness between the factory harness and the hood latch assembly.

4a. Disconnect the factory harness from the hood latch assembly.  The place where the factory harness connects to the hood latch assembly is clearly visible down in the hood latch well--this is where the lever that you use to release the hood is located.  Refer to Figure 4-2.

Figure 4-2 (Above):  The Hood Latch Assembly

If you look down in there carefully you will be able to see where the factory wiring harness connects to the hood latch assembly ("Hood Ajar Switch Connector" in the photo above).  You will need to remove this connector from the hood latch assembly.  This is done by pressing the latch button (marked "Connector Release" in Figure 4-3) on the RIGHT HAND END OF THE HOOD LATCH ASSEMBLY CONNECTOR:

Figure 4-3 (Above): Hood Latch Switch Connector Release Detail

Once this button is pressed the male harness connector can be removed from the hood latch assembly connector.  It takes some trial and error to do it.

A little tip: We've found that the easiest way to do this is to push your right hand through the grill to the right of the hood latch assembly and your left hand through the grill to the left of the hood latch assembly.  Then, you need to press the latch button with your right thumb while gently "bending" left end of the male harness connector toward the a/c condenser.  Please refer to the following video:

Figure 4-4 (above):  HOOD LATCH CONNECTOR EXPLANATION VIDEO

You'll be able to feel and hear the connector release when this has been done properly.  Once done you can remove the male harness connector from the hood latch assembly connector. 

CAUTION:

DO NOT pull on the connector by the wires--pull on the connector body only.

4b. Next, lift the end of the shroud that you released in steps 3f and 3g.  Once the shroud has been lifted the path to route the end of the harness over to the hood latch assembly should be obvious.

4c. Route the harness beneath the shroud and over to the hood latch assembly.

4d. Connect the two Power and Vehicle Interface Harness connectors to your vehicle's factory harness and hood latch assembly.  The Ford factory male connector will plug into the female Power and Vehicle Interface Harness connector.  Then the male Power and Vehicle Interface Harness connector will plug into the female hood latch assembly connector.

4e. Then, working back from the hood latch assembly route the harness back toward the windshield washer fluid bottle.  Take care to ensure that nothing snags the harness.  The assembly photo highlights where and how you can secure the harness with the included small zip ties as you work your way back toward the engine compartment firewall.  The CAT SAFEGUARD kit includes some self-adhesive zip tie mounts that allow you to secure the harness between the shroud and the firewall.  CAUTION: The self-adhesive zip tie mounts are intended for initial installation only and may not survive the engine compartment's environment.  Therefore, it is STRONGLY RECOMMENDED that you make every effort to secure with the included zip ties the Power and Vehicle Interface cable to existing wiring that already exists in the engine compartment. 

4f.  As you approach the ground lug on the harness you will again notice the ground screw that is securing the factory ground wires to the vehicle engine compartment.  Remove the screw, insert it through the Power and Vehicle Interface Cable ground lug and then through the factory ground lugs.  Tighten the screw securely, however do not over-tighten it.

THIS CONCLUDES THE FIRST PART OF THE ENGINE COMPARTMENT INSTALLATION SECTIONS

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Transmission Crossmember Zip Tie Installation:

6a. Install five (5) 14 inch zip ties around the transmission crossmember as shown in Figure 6-1.  These zip ties will be used as tie points to hold various wires in place in later steps.  Tighten them securely.

Figure 6-1 (above):  14 Inch Zip Ties Placement Along the Transmission Crossmember

Main Module Orientation and Installation

NOTE:

READ THIS BEFORE ATTEMPTING STEP 6b IMMEDIATELY BELOW: 

ENSURE THAT THE MAIN MODULE IS ORIENTED CORRECTLY

>> BEFORE <<

PLACING IT ONTO THE TRANSMISSION CROSSMEMBER. 

>> DO NOT ROTATE IT AFTER IT HAS BEEN INSTALLED! <<  

ROTATING IT MAY LOOSEN THE HARDWARE THAT SECURES THE MAGNET TO THE HOUSING INSIDE >>> AND YOU WILL VOID THE WARRANTY.

IF YOU NEED TO CHANGE THE MAIN MODULE'S ANGLE THEN SLIDE IT OFF OF THE CROSSMEMBER, ROTATE IT AS NECESSARY AND THEN PLACE IT BACK ONTO THE CROSSMEMBER.

6b. Having read the note above---and while looking forward from behind the transmission crossmember orient BUT DO NOT INSTALL the Main Module such that the gold SMA antenna connector is pointed toward the driver's side and is nominally parallel with the transmission crossmember.  Please refer to Figure 6-2 below.

6c. Once you are satisfied with the angle of the Main Module relative to the transmission crossmember place the Main Module onto the transmission crossmember, just left of the rear transmission mount as shown in Figure 6-2 above.

Figure 6-2 (above):  Main Module Orientation and Placement on the Crossmember

Figure 6-3 (above):  Placement of Two 36 Inch Zip Ties Around the Driver's Side Main Frame Rail

Driver's Side Sensor Assembly

6e. Install the driver's side sensor assembly onto the driver's side exhaust pipe by doing the following:

1) Install the gold-colored fiberglass exhaust pipe insulation around the exhaust pipe and secure it with a short piece of tape to hold it in place.

2) Remove the U-bolt from the Driver's Side sensor assembly.  Slide it over the previously-installed fiberglass exhaust pipe insulation such that the threaded ends point TOWARD the transmission. 

3) Slide the mating piece of the U-bolt over the threaded ends.

4) Slide the Driver's Side sensor assembly bracket over the U-bolt's threaded ends and secure loosely with the included nuts.  The sensor should be nominally beneath the exhaust pipe.

5) Push the U-bolt forward (toward the catalytic converter) as far as you can, until the bracket contacts the vehicle's fiber heat shield.

6) Begin to EVENLY tighten the U-bolt nuts.  When they start to become snug stop tightening and rotate the sensor assembly until the sensor's opening is as close as you can get to parallel with the ground.

7) Finish securing the U-bolt nuts.

8) Install two 8 inch zip ties around the heat shield mounting bracket in order to create two sensor cable tie points.  Refer to Figure 6-4 below.

Figure 6-4 (above):  Sensor Cable Tie Points Created From Two 8 Inch Zip Ties

9) Route the Driver's Side Sensor Cable toward the Driver's side main frame rail and secure it to the two sensor cable tie points that you created in step 8).  Refer to Figure 6-4 above.

10) Install an 8 inch zip tie around the large factory cable bundle and use a small zip tie to secure the Driver's Side Sensor Cable to the zip tie that you just installed, as shown in Figure 6-5.

Figure 6-5 (above):  Sensor Cable Secured to Large Factory Cable Bundle

11) Continue routing the sensor cable rearward toward the first of the two 36 inch zip ties that you installed around the main frame rail in step 6d.  Secure the sensor cable to the 36 inch zip tie with a small included zip tie.  Refer to figures 6-6 and 6-7 below.

NOTE: After completion of step 11) the sensor cable is ready to be routed along the transmission crossmember.  This is readily apparent in Figures 6-6 and 6-7, although please note that the figures show the sensor cable to have been already routed and secured. 

Figure 6-6 (above):  Showing Driver's Side Sensor Cable and Antenna Cables Secured to the 36 Inch Zip Ties

Figure 6-7 (above):  Closeup of Sensor and Antenna Cable Routing Along Transmission Crossmember

Routing the Driver's Side Sensor Cable to the Main Module

6f.  Route the Driver's Side Sensor Cable along the REAR LOWER SURFACE of the transmission crossmember and connect it to the only cable coming out of the Main Module that has a matching connector AND is long enough to reach the Driver's Side Sensor cable.  Mate the two connectors and screw them together HAND TIGHT BUT SNUG.  The connectors are waterproof and DO NOT need to be tightened with a wrench.

Secure the Driver's Side Sensor Cable to the REAR LOWER SURFACE of the transmission crossmember by securing it to the 14 inch zip ties around the crossmember that were installed in step 6a.  Refer to Figures 6-8 and 6-9.

6g. In a similar way as in step 5d route the Antenna Cable along the REAR UPPER SURFACE of the transmission crossmember and connect it to the gold connector on the Main Module that has a matching connector.  Mate the two connectors and screw them together just slightly tighter than hand tight.  Use a 5/16 open end wrench to SNUG the connection.

Secure the Antenna Cable to the REAR UPPER SURFACE of the transmission crossmember by securing it to the 14 inch zip ties around the crossmember that were installed in step 6a.  Refer to Figures 6-8 and 6-9.

Figure 6-8 (above):  Sensor and Antenna Cable Traversing Transmission Crossmember-View 1

Figure 6-9 (above):  Sensor and Antenna Cable Traversing Transmission Crossmember-View 2

Installation of Driver's Side Tamper-Resistant Hardware

6h. Using a 13mm socket (preferred) or 13mm box wrench remove the screw that secures the heat shield mounting bracket to the main frame rail.  Refer to Figure 18.  Using the included T45 Torx bit install and tighten the the included tamper-resistant driver's side heat shield mounting bracket screw.  Refer to Figure 6-10.

Using a 9mm socket (preferred) or 9mm box wrench remove the screw that secures the heat shield to the heat shield mounting bracket.  Refer to Figure 18.  Using the included T27 Torx bit install and tighten the the included tamper-resistant driver's side heat shield mounting screw.  Refer again to Figure 6-10.

Figure 6-10 (above):  Driver's Side Heat Shield Mounting Screw and Mounting Bracket Screw

Using a 9mm socket (preferred) or 9mm box wrench remove the screw that secures the heat shield to the forward heat shield mounting bracket.  Refer to Figure 6-11.  Using the included T27 Torx bit install and tighten the the included tamper-resistant driver's side heat shield mounting screw.

Figure 6-11 (above):  Driver's Side Forward Heat Shield Mounting Screw

Passenger's Side

6i. On the passenger's side of the vehicle install two 36 inch zip ties around the main frame rail, with the first one directly against the rear face of the transmission crossmember and the second one three inches behind the first.  These zip ties will be used as tie points to hold various wires in place in later steps.  Tighten them securely.  Refer to Figure 6-12.

  

Figure 6-12 (above):  36 Inch Zip Ties Placement Around the Passenger's Side Main Frame Rail  

Passenger's Side Sensor Assembly

6j. Install the passenger's side sensor assembly onto the passenger's side exhaust pipe by doing the following:

1) Install the fiberglass exhaust pipe insulation around the exhaust pipe and secure it with a piece of tape to hold it in place.

2) Remove the U-bolt from the Passenger's Side sensor assembly.  Slide it over the previously-installed fiberglass exhaust pipe insulation such that the threaded ends point TOWARD the transmission. 

3) Slide the mating piece of the U-bolt over the threaded ends.

4) Slide the Passenger's Side sensor assembly bracket over the U-bolt's threaded ends and secure loosely with the included nuts.  The sensor should be nominally beneath the exhaust pipe.

5) Push the U-bolt forward (toward the catalytic converter) to get it as close as you can.

6) Begin to EVENLY tighten the U-bolt nuts.  When they start to become snug stop tightening and rotate the sensor assembly until the sensor's opening is as close as you can get to parallel with the ground.

7) Finish securing the U-bolt nuts.

8) Install two 8 inch zip ties around the heat shield mounting bracket in order to create two sensor cable tie points.  Refer to Figure 6-13 below.

Figure 6-13 (above):  Sensor Cable Tie Points Created From Two 8 Inch Zip Ties

9) Route the Passenger's Side sensor cable outward, toward the Passenger's side main frame rail and secure it to the two sensor cable tie points that you created in step 8).  Refer to Figure 6-13 above.

10) Continue routing the sensor cable rearward toward the first of the two 36 inch zip ties that you installed around the main frame rail in step 5d. 

Secure the sensor cable to that first 36 inch zip tie with a small included zip tie.  Refer to figure 6-14 below.

NOTE: After completion of step 10) the sensor cable is ready to be routed along the transmission crossmember.  This is readily apparent in Figure 6-14. 

Figure 6-14 (above):  Sensor Cable Secured to the 36 Inch Zip Tie

Power and Vehicle Interface Cable Routing:

Next, turn your attention to the Power and Vehicle Interface Cable that was fished down from the engine compartment in step 3d:

6k. Install an 8 inch zip tie around the Frame Extension Bracket as shown in Figure 6-15.  

6l. Secure the Power and Vehicle Interface Cable to the Frame Extension Bracket with a small zip tie.

Figure 6-15 (above):  Power and Vehicle Interface Cable Secured to Frame Extension Bracket

6m. Route the Power and Vehicle Interface Cable toward the transmission crossmember until it reaches the first 36 inch zip tie that was installed in step 6i.  Using a small zip tie secure the Power and Vehicle Interface Cable to the first 36 inch zip tie as shown in Figure 6-16.

Ensure that the Power and Vehicle Interface Cable is several inches ABOVE the Passenger's Side Sensor Cable as shown in Figure 6-16.

Figure 6-16 (above):  Power and Vehicle Interface Cable Secured to first 36 Inch Zip Tie

6n.  Route the Passenger's Side Sensor Cable along the REAR LOWER SURFACE of the transmission crossmember and connect it to the only cable coming out of the Main Module that has a matching connector AND is long enough to reach the Passenger's Side Sensor cable.  Mate the two connectors and screw them together SNUGLY BUT HAND TIGHT.  The connectors are waterproof and DO NOT need to be tightened with a wrench.

Secure the Passenger's Side Sensor Cable to the REAR LOWER SURFACE of the transmission crossmember with a small zip tie to secure it to the 14 inch zip ties around the crossmember that were installed in step 6a.  Refer to Figures 6-16, 6-17, and 6-18 for different views of the Passenger's Side Sensor Cable routing.

6o.  Route the Power and Vehicle Interface Cable along the REAR UPPER SURFACE of the transmission crossmember and connect it to the only cable coming out of the Main Module that has a matching connector.  Mate the two connectors and screw them together SNUGLY BUT HAND TIGHT.  The connectors are waterproof and DO NOT need to be tightened with a wrench.

Secure the Power and Vehicle Interface Cable to the REAR UPPER SURFACE of the

transmission crossmember with a small zip tie to the 14 inch zip ties around the crossmember that were installed in step 6a.  Refer to Figures 6-16, 6-17, and 6-18 for different views of the Power and Vehicle Interface Cable routing.

FINALLY:

PLEASE NOTE IN FIGURE 6-18 THE PRESENCE OF A DIAGNOSTIC AND TEST CABLE: 

THE VEHICLE IN THE PHOTO WAS THE ONE ON WHICH WE DEVELOPED THE CAT SAFEGUARD SYSTEM. 

THE CONNECTOR TO WHICH THE TEST CABLE WAS ATTACHED WAS DEACTIVATED PRIOR TO GOING INTO PRODUCTION. 

PLEASE KNOW THAT CONNECTING ANYTHING TO THAT CONNECTOR WILL IMMEDIATELY BRICK THE SYSTEM, RENDERING IT INOPERATIVE...THIS IMMEDIATELY VOIDS THE WARRANTY. 

SO, DON'T DO IT.

Figure 6-17 (above):  DIFFERENT VIEW OF THE PASSENGER SIDE SENSOR CABLE AND THE POWER AND VEHICLE INTERFACE CABLE

Figure 6-18 (above):  VIEW FROM BEHIND OF THE PASSENGER SIDE SENSOR CABLE AND THE POWER AND VEHICLE INTERFACE CABLE

SECTION 7:  BATTERY JUNCTION BOX (AKA FUSE BOX) CONNECTIONS

Section 7 is specific to each particular model year truck.  This particular instruction guide is specifically intended for the 2016 F150 truck.  If this is not your particular model year then please don't use it--contact the factory to receive the correct one.

The CAT SAFEGUARD Power and Vehicle Interface harness comes with the correct fuses already installed for your specific model as defined in your owner's manual--all you will need to do is to verify that the fuses that are installed in the harness are the same values as the ones you will remove from your panel.  The fuses that we have included for this vehicle (a 2016 F150 XLT) in this instruction guide are the same quantities and values as those that are specified in the 2016 F150 owner's manual.

You will notice that there are two fused wires in the harness: a short wire and a long wire--each wire generally contains two fuses-- ALWAYS a 2 amp fuse to protect the CAT SAFEGUARD equipment, and a second fuse (per your owner's manual) to protect the truck's particular circuit.

NOTE: 

NOT ALL POWER AND VEHICLE CABLES WILL HAVE FUSES IN BOTH SLOTS, ALTHOUGH THERE WILL ALWAYS BE A 2 AMP FUSE IN AT LEAST ONE OF THE TWO SLOTS

7a. We will begin with the short wire that protrudes from the Power and Vehicle Interface cable: 

In the 2016 F150 the short wire in the Power and Vehicle Interface cable has two fuse positions, each of which contains a fuse: a 2 amp fuse in one position and a 7.5 amp fuse in the other--see Figure 7-1. 

 

Figure 7-1 (above:) FUSED SHORT WIRE

This short fuse wire will plug into Battery Junction Box fuse position #113 as highlighted in the Battery Junction Box photo immediately below:

Verify that fuse # 113 in your Battery Junction Box is 7.5 amp.  If it is not 7.5 amp stop work and contact the factory immediately for assistance.  However, assuming that it is a 7.5 amp fuse then use a fuse puller to remove fuse # 113 from the truck's Battery Junction Box.  Temporarily route the short wire over to fuse panel slot # 113, but do not install the wire into the fuse slot yet.  

Using a soldering iron or electric wood burner tool melt a small divot in the side of the Battery Junction Box IN THE LOCATION SHOWN in the Battery Junction Box photo above.  The divot should be deep enough that the wire is not chafed, cut, or crushed when the cover is replaced.

Verify one last time that you are about to install the short wire connector into fuse # 113 and then press the short wire firmly into place.

7b. Next, we will work on the long wire that protrudes from the Power and Vehicle Interface cable: 

In the 2016 F150 the long wire in the Power and Vehicle Interface cable has two fuse positions, ONE of which contains a fuse: a 2 amp fuse in one position and NO fuse in the other--see Figure 7-2. 

This long fuse wire will plug into Battery Junction Box fuse position #21A as highlighted in the Battery Junction Box photo immediately below:

2016 F150 BATTERY JUNCTION BOX PHOTO (Fuse #21A)

Verify that fuse slot # 21A in your Battery Junction Box is has  NO fuse in it.  If your fuse location 21A is different then please stop work and contact the factory immediately for assistance.  However, assuming that it contains no fuse then temporarily route the long wire over to fuse panel slot # 21A, but do not install the wire into the fuse slot yet.  

Using a soldering iron or electric wood burner tool melt a small divot in the side of the Battery Junction Box IN THE LOCATION SHOWN in the Battery Junction Box photo above.  The divot should be deep enough that the wire is not chafed, cut, or crushed when the cover is replaced.

Verify one last time that you are about to install the long wire connector into fuse slot # 21A and then press the long wire firmly into place.

7c. Verify the connections one last time.

7d. Apply a large drop of YOUR caulk (black is recommended) into the well of each divot.  Then gently press each of the two wires into the caulk. 

Ensure that the caulk completely encircles each wire and that it extends above the level of the surfaces that meet the Battery Junction Box cover.

ALLOW THE CAULK TO PARTIALLY CURE FOR APPROXIMATELY ONE HOUR BEFORE REPLACING THE BATTERY JUNCTION BOX COVER.

7e. After waiting for the caulk to partially cure replace the Battery Junction Box cover and secure as described in your factory owner's manual.

7f. Verify that the harness routing is correct and that nothing has been pinched, chafed, cut, or otherwise damaged during installation.

7g. Apply any needed self-adhesive zip tie mounts as required.  Tighten the zip ties and trim the ends.  Ensure that you do not accidentally cut any wires in the process.

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SECTION 8:  RECONNECTING THE BATTERY GROUND WIRE

PLEASE NOTE THAT CAT SAFEGUARD WILL EMIT THREE LOUD BEEPS AT THE MOMENT THAT THE VEHICLE'S NEGATIVE BATTERY TERMINAL IS CONNECTED.

8a. Having verified everything one last time reconnect the vehicle's negative battery terminal and tighten securely but do not overtighten it.

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SECTION 9:  CAT SAFEGUARD FUNCTIONAL SYSTEM TESTS

This final section of these instructions cover the installation of the shield plates that prevent your vehicle's catalytic converter exhaust pipes from being accessed by potential thieves.

DRIVER'S SIDE SHIELD PLATE

10a. Unlatch the hood.  This will temporarily disable the Cat Safeguard alarm system.

10b. Place the Driver's Side Shield Plate over the Driver's Side Sensor.  Refer to Figure 10-1.

10c. Align the holes in the shield plate with the holes in the Driver's Side Sensor Shield Support Plate.

10d. Insert a 3/16 rivet into one of the two holes and clinch down with your hand rivet tool.

10e. Insert a 3/16 rivet into the second of the two holes and clinch down with your hand rivet tool.

10b. PASSENGER'S SIDE SHIELD PLATE

With the hood still unlatched and the Cat Safeguard alarm system still disabled.

10f. Place the Passenger's Side Shield Plate over the Passenger's Side Sensor.  Refer to Figure 10-2.

10g. Align the holes in the shield plate with the holes in the Passenger's Side Sensor Shield Support Plate.

10h. Insert a 3/16 rivet into one of the two holes and clinch down with your hand rivet tool.

10i. Insert a 3/16 rivet into the second of the two holes and clinch down with your hand rivet tool.

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CONGRATULATIONS, YOU'VE JUST INSTALLED

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CATALYTIC CONVERTER ALARM SYSTEM!

Cat Safeguard

Houston, TEXAS USA