Ford TRANSIT CUSTOM 2012.75 Page 149 Mounting Manual Download

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5.1.3 Boron Steel Parts

Boron Steel Parts - No Drill or Weld Zones

Date of Publication: 04/2012

FORD

TRANSIT CUSTOM

2012.75

5 Body and P

aint

149

Summary of Contents for TRANSIT CUSTOM 2012.75

Page 1: ...Body and Equipment Mounting Manual FORD TRANSIT CUSTOM 2012 75 Date of Publication 04 2012...

Page 2: ...evelopment the right is reserved to change specifications design or equipment at any time without notice and without incurring any obligations This publication or part thereof may not be reproduced no...

Page 3: ...tion 26 1 13 7 Recommended Main Load Area Dimensions 27 1 14 Hardware Specifications 30 1 15 Load Distribution 31 1 15 1 Load Distribution 31 1 15 2 Center of Gravity Position 31 1 15 3 Center of Grav...

Page 4: ...10 2 Additional Rear Speakers 109 4 11 Cellular Phone 111 4 12 Exterior Lighting 112 4 12 1 Reversing Lamps 112 4 12 2 Additional External Lamps 112 4 12 3 Lamps Hazard Direction Indication 112 4 12 4...

Page 5: ...5 9 2 Roof Racks 171 5 10 Airbag Supplemental Restraint System SRS 173 5 10 1 Air Bags 173 5 11 Safety Belt System 176 5 11 1 Seat Belts 176 5 11 2 Driver Belt Minder 176 5 12 Corrosion Prevention 177...

Page 6: ...or cautions as to each Anyone who does not follow the instructions provide in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice o...

Page 7: ...A526 and mini overhead console 1DIN A606 Utility Vehicle Switch Pack Provides 3 switches for beacon and two power outputs includes A526 A606 and mini overhead console 1 DIN A607 High Specification Int...

Page 8: ...hicle may affect its legal compliance Strict adherence to the original design intent for brakes weight distribution lighting occupant safety and hazardous materials compliance in particular is mandato...

Page 9: ...nd transmission linkage retarders Functional safety and freedom of the tested and approved flexibility of the body and integral chassis structure 1 2 8 Restraints System WARNINGS Modifications to the...

Page 10: ...1 Cologne 50725 DEU Ford of France Antoine de Finance CV Brand Manager Contact 33 1 61016535 Phone 33 1 61016505 Fax adefinan ford com E Mail St Germain Postal Address 34 rue de la Croix de Fer Saint...

Page 11: ...i Transit Brand Manager Contact 41 43 2332253 Phone 41 43 2332005 Fax dbaechi ford com E Mail Wallisellen Postal Address Geerenstrasse 10 Wallisellen 8304 CHE Ford of Denmark Rie Gebauer Transit Brand...

Page 12: ...szczygiel CV Brand Manager Contact 48 22 6086854 Phone 48 22 6086819 Fax moszczyg ford com E Mail Al Jerozolimskie 181 Postal Address Warsaw 02 222 POL Ford of Czech Republic Martin Burda CV Brand Man...

Page 13: ...ct Marketing Contact 61 3 93598396 Phone 61 3 93598944 Fax adoll ford com E Mail 1735 Sydney Road Postal Address Campbell Field VI 3061 AUS 2D Engineering Drawings can be downloaded in DWG format via...

Page 14: ...4 5 Climate Control System page 94 Refer to 4 15 Fuses and Relays page 117 Refer to 5 9 Roof Opening Panel page 171 Roof Racks Refer to 3 3 Accessory Drive page 48 Compressor Installa tion Dry Freigh...

Page 15: ...Auto Wipe and Auto Light for Vehicles with large over hangs Refer to 4 4 Battery and Cables page 80 Generator and Alternator Mobile Shops Offices Refer to 4 9 Tachograph page 104 Refer to 5 2 Hydraul...

Page 16: ...5 7 Seats page 166 Refer to 5 8 Glass Frames and Mechanisms page 169 Refer to 5 9 Roof Opening Panel page 171 Roof Ventilation Refer to 5 10 Airbag Supplemental Restraint System SRS page 173 Refer to...

Page 17: ...ing of the body to the donor vehicle Operating conditions The responsible Technical Service may require additional information and or testing NOTE For further information please contact yourlocalNatio...

Page 18: ...requency Overview table There are no special provisions or conditions for installations or use Do not mount any transceiver microphones speakers oranyotheritem in the deployment path of the airbag sys...

Page 19: ...standby and transmit modes Check all electrical equipment With ignition ON With the engine running During a road test at various speeds Check that electromagnetic fields generated inside the vehicle c...

Page 20: ...railer tow Frequent stop and go cycles High altitude and gradients Terrain conditions such as found on building and construction sites 1 7 1 Conversion Affect on Fuel Economy and Performance Any conve...

Page 21: ...s and environmental burden along the product life cycle Maximizing use of renewable materials e g natural fibres Minimizing the presence of substances impacting vehicle interior air quality clean comp...

Page 22: ...that access to the spare wheel ismaintainedwhenconvertingthevehicle or relocating the spare wheel NOTE When using the vehicle jack refer to the owner guide for correct operating instructions NOTE Mak...

Page 23: ...ow these instructionsmayresultinpersonalinjury CAUTIONS When lifting the vehicle with two post lift vehicle lift arm adapters must be used under the lifting points When lifting the vehicle with a two...

Page 24: ...ion exhaust air intake system or tires may influence the exterior noise emission Therefore the exterior noise level of the converted vehicle has to be verified The interior noise levels should not be...

Page 25: ...fitted removed and stored in the luggage compartment Engage first gear and release the parking brake completely Chock the wheels first if the vehicle is not on level ground Set climate controls to th...

Page 26: ...elevant legal requirements If this modification alters the homologateddimensions anewapproval may be necessary CAUTION Makesurethatreinforcements are installed to maintain the integrity of the origina...

Page 27: ...ensions Full Bulkhead Fixed Glazed C mm B mm A mm Vehicle 1400 1400 2412 L1 H1 1400 1400 2818 L2 H1 L1 3 0m Wheel Base L2 3 3m Wheel Base H1 Low Roof Height Date of Publication 04 2012 FORD TRANSIT CU...

Page 28: ...m Vehicle 200 590 3061 L1 H1 200 590 3437 L2 H1 L1 3 0m Wheel Base L2 3 3m Wheel Base H1 Low Roof Height Load Through Hatch only available with Dual Front Passenger Seat FORD TRANSIT CUSTOM 2012 75 Da...

Page 29: ...an Bulkhead C mm B mm A mm Vehicle 1400 1400 1468 L1 H1 1400 1400 1853 L2 H1 L1 3 0m Wheel Base L2 3 3m Wheel Base H1 Low Roof Height Date of Publication 04 2012 FORD TRANSIT CUSTOM 2012 75 1 General...

Page 30: ...mum Maximum Minimum Thread Size 3 4 2 4 1 4 1 1 M4 6 7 4 9 2 7 2 2 M5 15 0 11 0 11 5 8 5 4 7 3 7 M6 35 0 25 0 28 0 20 0 M8 70 0 50 0 55 0 41 0 M10 125 0 95 0 92 0 68 0 M12 200 150 153 113 M14 310 0 23...

Page 31: ...CGv is less than 800mm and no modifications have been made to the components of the braking system suspension wheels and tires the converted vehicle complies with ECE 13 H ANNEX 9 standard If the Cent...

Page 32: ...Front Axle Weight kg m H Rear Axle Weight mm H Height Lift deg Inclination Angle mm Center of Gravity Height Z Inclination Angle Center of Gravity Height Z 1 15 4 Center of Gravity Height Calculation...

Page 33: ...as Masses and lengths Total vehicle mass is the sum of front and rear axle weight mG mV mH Taking the sum of moments equals zero law the distance Center of Gravity and wheel center can be calculated a...

Page 34: ...Using the rule of proportion leads to the Center of Gravity height formula FORD TRANSIT CUSTOM 2012 75 Date of Publication 04 2012 1 General Information 34...

Page 35: ...he tow ball for vehicles with 15 inch wheels and the lower position for vehicles with 16 inch wheels Any modifications to the vehicle must be noted in the owner s handbook or new descriptive literatur...

Page 36: ...Van Bus and Kombi 2 8 3 3 tonne DESCRIPTION ITEM M16 x 55 Screw 1 M16 Washer 2 M16 Nut 3 M12 x 75 x 90 Hexagonal Flange Bolt 4 M12 Hexagonal Flange Nut 5 177mm A 53mm B 75mm C 35mm D 20mm E FORD TRANS...

Page 37: ...springs or shock absorbers including mounting brackets CAUTION Modifications to the suspension system can cause a deterioration of the vehicle handling characteristics and durability NOTE For detailed...

Page 38: ...tongs Make sure that components loosened or removed and reinstalled are properly reassembled and the torque set in accordance with manufactures requirements NOTE Do not modify the wheelbase or add any...

Page 39: ...ding work the springs must be covered to protect them against weld splatter Do not touch springs with welding electrodes or welding tongs Make sure that components loosened or removed and reinstalled...

Page 40: ...pattern and load rating as the Original Equipment Manufacturer Under these conditions the original tire label should be satisfactory however if the specified tires and or inflation pressures are chang...

Page 41: ...Make sure that the front and rear brake hoses are not twisted and are correctly located away from body and chassis components Front and rear brake hoses must not rub chafe or rest on body or chassis...

Page 42: ...trical supply to auxiliary equipment Refer to 4 3 Charging System page 74 3 1 1 Engine Power Curves Front Wheel Drive FWD Common Rail 2 2L TDCi 74kW 100PS Diesel Engine Common Rail 2 2L TDCi 92kW 125P...

Page 43: ...00PS Diesel Engine Description Item Torque Curve Nm Max Torque 310Nm at 1300 2100 1 min 1 Power Curve kW Max Power 74kW 100PS at 3500 1 min 2 Nm A 1 min B kW C Date of Publication 04 2012 FORD TRANSIT...

Page 44: ...25PS Diesel Engine Description Item Torque Curve Nm Max Torque 330Nm at 1350 2400 1 min 1 Power Curve kW Max Power 92kW 125PS at 3500 1 min 2 Nm A 1 min B kW C FORD TRANSIT CUSTOM 2012 75 Date of Publ...

Page 45: ...55PS Diesel Engine Description Item Torque Curve Nm Max Torque 385Nm at 1700 2200 1 min 1 Power Curve kW Max Power 114kW 155PS at 3500 1 min 2 Nm A 1 min B kW C Date of Publication 04 2012 FORD TRANSI...

Page 46: ...E74570 in this section with standard Ford water hose clip or suitable equivalent specification clip Ensure interference fit between hose and T joint Tube routing must be secured to the body structure...

Page 47: ...e the paint must be fully protected against corrosion Refer to 5 12 Corrosion Prevention page 177 NOTE The installation must be in line with the appropriate legal requirements 3 2 3 Air Flow Restricti...

Page 48: ...If they are unable to help you then please contact the Vehicle Converter Advisory Service at VCAS ford com The Eigen frequency of the bracket with auxiliary unit should be above the maximum excitation...

Page 49: ...ioning Description Item Idler 1 Idler 2 Alternator 3 Idler 4 Power Steering Pump 5 Crankshaft Pulley 6 Compressor 7 Auto Tensioner 8 Front End Accessory Drive Shield only Start Stop A Engine Top Cover...

Page 50: ...e is dependent on the weight of the specified donor vehicle It is necessary to select the appropriate drive engine gear ratio gross vehicle mass gross train mass axle plates and payloads of the base v...

Page 51: ...s ford com fordservice VMT6 6 Speed Manual FWD Transmission Overall Transmission and Differential Drive Ratio Base Transmission Ratio Gear Vehicles greater than 3000kg GVM Vehicles less than or equal...

Page 52: ...smaller to larger diameter pipes Exhaust Pipe Design Principles Description Item diameter d radius 2 5d r 3 6 2 Exhaust Pipes and Supports CAUTIONS Maintain the original set up and heat shields Do no...

Page 53: ...designed to regenerate or clean itself to maintain operating efficiency The regeneration process takes place automatically However some driving conditions mean that you may need to support the regene...

Page 54: ...fuel line To refit fuel tank Lift fuel tank ensuring not to trap fuel lines and electrical wires Refit straps torque bolts to 47 5Nm 7 2Nm Refit filler pipe to tank spud securing hose clip torque to...

Page 55: ...21 9T308 A_ 2 Fix quick fit connector of fuel line to heater tube part number BK21 9N126 A_ 3 Auxillary fuel line has a female connector TI LOCC QC 7 89 fitted as standard It is recommended to use a 7...

Page 56: ...m clearance of all moving parts of the parking brake assembly If these clearances can not be met protect the wires with a convolute For conversions with walkthroughs it is recommended to provide appro...

Page 57: ...water leakage into the vehicle interior passenger and cargo compartments using wiring assemblies that pass from outside into the vehicle interior The drip loop is a section of wiring that is deliberat...

Page 58: ...NOTE The maximum continuous current A values for 30 c and 50 c is a value below the maximum fuse rating allowed for the cable This is because the fuse cable system values at these temperatures are the...

Page 59: ...ed WARNING Do not route other wiring near close to electrical cables with the Anti Lock Brake System and Traction Control System cables because of extraneous signal risk It is generally not recommende...

Page 60: ...s 1 and 2 shown in figure E145360 are moulded directly to wire bundles in polyurethane foam material It is not possible to feed extra wires through with the wire bundle The grommets have an indent mou...

Page 61: ...Rear Cargo Area No Drill Zones L1 H1 with Lift Gate Right Hand Side L1 3 0m Wheel Base L2 3 3m Wheel Base H1 Low Roof No Drill Zones L1 H1 Lift Gate Date of Publication 04 2012 FORD TRANSIT CUSTOM 20...

Page 62: ...s L1 H1 with Lift Gate Left Hand Side L1 3 0m Wheel Base L2 3 3m Wheel Base H1 Low Roof No Drill Zones L2 H1 Rear Cargo Doors Right Hand Side FORD TRANSIT CUSTOM 2012 75 Date of Publication 04 2012 4...

Page 63: ...ll Zones L2 H1 Rear Cargo Doors L1 3 0m Wheel Base L2 3 3m Wheel Base H1 Low Roof No Drill Zones L2 H1 Rear Cargo Doors Left Hand Side Date of Publication 04 2012 FORD TRANSIT CUSTOM 2012 75 4 Electri...

Page 64: ...under floor so it is important to check before drilling For additional information refer to the following links Refer to 5 1 Body page 147 No Drill Zones Under the Floor Tank Refer to 5 4 page 158 Lo...

Page 65: ...tem will not detect a trailer has been connected and shuts down all outputs sleep mode It is recommended to target a 550mA mimimum load to allow for system tolerances This would need to be obtained wi...

Page 66: ...er tow system is to be added the correct wiring and module needs to be ordered The vehicle needs to have Central Car Configuration CCC programmed to the correct parameters CCC Parameter 20 0x1 without...

Page 67: ...sition Lamp Licence Lamp 7 Brown 13 Reverse Lamp 8 Grey Brown 11 KL30 Power 9 Blue Red 9 KL15 Ignition 10 Grey Yellow 10 Ignition Ground KL15 11 Black Violet 8 Trailer Detect 12 Not Used Not Used Powe...

Page 68: ...modules could impact the safe operation of the vehicle CAN Controller Area Network uses propriety message sets to communicate between the devices shown via Medium Speed MS High Speed HS Private and Pu...

Page 69: ...Radio CD A1 Light Switch Module L10 Front Control Display Interface Module MFD 2 3 5 A2 Remote Keyless Entry M Integrated Control Panel A3 Passive Anti Theft System N Sync Gen1 B Adaptive Cruise Cont...

Page 70: ...to the BCM itself Vehicle BCM configuration must NOT be modified once the vehicle has left a Ford production plant except for any changes that may be carried out using dealership integrated diagnostic...

Page 71: ...on Indicators and Hazard Lights Base Remote Locking Courtesy Lights Brake Pad Wear Indication Battery Saver Timer Mid Series BK2T 14B467_B incremental over Low Power Fold mirrors Perimeter Alarm Rear...

Page 72: ...t Shutdown 42W Bulb High Side Pulse Width Modulation Rear Fog Light Output Shutdown 21W Bulb High Side Pulse Width Modulation Stop Lamp Left Output Shutdown 21W Bulb High Side Pulse Width Modulation S...

Page 73: ...igh F6 Mirror Supply 7 5A F6004 Mid High F7 Fog Lights Front Supply 15A F6000 Mid High F8 Main Beam Right Supply 10A F6020 Low Mid High F9 Main Beam Left Supply 10A F6019 Low Mid High F10 Exterior Lig...

Page 74: ...to ensure engine cranking in unfavorable climatic conditions The Transit utilizes multiplexed vehicle electronics it is recommended that the appropriate Ford proprietary accessory systems are used In...

Page 75: ...trol Module PCM or Engine Control Module ECM 1 Body Control Module BCM 2 Battery Monitoring Sensor BMS Where fitted 3 Battery For Start Stop application there will be two batteries 4 Electrical consum...

Page 76: ...15 2V These refresh phases are required as the battery charge status is 80 over long periods of time Refer to 4 4 Battery and Cables page 80 Comparison of SRC and Conventional Charging The following...

Page 77: ...nning for example ignition off or with ignition on and engine not running with engine running the vehicle operates with full functionality When in Transport mode the interior lights clocks and power l...

Page 78: ...y disconnect switch Additional batteries can be fitted in conjunction with a battery disconnect switch cut off relay described in the section Battery and Cables It is important to also read relative i...

Page 79: ...t the airbag control module Disconnect the alternator multi plug prior to using welding or cutting equipment If welding or cutting is to be performed directly near a control module it must be removed...

Page 80: ...is no longer a need to re program the electronic security code as it is tied into the VIN of the Factory fit Transit system The clock initializes to 1200 and will need to be reset to correct time in...

Page 81: ...r than that specified in the Owners manual There is a dedicated charge point under the hood Failure to comply may lead to high current paths that may damage peripherals and ECU s especially in a jump...

Page 82: ...attery capacity On battery choice a number of factors are important Battery specification capability in ampere hours for continuously loading until empty For instance an 80Ah fully charged battery can...

Page 83: ...vehicle to be in line with the Homologation Vehicle Tax and Excise Requirements Convert Fit Additional Third Batteries If additional batteries are added a disconnect relay or main manual switch syste...

Page 84: ...trol Relay D Converter Fit Third Battery E Ford Fit Auxiliary Battery F Ford Fit Vehicle Start Battery G Ford Fit SureStart Battery Relay H Ford Fit Loads from Auxiliary Battery J Switched Ground Engi...

Page 85: ...e grounded directly to the vehicle body and not the negative battery terminal Connecting to the negative battery terminal will bypass the BMS and affect the correct assessment of the battery state of...

Page 86: ...ter fit system Any third party installations should ideally be activated via Ignition or engine RUN However a sleep mode of 100mA is still high and will lead to deep discharge The deep cycle battery o...

Page 87: ...orting bar This ensures that auxiliary circuits are isolated from the vehicle start battery at key off ensuring the engine can be cranked The battery disconnect relay is controlled from the BCM using...

Page 88: ...nverting to the SVO it is necessary to replace the original battery with two SVO batteries of the same type The battery part numbers for each option is shown later in this section The shorting bar nee...

Page 89: ...e running then recommend the 210 Ampere Alternator option HFL Electrical loads greater than 30A at engine run or greater than 5mA at key off over a long duration For example Maintenance Van with power...

Page 90: ...is B shows the alternators revolutions per minute 1 min NOTE For equivalent engine revs per minute RPM the alternators revolutions axis B should be divided by the following factor 2 66 for 2 2L diesel...

Page 91: ...Temperature 115 C Voltage 12 9V 5 Diagram E75873 shows the alternator output performance at five different temperatures In accordance to Ford specification at five different temperatures The vertical...

Page 92: ...ws the torque in Nm which is required to drive the alternator The vertical axis A shows the torque Nm and the horizontal axis B shows the alternators revolutions per minute 1 min FORD TRANSIT CUSTOM 2...

Page 93: ...tor speed in revolutions per minute 1 min NOTE Vehicles fitted with SRC and Start Stop will switch off the alternator if the batteries are at a high state of charge when at engine idle Requirements fo...

Page 94: ...refrigerant lines near or directly over any exhaust system component including the exhaust manifolds Avoid routing of hoses in the wheelhouse or stone kick up arch If routing is required in these area...

Page 95: ...e Color Description Connector Pin C1 Twisted Violet Orange MS CAN 1 Grey Orange MS CAN 2 Red Power 3 Twisted Violet Grey MS CAN Low 4 Blue Grey MS CAN High 5 White Brown Cluster Signal Ground 6 Yellow...

Page 96: ...the vehicle in place of the single horn Any other aftermarket horn for example an air horn will need to be driven by a separate relay energised by the horn circuit FORD TRANSIT CUSTOM 2012 75 Date of...

Page 97: ...cted AND the clutch has been fully released The engine is restarted on clutch pedal press in neutral Inhibitors Sometimes the engine may not shut down or restart due to one or more system inhibitors b...

Page 98: ...a modified version of Ford s patented SureStart twin battery system to isolate the vehicle electrical system from the effects of the voltage transients from increase starter motor warm crank cycles Th...

Page 99: ...etween 1300 3000rpm in 25rpm steps A single press results in a 25 rpm jump If a ramp button is held depressed by the end user then the rate of change is 250rpm sec Very limited vehicle speed is allowa...

Page 100: ...of the green and white loop Resistance Ladder Resistance Ladder Circuit Description Item To Green White Wire 1 Stop Engine 2 RPM 1 on off or Variable Control Idle 3 RPM 2 on off or Variable Control Ne...

Page 101: ...d occurs as the button is pressed The final button the one on the left in figure E88295 acts as an emergency vehicle engine stop It is recommended that this be a red and oversize non latching micro sw...

Page 102: ...or the remaining RPM buttons The 3 RPM speeds should now be re programmed to the new RPM speeds The new settings can be saved and learn mode exited see below How to save new settings and exit from Lea...

Page 103: ...red via a transmission speed sensor and or the need to press the clutch in order to put the vehicle in gear while in RPM speed control mode 4 8 3 Changing Vehicle Speed Maximum Setting The Vehicle Spe...

Page 104: ...ections as this is controlled by tachograph legislation NOTE Digital Tachograph DTCO is the legal requirement for Europe Digital DTCO Tachograph Pin Assignment For detailed information about pin assig...

Page 105: ...nting Description Item In line connector to main harness 1 Tachograph Harness 2 Bracket Roof Console 3 Bracket Console Mounting Tachograph 4 Date of Publication 04 2012 FORD TRANSIT CUSTOM 2012 75 4 E...

Page 106: ...ness s will support Tachographs It is recommended for your local Ford Dealer to assess compatibility first NOTE The base vehicle ordered must have an overhead console and the correct level of trim hea...

Page 107: ...iguration Change For the cluster to obtain the vehicle speed from the Tachograph the central car configuration parameter 118 needs to be changed to 0x03 this will be done at the Dealer 118 Tachograph...

Page 108: ...splay MFD and Integrated Control Panel ICP NOTE Power for radio do not switch the permanent battery feed KL 15 and ignition feed KL 30 on the radio connection The ignition feed 15 is only used to wake...

Page 109: ...Battery 1 Input Output MFD LIN Bus 8 Input Output MS Body CAN 2 Input Output Ground 9 Input Output MS Body CAN 3 Stalk Switch Return Alarm Sense 10 Input Output CAN High 4 Input Output Ground 11 Input...

Page 110: ...e Green Left Rear 21 Brown Yellow Left Rear 9 Rear Speakers In line connector 14401 14K024 Description Item Rear Speaker Left White Green Pin 40 Rear Speaker Left Brown Yellow Pin41 Rear Speaker Right...

Page 111: ...warranty Ford offer hands free and wireless technology Bluetooth phone systems including voice recognition as factory fit options these will also be available as aftermarket accessory kits from your F...

Page 112: ...2x15W 30W High Side Driver Daytime Running Light Left Right Turn Indicator Supply smaller load will cause double flashing bulb outage detection Licence Plate and Marker Lights not to exceed 46W Light...

Page 113: ...irrors WARNING Do not tamper with the base system controlled by Body Control Module and multiplex architecture and any feeds taken from the associated wiring or controller NOTE These options are not s...

Page 114: ...minutes after ignition off dependent on vehicle configuration Fluorescent lighting must not be connected to the existing interior cabin or cargo lighting as it is not compatible with the pulse width m...

Page 115: ...e into either the BCM connector or the in line connector for the door jumper harness The coil of the relay max 300mA should be added across the relevant pin and ground i e one relay for lock all one r...

Page 116: ...Lock Supply Pin 27 Driver Door Unlock Supply Pin 39 Dead Lock Left Door Supply Pin 40 Lift Gate Latch Release Pin41 Dead Lock Right Door Supply Pin 42 Rear Cargo Door Pin 44 Passenger Door Unlock Sup...

Page 117: ...olor Ampere Rating Part Number Mini Fuse Grey 2A 1L3T 14A094 A_ Violet 3A 1L3T 14A094 B_ Pink 4A 1L3T 14A094 C_ Tan 5A 1L3T 14A094 D_ Brown 7 5A 1L3T 14A094 E_ Red 10A 1L3T 14A094 F_ Blue 15A 1L3T 14A...

Page 118: ...standard relays have a nominal coil current of 300mA max at 25 C Relays with higher loads should not be used For maximum switching currents please refer to Relay Figures E75017 E75021 Micro Relay Mic...

Page 119: ...rent B A 3 3 Amps 25 C for 60ms Nominal excitation coil current High Power Bi stable relay Part number BK2T 10B728 A_ 4 15 3 Windscreen Wipers The base wiper system should not be tampered with control...

Page 120: ...BK2V 14A411 C_ High Specification Interface Connector Jumper Harness KTBK2V 14A411 D_ Trailer Tow Jumper BK2T 13B576 A_ Trailer Tow Socket Jumper BK2T 13B576 D_ Trailer Tow Module BK2T 19H378 A_ 4 16...

Page 121: ...nal Pin 11 In addition the reverse signal is also available directly from the BCM max 300mA but there is no free pin available The only way to access this signal at this location would be via a splice...

Page 122: ...onnectors are located at the rear of the vehicle near the interface of the rear door or lift gate wiring This circuit can only have a relay added maximum 300mA to control additional lighting Check wit...

Page 123: ...ide marker lamps if they exist and the rear registration plate light can only be switched on and off simultaneously This condition does not apply when using front and rear position lights as well as s...

Page 124: ...or vehicle has been supplied with these features the dealer can configure the vehicle to manual light and wipe with the following settings Set Central Car Configuration parameter 24 With Rain sensor t...

Page 125: ...onjunction with Special Vehicle Option SVO Auxiliary Fuse Panel or the High Specification Interface Connector Long term risk of a faulty connection developing Potential fire risk from over loading All...

Page 126: ...60 Ampere A These points are located on the driver s seat pedestal and are protected by a cover Only one of the customer connection points is always fitted standard on vehicles the remaining two can...

Page 127: ...ctor is 4S7T 14489 VD_ A service kit KTBK2V 14A411 C_ can be ordered from your local Ford Dealer the kit contains the mating connector to access these signals and 3 meters of wiring When the Auxiliary...

Page 128: ...relays switched by this signal to meet this durability cycle The fitment of the Auxiliary Fuse Panel will provide a power 12V side for the relay although connection to the engine run pin is still req...

Page 129: ...ption Item C1 Connector 1 C2 Switch Connector 2 Standard Interface Connector 3 Ground 4 C3 2 Way Radio Connector 5 SVO Auxiliary Fuse Panel within the Pre Fuse Box lid not shown 6 Date of Publication...

Page 130: ...ption Item C1 Connector 1 C2 Switch Connector 2 Standard Interface Connector 3 Ground 4 C3 2 Way Radio Connector 5 SVO Auxiliary Fuse Panel within the Pre Fuse Box lid not shown 6 FORD TRANSIT CUSTOM...

Page 131: ...948 and E152949 The mating connector for the C1 is DELPHI 15326956 The fuse ratings relays and circuits are shown in figure E152950 and table A service kit KTBK2V 14A411 A_ can be ordered from your lo...

Page 132: ...SVO Auxiliary Fuse Panel Circuit Diagram FORD TRANSIT CUSTOM 2012 75 Date of Publication 04 2012 4 Electrical 132...

Page 133: ...Output C1 P 15A Fuse F6 R5 Output C1 R 15A Fuse F7 Vehicle Speed C1 S 10A Fuse F8 R1 Output C2 1 20A Fuse F9 Ground C2 2 5A Fuse F10 Switch Illumination C2 3 15A Fuse F11 R3 Solenoid IN C2 4 SPARE F1...

Page 134: ...e fitment of the beacon switch BK2V 13D768 A_ see figures E152953 and E152954 in SVO Switches and SVO Auxiliary Fuse Panel see figures E152948 and E152949 shown in this section The beacon wiring circu...

Page 135: ...Preparation Pack and an additional harness BK2V 14659 B_ The beacon wiring is always on the right hand side of the vehicle and connects into the C2 connector of the SVO switch harness BK2V 14A303_ Har...

Page 136: ...A Right Hand Drive location B C2 Connector 1 In line Connector 10A933 2 BK2V 14A303_ Harness see E152954 and switch table 3 Front Beacon Connector 4 Over Head Console Containing Switches 5 FORD TRANSI...

Page 137: ...atched switches that control relays in the Auxiliary Fuse Panel When the switches are pressed light on the switches provide a 12V 20A output NOTE The Water Heater or Aux 2 switches must have the engin...

Page 138: ...gh specification vehicles there will only be one remaining customer connection point available for customer to use See also Fuse Rating table The High Specification Interface Connector 43 way connecto...

Page 139: ...ters of wiring with all wires is available as a kit KTBK2V 14A411 D_ from your local Ford dealer WARNING This link wire provides a no start function If the connection becomes Open Circuit by removing...

Page 140: ...KL15 1 00 18 Not available until 2013 Audio Mute 0 50 19 300mA Pulse Width Modulation Signal from BCM IP SwitchIllumina tion 0 75 20 NA AC Active Ground 50 ohms AC Active 0 50 21 3A Pulse Width Modula...

Page 141: ...0 40 NA Door Closed Ground 50 ohms Driver Door Ajar 0 50 41 NA Lock Request Ground 50 ohms Lock 0 50 42 NA Unlock Request Ground 50 ohms Unlock 0 50 43 KL Terminology Ignition Position 2 KL15 B Always...

Page 142: ...094 H_ Fused Ground Yellow 20 Mini F16 1L3T 14A094 H_ Fused Ground Yellow 20 Mini F17 Spare F18 WARNINGS No increase in existing vehicle standard fuse capacity is allowed under any circumstances The f...

Page 143: ...ay have a number of unused connectors these are dedicated to other features and options e g heated seats but are not always present depending on level of harness fitted Ford do not recommend the use o...

Page 144: ...ightened to the correct torque Ground wires should be brought back to the Ford ground points provided please refer to the following figures For very high current users it is recommendedthatthegroundco...

Page 145: ...gine Bay RHS GP14 14K024 Mis Power Electric W505255 S437M Cross Car Beam LHS GP15 14K024 Mis Power Electric W505255 S437M Cross Car Beam LHS GP16 14K024 Mis Power Electric W505255 S437M Cross Car Beam...

Page 146: ...Engine Bay FORD TRANSIT CUSTOM 2012 75 Date of Publication 04 2012 4 Electrical 146...

Page 147: ...voltages produced during welding and in alignment work during body shell rectification may cause electronic systems to be damaged In particular the safety instructions for performing welding work on...

Page 148: ...th a lint free cloth If the join area is accessible from the inside the transition area to the paint must be abraded for all types of join so that good adhesion of the primer is achieved later If the...

Page 149: ...5 1 3 Boron Steel Parts Boron Steel Parts No Drill or Weld Zones Date of Publication 04 2012 FORD TRANSIT CUSTOM 2012 75 5 Body and Paint 149...

Page 150: ...d by adding any additional equipment If uncertain please consult the Vehicle Converter Advisory Service VCAS ford com Lighting Do not alter the lighting system Crash Do not cut drill or weld any parts...

Page 151: ...egs are stowed and locked away prior to engaging vehicle drive NOTE There are no tie down locations in the floor It is the converters responsibility to fix with adequete reinforcements from below For...

Page 152: ...to design sub frames in way that there is no adverse strain on the vehicle structure Use compliant and fixed mounts to attach to the vehicle body For design principle refer to E145387 For Van Bus and...

Page 153: ...or edge to center of load If mounted asymmetrical to the vehicle center line or if mounted at side load door load capacity is up to 500kg at 1000mm from floor edge to center of load For pillar lifts w...

Page 154: ...upper area additional cross brace roof bows are to be used If linings are planned for the inside of the load area All racking through bolts must be designed to be accessible through the lining to the...

Page 155: ...Recommended Fixing Locations Date of Publication 04 2012 FORD TRANSIT CUSTOM 2012 75 5 Body and Paint 155...

Page 156: ...n Racking System Left Hand Side Shown Racking Floor Fixings to Load Compartment Tie Downs Description Item Rigid Self Supporting Racking Frame Work 1 Fixing to floor 2 FORD TRANSIT CUSTOM 2012 75 Date...

Page 157: ...r Load Bearing Attachments through body side to internal racking 2x 2 New Through Bolts 2 bolts per top attachment and 1 bolt per lower attachment 3 For designing glass carrying rack on body side oute...

Page 158: ...es are fitted with load compartment tie downs these are all D rings as shown in E145395 Not all vehicles will have all locations shown it will depend on the base vehicle For additional fixing location...

Page 159: ...8 A 1177 B 2083 1716 C 2611 2374 D 2882 2515 E Vertical from floor 137 A1 61 B1 395 C1 75 D1 2 E1 From center line of vehicle 733 A2 817 B2 882 C2 791 D2 450 E2 L1 3 0m Wheel Base L2 3 3m Wheel Base D...

Page 160: ...air circulation from the cab to the rear load space for ventilation control Air circulation and body flexing must be also given consideration when engineering an alternative bulkhead It is not recomme...

Page 161: ...d advice please consult your local National Sales Company representative or Local Ford Dealer If they are unable to help you then please contact the Vehicle Converters Advisory Service at VCAS ford co...

Page 162: ...Drill Zone Driver and Passenger Doors No Drill Zone Driver and Passenger Doors Description Item 300mm A 55mm B 150mm C 190mm D FORD TRANSIT CUSTOM 2012 75 Date of Publication 04 2012 5 Body and Paint...

Page 163: ...No Drill Zone Lift Gate No Drill Zone Lift Gate Description Item 480mm A 430mm B 305mm C Date of Publication 04 2012 FORD TRANSIT CUSTOM 2012 75 5 Body and Paint 163...

Page 164: ...Side Sliding Doors No Drill Zone Sliding Doors Description Item 620mm A 165mm B 360mm C 740mm D 290mm E 250mm F 215mm G 500mm H 300mm J FORD TRANSIT CUSTOM 2012 75 Date of Publication 04 2012 5 Body...

Page 165: ...ll Zone Rear Cargo Doors No Drill Zone Rear Cargo Doors Description Item 250mm A 115mm B 385mm C 250mm D 480mm E 260mm F 175mm G Date of Publication 04 2012 FORD TRANSIT CUSTOM 2012 75 5 Body and Pain...

Page 166: ...t belts For installation of non OEM rear seats the rear seats and seat belt systems need to comply with the relevant legal requirements and ECE directives Refer to 3 6 Exhaust System page 52 Vehicle E...

Page 167: ...Kombi Van Rear Seat Fixing Positions Left Hand Drive Shown Date of Publication 04 2012 FORD TRANSIT CUSTOM 2012 75 5 Body and Paint 167...

Page 168: ...794 M Right Hand Drive symmetrically opposite about center line of vehicle Double Cab in Van DCIV Rear Seat Fixing Locations Left Hand Side Shown DCIV Rear Seat Fixing Locations Triple Seat Second Row...

Page 169: ...u then please contact the Vehicle Converter Advisory Service at VCAS ford com 5 8 2 Rear Windows For windows it is recommended to specify the base vehicle as a Kombi or Bus body however when convertin...

Page 170: ...orizontal Section Through C Pillar A Vertical Section Through Side Window Non Side Load Door B Glass 1 Adhesive 2 Cut within 0 and 1 5mm of inner body panel flange edge all around 3 Window trim strip...

Page 171: ...ort up to 1kg on an unsupported area of roof Loads up to a maximum of 25kg must be distributed over 2 roof bows Air Conditioning Units Units weighing more than 25kg must be internally supported on cro...

Page 172: ...limitation The load is evenly distributed converter to ensure owner s information book identifies this limitation The load of a single attachment under worst case loading must not exceed 75kg The roo...

Page 173: ...side air bags if planning to retrofit a swivelling device on the front seats and or an armrest on the outer side of the front seats this may affect the function and or deployment of the side air bags...

Page 174: ...ionfortheRCM Restraints Control Module RCM Front and Side Sensors The airbag sensor for the front air bags is located behind the front grille see figure E145411 The sensors for the side air bags are l...

Page 175: ...Front Sensor Side Sensor Date of Publication 04 2012 FORD TRANSIT CUSTOM 2012 75 5 Body and Paint 175...

Page 176: ...webbing button stop This prevents a situation where all the webbing runs back into the retractor and the retractor becomes locked When reinstalling fit the retractor to the body first and gently pull...

Page 177: ...atalytic converters Ensure all materials are compatible with the relevant Ford specifications and maintain the original performance where possible Some proprietary products affect the original coating...

Page 178: ...f the chassis frame Locate and drill holes accurately using a drill guide to ensure holes are square to frame vertical center line allow for side member draft angle Drill undersize and ream out to siz...

Page 179: ...esignated for the fitting of attachment is defined as 220mm horizontally by 95mm vertical downward to the road surface with a max width of 1390mm about vehicle center line It is not the manufactures r...

Page 180: ...Commercial and Legal Aspects 8 Communications Network 68 Connector Pin Out Practices 56 Connectors 125 Contact Corrosion 177 Contact Information 10 Conversion Affect on Fuel Economy and Performance 20...

Page 181: ...ss NVH 24 P Package and Ergonomics 26 Painting Road Wheels 40 177 Parking Brake 41 Partitions Bulkhead Driver and Front Passenger s Protection on Van Bus and Kombi 160 Plywood Lining Cladding 161 Powe...

Page 182: ...ids and Vehicle Storage 25 W Warnings Cautions and Notes in This Manual 6 Warranty on Ford Vehicles 8 Water Leakage Prevention 57 Water Tank on Camper Vehicles 179 Welding 147 Wheel Clearance 40 Wheel...

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