Body and Equipment Mounting Manual - Ford México€¦ · 1.1 About This Manual 1.1.1 New for this...

Body and Equipment Mounting ManualFORD TOURNEO CUSTOM/TRANSIT CUSTOM 2013

Date of Publication: 04/2017

The information contained in this publication was correct at the time of going to print. In the interest of development the right is reserved to changespecifications, design or equipment at any time without notice and without incurring any obligations. This publication, or part thereof, may not bereproduced nor translated without our approval. Errors and omissions excepted.

© Ford Motor Company 2017

All rights reserved.

1 General Information1.1 About This Manual..............................6

1.1.1 New for this Body and EquipmentMounting Manual (BEMM) Publication04/2017............................................................6

1.1.2 Introduction....................................................61.1.3 Important Safety Instructions.................61.1.4 Warnings, Cautions and Notes in This

Manual.............................................................61.1.5 How to Use This Manual...........................61.1.6 Supplemental Information.......................7

1.2 Commercial and Legal Aspects..........81.2.1 Terminology....................................................81.2.2 Warranty on Ford Vehicles.......................81.2.3 Whole Vehicle Type Approval.................81.2.4 Legal and Vehicle Type Approval...........81.2.5 Alternative Type Approval........................91.2.6 Legal Obligations and Liabilities............91.2.7 General Product Safety

Requirement..................................................91.2.8 Product Liability............................................91.2.9 Restraints System........................................91.2.10 Drilling and Welding..................................101.2.11 Minimum Requirements for Brake

System............................................................101.2.12 Road Safety..................................................10

1.3 Contact Information...........................111.4 Conversion Type.................................15

1.4.1 Special Vehicle Option (SVO) OrderCodes..............................................................15

1.4.2 Conversion Type - ReferenceTables..............................................................15

1.5 Conversion Homologation.................191.6 Electromagnetic Compatibility

(EMC)................................................201.6.1 Permitted Antenna Location..................21

1.7 Vehicle Duty Cycle Guidelines...........221.7.1 Conversion Affect on Fuel Economy

and Performance.......................................221.7.2 Vehicle Ride and Handling

Attributes......................................................221.8 Jacking...............................................231.9 Lifting................................................241.10 Noise, Vibration and Harshness

(NVH).................................................251.11 Vehicle Transportation Aids and

Vehicle Storage.................................261.12 Package and Ergonomics..................27

1.12.1 General Component PackageGuidelines.....................................................27

1.12.2 Driver Reach Zones....................................271.12.3 Driver Field of View....................................271.12.4 Conversion Affects on Parking

Aids..................................................................271.12.5 Aids for Vehicle Entry and Exit..............271.12.6 Front, Rear and Side Under-run

Protection......................................................271.12.7 Vehicle Dimensions Key..........................281.12.8 Recommended Main Load Area

Dimensions..................................................291.13 Hardware—Specifications................331.14 Load Distribution..............................34

1.14.1 Load Distribution.......................................341.14.2 Center of Gravity Position.......................341.14.3 Center of Gravity Height Test

Procedure.....................................................34

1.14.4 Center of Gravity HeightCalculation...................................................36

1.14.5 Formulas.......................................................361.15 Towing...............................................38

1.15.1 Tow Bar Requirements............................381.15.2 Tow Bar Types............................................38

2 Chassis2.1 Suspension System...........................412.2 Front Suspension..............................42

2.2.1 Springs and Spring Mounting................422.3 Rear Suspension...............................43

2.3.1 Springs and Spring Mounting...............432.4 Wheels and Tires...............................44

2.4.1 Wheel Clearance.......................................442.4.2 Tire Manufacturers....................................442.4.3 Tire Pressure Monitoring System

(TPMS).........................................................442.4.4 Spare Wheel................................................442.4.5 Temporary Mobility Kit............................442.4.6 Painting Road Wheels.............................44

2.5 Brake System.....................................452.5.1 General..........................................................452.5.2 Kerb Mass Data..........................................452.5.3 Brake Hoses General................................452.5.4 Parking Brake..............................................452.5.5 Hydraulic Brake—Front and Rear

Brakes............................................................452.5.6 Anti-Lock Control — Stability

Assist..............................................................45

3 Powertrain3.1 Engine................................................46

3.1.1 Engine Selection for Conversions.......463.1.2 Engine Power Curves...............................46

3.2 Engine Cooling..................................503.2.1 Auxiliary Heater Systems.......................503.2.2 Auxiliary Heater Installation...................513.2.3 Air Flow Restrictions..................................51

3.3 Accessory Drive.................................523.3.1 Front End Accessory Drives — General

Information..................................................523.4 Clutch................................................543.5 Manual Transmission........................553.6 Exhaust System................................56

3.6.1 Extensions and OptionalExhausts.......................................................56

3.6.2 Exhaust Pipes and Supports................563.6.3 Exhaust Heat Shields...............................563.6.4 Diesel Particulate Filter (DPF)..............573.6.5 Vehicle Exhaust Systems — Vans with

Bulkheads.....................................................573.7 Fuel System.......................................58

4 Electrical

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4.1 Wiring Installation and RoutingGuides.................................................61

4.1.1 Wiring Harness Information ....................614.1.2 General Wiring and Routing.....................614.1.3 Connector Pin Out Practices...................614.1.4 Unused Connectors...................................624.1.5 Grounding......................................................624.1.6 Prevention of Squeaks and

Rattles.............................................................624.1.7 Water Leakage Prevention......................624.1.8 Wiring Splicing Procedures.....................624.1.9 Wiring Specification...................................634.1.10 Electromagnetic Compatibility (EMC)

Awareness.....................................................644.1.11 Wiring Through Sheet Metal..................654.1.12 No Drill Zones — Rear Cargo Area........664.1.13 Electrics for Tow Bar...................................714.1.14 Trailer Tow Connectivity...........................74

4.2 Communications Network.................754.2.1 CAN-Bus System Description and

Interface..........................................................754.2.2 Body Control Module (BCM)...................77

4.3 Charging System.................................814.3.1 General Information and Specific

Warnings.........................................................814.3.2 System Operation and Component

Description ...................................................824.3.3 Start-Stop Override and Configurable

Charging.........................................................844.3.4 Power Management Settings................894.3.5 Electrical Conversions..............................904.3.6 Fitting Equipment Containing Electric

Motors.............................................................924.3.7 Vehicle Electrical Capacity —

Alternator.......................................................924.3.8 Charge Balance Guidelines.....................924.3.9 Circuit Diagrams..........................................92

4.4 Battery and Cables.............................934.4.1 High Current Supply and Ground

Connections..................................................934.4.2 Battery Information...................................934.4.3 Battery Rules................................................974.4.4 Battery Configurations..............................974.4.5 Battery Configuration, Additional

Loads, Start-Stop and SmartRegenerative Charging (SRC)................97

4.4.6 Additional Loads and ChargingSystems.........................................................101

4.4.7 Battery Monitoring Sensor (BMS)......1034.4.8 Single and Twin Battery Systems.......1044.4.9 Power and Connectivity Usage

Recommendations..................................1064.4.10 Generator and Alternator.......................107

4.5 Climate Control System.....................1114.6 Instrument Panel Cluster (IPC)........1124.7 Horn....................................................1134.8 Electronic Engine Controls................114

4.8.1 Start-Stop.....................................................1144.8.2 Engine RPM (Revs Per Minute) Speed

Controller (A003)......................................1164.8.3 DPF and RPM Speed Control...............1204.8.4 Changing Vehicle Speed Maximum

Setting...........................................................1204.9 Information and Entertainment

System - GeneralInformation—Specifications............121

4.9.1 Audio Head Unit (AHU) - MultimediaIn Car Entertainment (ICE) PackSummary.......................................................121

4.9.2 MyConnection Radio andMyConnection Radio with DAB............122

4.9.3 Mid-Radio and Mid-Radio withDAB.................................................................123

4.9.4 Additional Rear Speakers.......................1254.10 Cellular Phone...................................1274.11 Exterior Lighting...............................128

4.11.1 Reversing Lamps.......................................1284.11.2 Additional External Lamps....................1284.11.3 Lamps – Hazard / Direction

Indication......................................................1284.11.4 Lamps – Front and Rear Fog................1284.11.5 Electrically Operated Door Mirrors.....128

4.12 Interior Lighting................................1294.12.1 Additional Internal Lamps ....................1294.12.2 Additional 'Theater Lighting' for rear

of vehicle interior.......................................1294.13 Cruise Control...................................130

4.13.1 Adaptive Cruise Control.........................1304.14 Handles, Locks, Latches and Entry

Systems..............................................1314.14.1 Door Removal or Modification..............1314.14.2 Central Locking...........................................1314.14.3 Remote Keyless Entry/Tire Pressure

Monitoring System Receiver(RKE/TPMS Receiver).............................132

4.15 Fuses and Relays..............................1344.15.1 Fuses..............................................................1344.15.2 Relays.............................................................1354.15.3 Windscreen Wipers..................................136

4.16 Special Conversions.........................1374.16.1 Special Vehicle Options (SVO)

Harnesses and Aftermarket Kits..........1374.16.2 Additional Vehicle

Signals/Features........................................1374.16.3 Auto Wipe and Auto Lamp for vehicles

with large overhangs.................................1414.17 Electrical Connectors and

Connections......................................1424.17.1 Connectors...................................................1424.17.2 Customer Connection Points

(CCP).............................................................1424.17.3 Camper Central Connectors.................1434.17.4 Vehicle Interface Connector.................1464.17.5 Auxiliary Fuse Panel (A526)..................1474.17.6 Beacon Preparation Pack (A606)......1534.17.7 Utility Vehicle Switch Pack

(A607)...........................................................1554.17.8 Auxiliary Switches.....................................1574.17.9 High Specification Vehicle Interface

Connector (A608)...................................1604.17.10 Adding Connectors...................................170

4.18 Grounding...........................................1714.18.1 Ground Points..............................................171

5 Body and Paint5.1 Body...................................................174

5.1.1 Body Structures - GeneralInformation..................................................174

5.1.2 Welding.........................................................1745.1.3 Boron Steel Parts......................................176

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5.1.4 Floor 'No Drill Zones' under the FloorFuel Tank......................................................177

5.1.5 Front End Integrity for Cooling, Crash,Aerodynamics and Lighting.................178

5.2 Hydraulic Lifting Equipment...........1795.2.1 Hydraulic Lifting Equipment for Van,

Bus and Kombi..........................................1795.3 Racking Systems.............................182

5.3.1 Racking Systems......................................1825.4 Body System - General

Information—Specifications..........1865.4.1 Load Compartment Tie Downs for

Van, Bus and Kombi................................1865.5 Front End Body Panels....................188

5.5.1 Partitions (Bulkhead) - Driver andFront Passenger(s) Protection on Van,Bus and Kombi.........................................188

5.6 Body Closures..................................1905.6.1 Security, Anti Theft and Locking

System ........................................................1905.7 Interior Trim.....................................194

5.7.1 Load Compartment InteriorLining............................................................194

5.7.2 Plywood Lining/Cladding.....................1945.8 Seats................................................195

5.8.1 Van.................................................................1955.8.2 Windowed Van..........................................1955.8.3 Heated Seats.............................................1955.8.4 Rear Seat Fixing Positions....................195

5.9 Glass, Frames and Mechanisms.....1985.9.1 Heated Windshield and Heated Rear

Window.......................................................1985.9.2 Rear Windows...........................................198

5.10 Airbag Supplemental RestraintSystem (SRS).................................200

5.10.1 Airbags........................................................2005.11 Seatbelt Systems............................203

5.11.1 Seat Belts...................................................2035.11.2 Driver Belt Minder...................................203

5.12 Roof.................................................2045.12.1 Roof Ventilation......................................2045.12.2 Roof Racks................................................204

5.13 Corrosion Prevention......................2065.13.1 General.......................................................2065.13.2 Repairing Damaged Paint...................2065.13.3 Under Body Protection and

Material......................................................2065.13.4 Painting Road Wheels..........................2065.13.5 Contact Corrosion..................................206

5.14 Frame and Body Mounting..............2075.14.1 Mounting Points and Tubing...............2075.14.2 Frame Drilling and Tube

Reinforcing.................................................2075.14.3 Area for Fitting Additional Body

Attachments to the Rear of theBumper.......................................................208

5.14.4 Water Tank on Camper Vehicles......208

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1.1 About This Manual

1.1.1 New for this Body and EquipmentMounting Manual (BEMM) Publication04/2017

This BEMM has been updated since the lastpublication dated 03/2017. It is recommended toreview this manual in full.For an overview of the main differences please seebelow:Refer to: 3.3 Accessory Drive (page 52).When installing a new front end accessory drive -text revised.Refer to: 4.4 Battery and Cables (page 93).Warning: Where a battery guard is fitted - textrevised.ADR references updated in various sections

1.1.2 Introduction

This manual has been written in a format that isdesigned to meet the needs of Vehicle Converters.The objective is to use common formats with theworkshop manual which is used by techniciansworldwide.This guide is published by Ford and providesgeneral descriptions and advice for convertingvehicles.It must be emphasized that any change to thebasic vehicle which does not meet the enclosedguideline standards may severely inhibit the abilityof the vehicle to perform its function. Mechanicalfailures, structure failure, component unreliabilityor vehicle instability will lead to customerdissatisfaction. Appropriate design and applicationof body, equipment and or accessories is key toensuring that customer satisfaction is notadversely affected.The information contained within this publicationtakes the form of recommendations to be followedwhen vehicle modifications are undertaken. It mustbe remembered that certain modifications mayinvalidate legal approvals and application forre-certification may be necessary.Ford cannot guarantee the operation of the vehicleif non-Ford -approved electrical systems areinstalled. Ford electrical systems are designed andtested to function under operational extremes,and have been subjected to the equivalent of tenyears of driving under such conditions.Not all information in this manual applies to allterritories. For availability of options and partsplease contact your National Sales Companyrepresentative or Local Ford Dealer.

1.1.3 Important Safety Instructions

Appropriate conversion procedures are essentialfor the safe, reliable operation of all vehicles aswell as the personal safety of the individualcarrying out the work.

This manual cannot possibly anticipate all suchvariations and provide advice or cautions as toeach. Anyone who does not follow the instructionsprovide in this manual must first establish that hecompromises neither his personal safety nor thevehicle integrity by his choice of methods, tools orcomponents.

1.1.4 Warnings, Cautions and Notes inThis Manual

WARNING: Warnings are used to indicatethat failure to follow a procedurecorrectly may result in personal injury.CAUTION: Cautions are used to indicatethat failure to follow a procedurecorrectly may result in damage to thevehicle or equipment being used.

NOTE: Notes are used to provide additionalessential information required to carry out acomplete and satisfactory repair.As you read through this manual, you will comeacross WARNINGS, CAUTIONS and NOTES.A warning, caution or note is placed at thebeginning of a series of steps if it applies tomultiple steps. If the warning, caution or note onlyapplies to one step, it is placed at the beginningof the specific step (after the step number).

1.1.5 How to Use This Manual

This manual covers vehicle conversion procedures.The pages at the start of this manual list thecontent, by group. A group covers a specific portionof the vehicle. The manual is divided into fivegroups, General Information, Chassis, Power train,Electrical and Body. The number of the group isthe first number of a section number. Each titlelisted in the contents links to the relevant sectionof the manual.In some section of the book it may refer you to seeadditional sections for information, links have beenprovided, these links are in blue text.This manual is also designed to be used as aprinted document, where there are links pagenumbers in brackets have been added, which willhelp guide you to the start of the section whichcontains the relevant information.There is also an alphabetical index at the back ofthe manual. As with the contents pages you willbe able to link to sections. To do this just click onthe page number.All left and right handed references to the vehicleare taken from a position sitting in the driver seatlooking forward unless otherwise stated.All references to ADR vehicle standards are onlyapplicable to the Australian and New Zealandmarkets. Where no ADR is specified the EUstandard is recommended.

FORD TOURNEO CUSTOM/TRANSIT CUSTOM 2013Date of Publication: 04/2017

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1.1.6 Supplemental Information

2D Engineering Drawings can be downloaded inDWG format via www.etis.ford.com/fordservice/.Select 'vehicle conversions' then 'BEMM Drawings'tab, this will then give you the option to navigatethough a drop-down menu to specific drawings.3D CAD data in IGES format can be requested bycontacting the Vehicle Converter Advisory Service,[email protected]'s Guide, which have been produced forTransit Custom to assist companies applyinglabels to the sides of the vehicle, can be requestedby contacting either the National SalesRepresentative or the Vehicle Advisory [email protected]

Date of Publication: 04/2017FORD TOURNEO CUSTOM/TRANSIT CUSTOM 2013

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1.2 Commercial and Legal Aspects

1.2.1 Terminology

NOTE: Any modifications to the vehicle must benoted in the owner's handbook or new descriptiveliterature included with the owner'sdocumentation.Vehicle Converter refers to any re-seller alteringthe vehicle by converting the body and adding ormodifying any equipment not originally specifiedand/or supplied by Ford.Unique component or similar wording refers tonon-Ford specified or after sale fitment notcovered by Ford warranty.

1.2.2 Warranty on Ford Vehicles

Please contact The National Sales Company inthe country where the vehicle will be registered fordetails of the terms of any applicable Fordwarranty.The Vehicle Converter should warrant its design,materials and construction for a period at leastequal to any applicable Ford warranty.The Vehicle Converter must ensure that anyalteration made to a Ford vehicle or componentdoes not reduce the safety, function, or durabilityof the vehicle or any component.The Vehicle Converter shall be solely responsiblefor any damage resulting from any alteration madeby the Vehicle Converter or any of its agents to aFord Vehicle Component.The Vehicle Converter releases Ford from allclaims by any third party for any cost or loss(including any consequential damages) arisingfrom work performed by a Vehicle Converter unlessFord has given its prior written consent to suchliability.

1.2.3 Whole Vehicle Type Approval

Fitment of Parts and Accessories

Whole Vehicle Type Approval (WVTA) legislationis to ensure that new vehicles, components andseparate technical units put on the market providea high level of safety and environmentalprotection. The aim is not to be impaired by thefitting of certain parts or equipment after vehicleshave been placed on the market or have enteredservice.Vehicle Converters are advised to check whetherthe fitment of parts require either Type Approvalor Individual Vehicle Approval before the vehicleis registered.

• Type Approval requires a Conformity ofProduction (CoP) inspection to be carried outat the conversion location to demonstrate thatall vehicles of the same type will conform tothe type approved specification.

• IVA requires inspection of an individual vehicleto establish compliance.

• Note:Ford parts fitted in the plant are coveredby the Certificate of Conformity (CoC).

Conversions from Commercial Vehicle N1to Passenger Car M1

Vehicle Converters of Passenger Car M1 vehiclesneed to be aware of the latest Whole Vehicle TypeApproval regulations, especially when the basevehicle is a Commercial Vehicle N1. This affectsvehicles which are homologated to meetPassenger Car M1 regulations.Guidance to Vehicle Converters for M1 registeredvehicles:• The Vehicle Converter is responsible for

checking the vehicle ordered can meet all theregulations for type approval.

• Exemptions for certain regulations should bechecked with latest regulation and ApprovalAuthority.

• Where possible, order a Passenger Car M1 basevehicle such as Kombi M1 and Tourneo CustomM1.

• If specifying Air Conditioning, if the refrigerantneeds meet the required AU Climate Guidelinesfor M1, then Transit Custom N1 entities are notsuitable.

• If Tire Pressure Monitoring System (TPMS) isrequired, specify this when ordering.

• If Belt minder is required, specify PassengerAirbag which includes the Belt minder functionfor the driver.

• The 180 degree cargo door hinges on TransitCustom N1 entities have not been designed tomeet the M1 requirements for ExteriorProjections. If this is required, then the TransitCustom N1 entities are not suitable.

For additional informationRefer to: 1.5 Conversion Homologation (page 19).

1.2.4 Legal and Vehicle Type Approval

• All components embodied on Ford vehicles areapproved to the applicable legal requirements.

• Ford vehicles have Type Approval for theintended marketing territories.

WARNING: Exception - Incompletevehicles require further approval whencompleted by the vehicle converter.


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• The Transit range has Type Approval for manyterritories, although the full range of vehiclesshown in this manual are not necessarilyreleased in all territories. Check with your localFord National Sales Company representative.

• Significant changes to the vehicle may affectits legal compliance. Strict adherence to theoriginal design intent for brakes, weightdistribution, lighting, occupant safety andhazardous materials compliance in particularis mandatory.

1.2.5 Alternative Type Approval

If significant changes are made the vehicleconverter must negotiate with the relevantauthority. Any changes to the vehicle operatingconditions must be advised to the customer.

1.2.6 Legal Obligations and Liabilities

The Vehicle Converter should consult with its legaladvisor on any questions concerning its legalobligations and liabilities.

1.2.7 General Product SafetyRequirement

The Vehicle Converter shall ensure that anyalteration it makes to a Ford vehicle or componentdoes not reduce its compliance with locallegislation.The Vehicle Converter shall release Ford from allliability for damages resulting from:• Failure to comply with these Body Equipment

Mounting directives, in particular warnings.• Faulty design, production, installation,

assembly or alteration not originally specifiedby Ford.

• Failure to comply with the basic fit for purposeprinciples inherent in the original product.

WARNINGS:Do not exceed the gross vehicle mass,gross train mass, axle plates and trailerplate.Do not change the tire size or load rating.

Do not modify the steering system.

Excessive heat can build up from theexhaust system, in particular from thecatalytic converter and from the Dieselparticulate filter (DPF). Ensure adequateheat shields are maintained. Maintainsufficient clearance to hot parts.Do not modify or remove heat protectionshields.Do not remove labels provided with thebase vehicle. Ensure appropriatevisibility.

Do not route any electrical cables withthe Anti-lock Brakes System and TractionControl System cables because ofextraneous signal risk. It is generally notrecommended to hang electrical cablesoff existing harnesses or pipes.Do not change original location or removewarning labels provided with the basevehicle in view to the driver. Ensure thatlabels remain in full view.

NOTE: For further information please contactyour local National Sales Company representative,or Local Ford Dealer. If they are unable to help youthen please contact the Vehicle ConverterAdvisory Service at [email protected] to: 1.3 Contact Information (page 11).

1.2.8 Product Liability

The Vehicle Converter shall be liable for anyproduct liability (whether for death, personalinjury, or property damage) arising from anyalteration to a Ford vehicle or component madeby the Vehicle Converter or any of its agents. Fordshall not be liable for any such liability (except asprovided by law).The Vehicle Converter or equipment manufactureris liable for the:• Operational reliability and road-worthiness of

the vehicle to its original intent.• Operational reliability and road-worthiness of

any component or conversion, not listed inoriginal Ford documentation.

• Operational reliability and road-worthiness ofthe vehicle as a whole (for example the bodychanges and/or additional equipment mustnot have a negative effect on the driving,braking or steering characteristics of thevehicle).

• Subsequent damage resulting from theconversion or attachment and installation ofunique components, including unique electricalor electronic systems.

• Functional safety and freedom of movementof all moving parts (for example axles, springs,propeller shafts, steering mechanisms, brakeand transmission linkage, retarders).

• Functional safety and freedom of the testedand approved flexibility of the body andintegral chassis structure.

1.2.9 Restraints System

WARNINGS:Modifications to the restraints systemare not allowed.Airbag are explosive. For safe removaland storage during conversion follow theprocedures in the Ford workshop manualor consult your local National SalesCompany representative.


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Do not alter, modify or relocate the airbag,sensor and modules of the restraintssystem or any of its components.Attachments or modifications to the frontend or B-Pillar of the vehicle may affectthe airbag deployment timing and resultin uncontrolled deployment.

For additional information:Refer to: 5.10 Airbag Supplemental Restraint

System (SRS) (page 200).

1.2.10 Drilling and Welding

WARNING: Do not Drill or Weld Boronsteel parts, see figure E146882 in thewelding section of this manual.

Drilling and welding of frames and body structurehave to be conducted following the guidelines inWelding and Frame Drilling and Tube Reinforcingsections.Refer to: 5.14 Frame and Body Mounting (page 207).Refer to: 5.1 Body (page 174).

1.2.11 Minimum Requirements forBrake System

It is not recommended to modify the brake system.If a special conversion should requiremodifications:• Maintain original settings.• Maintain brake certification load distribution.Changes to the Anti-lock Brake System (ABS),Traction Control System (TCS) and ElectronicStability Control ESC (also known as ESP) systemare not permitted.

1.2.12 Road Safety

The respective instructions should be strictlyobserved to maintain operational and road safetyof the vehicle.


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1.3 Contact InformationAs a manufacturer, we want to provide you withthe information you need for your vehicleconversion/modification. If the information yourequire is not in this manual or you have furtherquestions, please contact your local NationalSales Company Representative (NSC) or LocalFord Dealer in your Market.If your Local National Sales CompanyRepresentative or Local Ford Dealer are unableto help you, please contact the Vehicle ConverterAdvisory Service at [email protected].

Ford of BritainDebbie Ling - CV MarketingContact:+44-7803-055360Phone:[email protected]:GB-1/673Postal

Address:Eagle Way, GB-1BrentwoodCM13 3BWGBR

Ford of GermanyTorsten Wagner - CV BrandSpecialist

Contact:

+49-221-9017692Phone:+49-221-9018409Fax:[email protected]:D NH/4APostal

Address:Henry Ford Strasse 1Cologne50725DEU

Ford of FranceStephane Prolongeau - CV BrandManager

Contact:

+33-1-61016547Phone:+33-1-61016405Fax:[email protected]:St GermainPostal

Address:34 rue de la Croix de FerSaint Germain en Laye78100FRA

Ford of ItalyMichele Montalto - CV Staff Opera-tions Manager

Contact:

+39-06-51855332Phone:+39 035 4821331Fax:[email protected]:Via Andrea Argoli 54Postal

Address:ROME00143ITA

Ford of IrelandJohn O'Mahony - CV Brand ManagerContact:+353-21-4329276Phone:+353-21-4329211Fax:jomahon6@fordE-Mail:Elm Court,Postal

Address:Boreenmanna RoadCorkIRL

Ford of SpainJavier Martin Sanchez - CV BrandManager

Contact:

+34-91-7145143Phone:+34-91-7145477Fax:[email protected]:Edificio Minipark IV Calle Calendula,Postal

Address:13 Alcobendas,Madrid28109ESP

Ford of PortugalLuis Filipe Azinheiro - CV SpecialistContact:+351-21-3122450Phone:+351-21-3122482Fax:[email protected]:Avenida da Liberdade 249 7 AndarPostal

Address:Lisboa1250-143PRT


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Ford of BelgiumJean Vermeiren - CV Brand ManagerContact:+32-3-8212120Phone:+32-3-8212199Fax:[email protected]:HunderenveldlaanPostal

Address:Brussels1082BEL

Ford of NetherlandsLars Huisken - CV Brand ManagerContact:+31-20-5044714Phone:+31-20-5044718Fax:[email protected]:AMSTELDIJK 216Postal

Address:AMSTERDAM1000 ATNLD

Ford of AustriaPhilipp Edinger - CV Brand ManagerContact:+43-50-6581265Phone:+43-50-6581250Fax:[email protected]:Ford Austria ViennaPostal

Address:Hackingerstrasse 5cVienna1140AUT

Ford of SwitzerlandMarc Brunner - CV Brand ManagerContact:+41-43-2332255Phone:+41-43-2332005Fax:[email protected]:WallisellenPostal

Address:Geerenstrasse 10Wallisellen8304CHE

Ford of DenmarkBent Steen Jenson - CV BrandManager

Contact:

+45-43-480621Phone:[email protected]:5 D-E BorupvangPostal

Address:Ballerup2750DNK

Ford of FinlandJuuso Asp - CV Brand ManagerContact:+358-9-35170134Phone:+358-9-3743081Fax:[email protected]:Malminkaari 9bPostal

Address:Box 164HelsinkiFIN-00701FIN

Ford of NorwayDamir Ljubuncic - CV Brand ManagerContact:+47-66-997297Phone:+47-66-997252Fax:[email protected]:Lienga 2Postal

Address:P.O.BOX 514KOLBOTNN-1411NOR

Ford of SwedenNiklas Johansson - Field EngineerContact:+46-31-3259861Phone:+46-31-3259481Fax:[email protected]:Ravebergsvagen AngeredPostal

Address:GothenburgSE40531SWE


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Ford of HungaryAndrás Nagy - CV Brand ManagerContact:+36-26-802-685Phone:+36-26-802-637Fax:[email protected]:Ford Central and Eastern EuropeanSales LLc.

PostalAddress:

Galamb Jozsef u.3.Szentendre2000HUN

Ford of GreeceJohn Amarantos - CV Field andBrand Manager

Contact:

+30-210-5709913Phone:[email protected]:Ford Motor Hellas SAICPostal

Address:Monemvasias 25 and Akakion 39Marousi151 25AttikiGRC

Ford of PolandMarcin Marczewski - CV BrandManager

Contact:

+48-22-608 6854Phone:+48-22-6086819Fax:[email protected]:ul. Tasmowa 7Postal

Address:Warsaw02-677POL

Ford of Czech RepublicMarek Held - CV Brand ManagerContact:+420-23-4650119Phone:+420-23-4650147Fax:[email protected]:Karolinska 654/2Postal

Address:NILE1 Nile HousePRAGUE18600CZE

Ford of RussiaEvgeniy Gnusov - CV Sales andMarketing

Contact:

+7-495-7459700 x2226Phone:+7-495-7459750Fax:[email protected]:Leningradskaya Street 39, KhimkiBuilding 5

PostalAddress:

MOSCOW141400RUS

Ford Central & Eastern EuropeBalázs Págyi - CV Product SpecialistContact:+36-26-802538Phone:+36-26-802-590Fax:[email protected]:3 Galamb Jozef UtcaPostal

Address:SzentendreH-2000HUN

Rest of the World (RoW)Duvall Hunter - Transit BrandManager

Contact:

+44-1277-252073Phone:[email protected]:GB-1/389Postal

Address:EAGLE WAY, GB-1BRENTWOODCM13 3BWGBR


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Ford Otosan - TurkeySerkan Ozerbay - Transit BrandManager

Contact:

+90-216-5647211Phone:[email protected]:KocaeliPostal

Address:Ihsaniye - Golcuk41680TUR

Ford of AustraliaMichael Risby - Product MarketingSpecialist

Contact:

+61-3-83012613Phone:+61-3-83012621Fax:[email protected]:1735 Sydney RoadPostal

Address:CampbellfieldVIC3061AUS

Ford of New ZealandNZINFOContact:+64-9-2718500Phone:+64-9-2718573Fax:[email protected]:Private Bag 76912Postal

Address:Manukau City2241NZ


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1.4 Conversion Type

1.4.1 Special Vehicle Option (SVO) Order Codes

DescriptionOrder CodeBody

Omit Passenger Seat — No pedestal, not available on Double Cab in VanA304Spare Wheel Access — With rear doors closedA532

ElectricalRPM Speed Control — 1300-3000rpmA0032 High Performance AGM Batteries — 2x 80Ah capacity, 800CCA batteriesA736Auxiliary Fuse PanelA526Beacon Preparation Pack — Switch and wiring front and rear (includes A526 andmini overhead console - 1DIN)*

A606

Utility Vehicle Switch Pack — Provides 3 switches for beacon and two poweroutputs (includes A526, A606 and mini overhead console 1 DIN)*

A607

High Specification Vehicle Interface Connector — Provides a range of hard-wiresignals (includes A526)**

A608

It is necessary to take into account the anticipated usage of the modified vehicle in order to choosethe appropriate specification of the base vehicle.Availability of options will vary on territories.*Not to be ordered with tachograph, as uses the same 1 DIN console.**Not available with A607

1.4.2 Conversion Type - ReferenceTables

NOTE: The following tables are for guidanceonly. Full reference to the Body andEquipment Mounting Manual (BEMM) shouldbe made prior to starting any conversion.

NOTE: For any conversions requiringelectrical power:Refer to: 4.2 Communications Network (page 75).Refer to: 4.15 Fuses and Relays (page 134).The BEMM contains general and specificrecommendations covering conversions to thenew Transit range of vehicles. To assist userslocate information by conversion type thefollowing tables contain the relevant links withinthis Manual.

Camper ConversionRefer to: 1.12 Package and Ergonomics (page 27).Van Conversion / Multi

Purpose VehicleConversions Refer to: 1.15 Towing (page 38).

Refer to: 3.7 Fuel System (page 58).Refer to: 4.4 Battery and Cables (page 93).Refer to: 4.16 Special Conversions (page 137).Refer to: 5.8 Seats (page 195). Rear Seat Fixings Positions.Refer to: 5.12 Roof (page 204).

Refrigerated VehiclesRefer to: 4.4 Battery and Cables (page 93). Generator and Alternator.Van ConversionRefer to: 4.5 Climate Control System (page 111).Refer to: 4.15 Fuses and Relays (page 134).Refer to: 5.12 Roof (page 204). Roof Racks.Refer to: 3.3 Accessory Drive (page 52).Compressor Installa-

tion


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Dry FreightRefer to: 4.4 Battery and Cables (page 93). Generator and Alternator.Box VanRefer to: 5.2 Hydraulic Lifting Equipment (page 179).Refer to: 4.11 Exterior Lighting (page 128).Refer to: 4.16 Special Conversions (page 137). Auto Wipe and Auto Light forVehicles with large over-hangsRefer to: 4.4 Battery and Cables (page 93). Generator and Alternator.PantechniconRefer to: 5.2 Hydraulic Lifting Equipment (page 179).Refer to: 4.11 Exterior Lighting (page 128).Refer to: 4.16 Special Conversions (page 137). Auto Wipe and Auto Light forVehicles with large over-hangsRefer to: 4.4 Battery and Cables (page 93). Generator and Alternator.Money CarriersRefer to: 5.12 Roof (page 204). Roof Ventilation.Refer to: 4.11 Exterior Lighting (page 128).Refer to: 4.4 Battery and Cables (page 93). Generator and Alternator.Refuse CollectionRefer to: 4.11 Exterior Lighting (page 128).

Emergency ServicesRefer to: 3.2 Engine Cooling (page 50). Airflow Restrictions.Ambulance (Front

Line) / *Fire Brigade /*Armed Forces /*Police

Refer to: 4.4 Battery and Cables (page 93). Generator and Alternator.Refer to: 4.11 Exterior Lighting (page 128).Refer to: 4.12 Interior Lighting (page 129).Refer to: 4.15 Fuses and Relays (page 134).Refer to: 5.2 Hydraulic Lifting Equipment (page 179).Refer to: 5.8 Seats (page 195).Refer to: 5.10 Airbag Supplemental Restraint System (SRS) (page 200).* Refer to: 4.16 Special Conversions (page 137). Auto Wipe and Auto Light forVehicles with large over-hangs


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Vocational ConversionRefer to: 4.4 Battery and Cables (page 93). Generator and Alternator.

Mobile Workshops

Refer to: 5.2 Hydraulic Lifting Equipment (page 179).Refer to: 5.3 Racking Systems (page 182).Refer to: 5.12 Roof (page 204). Roof Racks.Refer to: 4.16 Special Conversions (page 137). Auto Wipe and Auto Light forVehicles with large over-hangsRefer to: 4.4 Battery and Cables (page 93). Generator and Alternator.

Mobile Shops / Offices

Refer to: 5.2 Hydraulic Lifting Equipment (page 179).Refer to: 5.3 Racking Systems (page 182).Refer to: 5.12 Roof (page 204). Roof Racks.Refer to: 4.16 Special Conversions (page 137). Auto Wipe and Auto Light forVehicles with large over-hangsRefer to: 4.4 Battery and Cables (page 93).Generator and Alternator.

Glass CarryingRefer to: 5.1 Body (page 174). Racking System.Refer to: 4.4 Battery and Cables (page 93).Generator and Alternator.

Racking ConversionsRefer to: 5.3 Racking Systems (page 182).Refer to: 4.4 Battery and Cables (page 93). Generator and Alternator.

Recovery Vehicles Refer to: 5.14 Frame and Body Mounting (page 207).Refer to: 4.16 Special Conversions (page 137). Auto Wipe and Auto Light forVehicles with large over-hangs


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Passenger CarryingRefer to: Commercial and Legal Aspects (page ?). Restraints System.

Taxi

Refer to: 4.11 Exterior Lighting (page 128).Refer to: 4.12 Interior Lighting (page 129).Refer to: 5.8 Seats (page 195).Refer to: 5.9 Glass, Frames and Mechanisms (page 198).Refer to: 5.12 Roof (page 204). Roof Ventilation.Refer to: 5.10 Airbag Supplemental Restraint System (SRS) (page 200).Refer to: 5.2 Hydraulic Lifting Equipment (page 179).

Mobility


Coach Built


Wheelchair Accessible

Refer to: 4.11 Exterior Lighting (page 128).Refer to: 5.8 Seats (page 195).Refer to: 5.9 Glass, Frames and Mechanisms (page 198).Refer to: 5.12 Roof (page 204). Roof Ventilation.Refer to: 5.10 Airbag Supplemental Restraint System (SRS) (page 200).Refer to: 4.11 Exterior Lighting (page 128).Refer to: 4.12 Interior Lighting (page 129).Refer to: 5.8 Seats (page 195).Refer to: 5.10 Airbag Supplemental Restraint System (SRS) (page 200).Refer to: 5.2 Hydraulic Lifting Equipment (page 179).

Mini Bus

Refer to: 4.11 Exterior Lighting (page 128).Refer to: 4.12 Interior Lighting (page 129).Refer to: 5.8 Seats (page 195).Refer to: 5.9 Glass, Frames and Mechanisms (page 198).Refer to: 5.12 Roof (page 204). Roof Ventilation.Refer to: 5.10 Airbag Supplemental Restraint System (SRS) (page 200).


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1.5 Conversion HomologationThe Vehicle Converter must observe any statutoryrules and regulations. When the conversion needsa new approval the following information mustbe quoted.• All dimensional, weight and center of gravity

data.• The fixing of the body to the donor vehicle.• Operating conditions.The responsible Technical Service may requireadditional information and/or testing.NOTE: For further information please contactyour local National Sales Company representative,or Local Ford Dealer. If they are unable to help youthen please contact the Vehicle ConverterAdvisory Service at [email protected] additional information on vehicle typeapprovalRefer to: 1.2 Commercial and Legal Aspects (page

8).


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1.6 Electromagnetic Compatibility (EMC)WARNINGS:

Your vehicle has been tested and certifiedto European legislation relating toelectromagnetic compatibility(72/245/EEC, UN ECE Regulation 10 orapplicable local legislation). It is yourresponsibility to make sure that anyequipment fitted complies withapplicable local legislation. Make sureany equipment is fitted by an authorizeddealer.Radio Frequency (RF) transmitterequipment (for example: cellulartelephones, amateur radio transmitters)may only be fitted to your vehicle if theycomply with the parameters shown in thefollowing 'Frequency Overview' table.There are no special provisions orconditions for installations or use.

Do not mount any transceiver,microphones, speakers, or any other itemin the deployment path of the airbagsystem.Do not fasten antenna cables to originalvehicle wiring, fuel pipes and brake pipes.Keep antenna and power cables at least100mm from any electronic modules andairbags.

NOTE: Only fit one antenna in the positions shownto the roof of your vehicle.NOTE: For EMC on Police conversions with rearview cameras please contact [email protected]

Frequency Overview

Antenna PositionMaximum Output Power Watts(Peak RMS)

Frequency Band MHz

250W1-301, 250W30-541, 250W68-87.51, 250W142-1761, 250W380-5121, 210W806-9401, 210W1200-14001, 210W1710-18851, 210W1885-2025


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1.6.1 Permitted Antenna Location

E145333

1 2

NOTE: After the installation of RF transmitters,check for disturbances from and to all electricalequipment in the vehicle, both in the standby andtransmit modes.Check all electrical equipment:• With ignition ON.• With the engine running.• During a road test at various speeds.Check that electromagnetic fields generatedinside the vehicle cabin by the transmitterinstalled do not exceed applicable humanexposure requirements.


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1.7 Vehicle Duty Cycle GuidelinesIt is necessary to take into account the customerusage profile and the anticipated vehicle dutycycles of the modified vehicle in order to choosethe appropriate specification of the base vehicle.It is necessary to select the appropriate drive,engine, gear ratio, gross vehicle mass, gross trainmass, axle plates and payloads of the base vehicleto match the customer requirements.Where possible make sure that the base vehicleis ordered with any necessary plant fit options.NOTE: For further information contact your localNational Sales Company representative, or LocalFord Dealer. If they are unable to help you thenplease contact the Vehicle Converter AdvisoryService at [email protected] high numeric gear ratio is recommended forvehicles with customer requirements for:• High payload.• Trailer 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 FuelEconomy and Performance

Any conversion may affect the fuel consumptionand performance depending on the aerodynamicsand the weight added by the conversion. Thepublished information for fuel consumption forthe incomplete base vehicles of category N1 arebased on the European Regulation EC 715/2007and 692/2008 (as last mentioned). The usedreference mass includes a 'Default Added Mass'(DAM). For specific figures for fuel consumptionand emissions of the base vehicle, please contactyour Local Ford Dealer or [email protected]. It isadvisable to control the weight, but withoutdeteriorating other vehicle attributes and functions(especially those related to safety and durability).

1.7.2 Vehicle Ride and HandlingAttributes

CAUTION: Do not exceed the axle plate,gross vehicle mass, trailer plate and grosstrailer mass limits.

Due to the displacement of the center of gravityoccurred by the conversion the ride and handlingattributes may be different to the base vehicle.NOTE: This vehicle should be evaluated for safeoperation prior to sale.


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1.8 JackingWARNING: Always position the vehicleon a hard level surface. If the vehiclemust be jacked up on a soft surface useload spreading blocks under the jack.Always chock the wheel diagonallyopposite the jacking point. Failure tofollow these instructions may result inpersonal injury.

CAUTIONS:It is important that only the correctjacking and support locations are usedat all times.Make sure that access to the spare wheelis maintained when converting thevehicle or relocating the spare wheel.

NOTE: When using the vehicle jack, refer to theowner guide for correct operating instructions.NOTE: Make sure that reinforcements areinstalled to maintain the integrity of the originalbody structure for/at jacking points.NOTE: Any modifications to the vehicle must benoted in the owner's handbook or new descriptiveliterature included with the owner'sdocumentation.

Front Jacking Points

E146881

Rear Jacking Points

E146843


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1.9 LiftingWARNING: When lifting the vehicle witha two post lift for the removal of theengine/transmission or rear axle, makesure the vehicle is secured to the lift usingvehicle retention straps to prevent tilting.Failure to follow these instructions mayresult in personal injury.

CAUTIONS:When lifting the vehicle with two post lift,vehicle lift arm adapters must be usedunder the lifting points.When lifting the vehicle with a two postlift, the maximum kerb weight must notbe exceeded.It is important that only the correct liftingand support locations are used at alltimes.

Lifting Points

E0025128


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1.10 Noise, Vibration and Harshness (NVH)WARNING: Make sure that the modifiedvehicle complies with all relevant legalrequirements.CAUTION: The travel and function ofpedals must not be restricted.

Changes to the powertrain, engine, transmission,exhaust, air intake system or tires may influencethe exterior noise emission. Therefore the exteriornoise level of the converted vehicle has to beverified.The interior noise levels should not be deterioratedby the conversion. Reinforce panels and structuresas appropriate to avoid vibrations. Consider theusage of sound deadening material on panels.


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1.11 Vehicle Transportation Aids and Vehicle StorageCAUTIONS:

Disconnect the battery if the vehicle is tobe stored for more than 7 days.Make sure that the protective covers arenot removed from an incomplete vehicleuntil the conversion is started.Make sure that components removedduring conversion are kept clean and dry.Make sure that components removedduring conversion are refitted to the samevehicle.

In addition:• The windscreen wipers should be lifted off the

glass and set right up.• All air intakes should be closed.• Increase normal tire pressure by 0.5 bar.• The hand brake system should not be used.• Apply suitable wheel chock to prevent roll away.A significant risk during storage is deterioration ofvehicle bodywork, therefore, appropriate storageprocedures must be observed, including periodicinspection and maintenance.Claims arising from deterioration caused byincorrect storage, maintenance or handling are notthe responsibility of Ford.Vehicle Converters must determine their ownprocedures and precautions, particularly wherevehicles are stored in the open as they are exposedto any number of airborne contaminants.The following may be considered a sensibleapproach to storage:Short Term Storage:• Wherever possible vehicles should be stored in

an enclosed, dry, well-ventilated area based onfirm, well drained ground which is free of longgrass or weeds and where possible protectedfrom direct sunlight.

• Vehicles must not be parked near, under foliageor close to water as additional protection maybe necessary for certain areas.

Long term storage:• Battery to be disconnected, but not removed

from the vehicle.• The wiper blades should be removed and

placed inside the vehicle. Make sure the wiperarms are suitably prevented from resting on thewindscreen.

• Wheel trims (where fitted) removed and storedin the luggage compartment.

• Engage first gear and release the parking brakecompletely. Chock the wheels first if the vehicleis not on level ground.

• Set climate controls to the "open" position toprovide ventilation, where possible.

• Where protective film has been applied inmanufacture it must be left on the vehicle untilprepared for delivery but must be removed aftera maximum storage period of six months (filmis date stamped to indicate required removaldate).

• Make sure that all windows, doors, hood, liftgate, tailgate, luggage compartment lid,convertible top and roof opening panel arecompletely closed and the vehicle is locked.

The Pre Delivery Inspection (PDI) is the finalopportunity to make sure a battery is fit forpurpose prior the customer taking delivery of theirnew vehicle. The battery must be checked andappropriate action taken prior to the vehicle beinghanded over to the customer. Test results mustbe recorded on the PDI repair order.Batteries. To make sure the battery is maintainedcorrectly and to assist in preventing prematurefailure, it is necessary to check and recharge thebattery monthly while a vehicle is not in use. Wherea battery is left below its optimum charge level forany length of time, it may result in prematurefailure of the battery.

Every 3Months

MonthlyAction / Time inStorage

-XCheck Vehicle isclean

-XRemove externalcontamination

-XCheck batterycondition —Recharge ifnecessary

-XVisually checktires

X-Check interior forcondensation

X-

Run engine for 5minutesminimum with airconditioningswitched on,where applicable

Refer to: 4.4 Battery and Cables (page 93).


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1.12 Package and Ergonomics

1.12.1 General Component PackageGuidelines

WARNING: Do not modify, drill, cut orweld any suspension components,specifically the steering gear system,subframe or anti-roll bars, springs orshock absorbers including mountingbrackets.

The Vehicle Converter has to ensure that sufficientclearance is maintained under all drive conditionsto moving components such as axles, fans,steering, brake system etc.The Vehicle Converter is responsible for allinstalled components during the conversion. Thedurability has to be confirmed by appropriate testprocedures.

1.12.2 Driver Reach Zones

Controls and/or equipment required to be usedwhile driving should be located within easy reachof the driver so as not to impair driver control.

1.12.3 Driver Field of View

WARNING: Make sure that the modifiedvehicle complies with all relevant legalrequirements.

1.12.4 Conversion Affects on ParkingAids

WARNING: Ensure that monitorsmounted in the cabin meet the interiorpackage and safety requirements.

On conversions requiring a rear camera, thereverse signal may be taken as described in theelectrical section, described in reversing lamps.Refer to: 4.11 Exterior Lighting (page 128).

1.12.5 Aids for Vehicle Entry and Exit

Steps

WARNINGS:Make sure that the modified vehiclecomplies with all relevant legalrequirements.

If this modification alters thehomologated dimensions, a newapproval may be necessary.CAUTION: Make sure that reinforcementsare installed to maintain the integrity ofthe original body structure.

Steps can be ordered as an option on the basevehicle. Please check for availability.Where additional steps are installed the requiredground clearance line is to be maintained.The Vehicle Converter must make sure that amovable step is set in the stored position whenthe vehicle is running. The step surface must benon-slip.

Grab Handles

WARNING: Make sure that the locationof the no-drill zones are checked beforedrilling.CAUTION: Make sure that reinforcementsare installed to maintain the integrity ofthe original body structure.

Grab handles can be ordered as an option on thebase vehicle. Please check for availability.NOTE: For further information please contactyour local National Sales Company representative,or Local Ford Dealer. If they are unable to help youthen please contact the Vehicle ConverterAdvisory Service at [email protected]

1.12.6 Front, Rear and Side Under-runProtection

WARNING: Check local legislation forlegal requirements.

Front Under run Protection must be designed todirective ECE 93* or 2000/40 EC* or applicablelocal legislation.Rear Under run Protection must be designed todirective ECE 58* or 70/221 EC* or applicable locallegislation.Side Under run Protection must be designed todirective ECE 73* or 89/297 EC* or applicablelocal legislation.*As amended periodically


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1.12.7 Vehicle Dimensions Key

L2L1Dimension (mm)33002933Wheel Base Length

Overall Vehicle Height @ Base Kerb Weight1967 - 20171972 - 2020H12332 - 23812338 - 2389H2

Overall Vehicle Height @ GVM1923 - 19541922 - 1953H12284 - 23202280 - 2314H2

All dimensions are subject to manufacturing tolerances and refer to minimum specification models anddo not include additional equipment.Transit Custom is available in two wheelbases; short (L1) and long (L2) and two roof heights; low (H1)and high (H2).Height dimensions show the range for the minimum to maximum weight range and are for guidanceonly.


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1.12.8 Recommended Main Load Area Dimensions

H1 Roof Height - Full Bulkhead - Fixed/Glazed

E145330

C

B A

C (mm)B (mm)A (mm)Vehicle131012602327L1 - H1131012602694L2 - H1

L1 = 2933mm wheel base, L2 = 3300mm wheel baseFor vehicle heights see 'Vehicle Dimension Key' table in this section of this manual


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H2 Roof Height - Full Bulkhead - Fixed/Glazed

E166787

C

B A




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Full Bulkhead with Load Through Hatch (with Dual Passenger Seat)

E145329

C

BA




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Double Cab In Van Bulkhead

E145331

C

B A




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1.13 Hardware—SpecificationsMaterial Specification, Strength and Torque

Standard Hardware and Tightening Torques (Nm) Bolts/Studs: ISO 898-1, Nuts: ISO 898-2Grade 10.9Grade 8.8Grade 4.8

MaximumMinimumMaximumMinimumMaximumMinimumThread Size3.42.41.41.1M46.74.92.72.2M5

15.011.011.58.54.73.7M635.025.028.020.0M870.050.055.041.0M10125.095.092.068.0M12200150153113M14

310.0230.0230.0170.0M16399.4317.5317.0252.0M18541.8434.7430.0345.0M20743.4592.2590.0470.0M22945.0756.0750.0600.0M24

This torque chart is a recommendation and the converter is responsible for the optimal torque for aspecific joint.


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1.14 Load Distribution

1.14.1 Load Distribution

CAUTIONS:Do not exceed the axle plated weights.

Do not exceed the gross vehicle weight.

The front axle load must, in all load cases,exceed 38% of the actual gross vehicleweight.

NOTE: Overloading of the vehicle could result inunacceptable ground clearance.NOTE: The center of mass of the payload shouldbe located within the wheelbase of the vehicle.NOTE: Avoid one-sided load distribution.NOTE: Uneven load distribution could result inunacceptable handling and braking characteristics.NOTE: Load distribution outside of the permittedrange may result in unacceptable steering,handling and braking characteristics.For further information please contact your localNational Sales Company representative, or LocalFord Dealer. If they are unable to help you thenplease contact the Vehicle Converter AdvisoryService at [email protected]

1.14.2 Center of Gravity Position

The position of the center of gravity is changedwhen masses are added or removed from thevehicle. This may influence the steeringcharacteristics, handling behavior and the brakeperformance.

Lateral Position

It is important to keep the Center of Gravitylaterally within given limits.Lateral Center of Gravity is determined by thevertical wheel forces difference right (front rightmass added to rear right mass) to left (front leftmass added to rear left mass).

WARNING: The difference right to leftmust not exceed 4% (absolute differenceright to left/total weight in per cent).

Vertical Position - Center of GravityHeight

The Center of Gravity Height of the vehicle isdetermined by the mass of the base deliveredvehicle and the added and removed masses. Inphysics this relation is described by the Steiner’stheorem.The Center of Gravity Height influences axleweights while braking. Center of Gravity heightinfluences roll stability. Safety systems will workproperly in the given boundaries.

Except Sport Series Vehicles.

WARNINGS:If the vertical center of gravity (CGv) isequal to or less than 800mm and nomodifications have been made to thecomponents of the braking system,suspension, wheels and tires theconverted vehicle complies with ECE13-H,ANNEX 9 standard or ADR 35 orapplicable local legislation.If the Center of Gravity (CGv) of theconverted vehicle exceeds 800mm, FordMotor Company makes no representationas to conformity with ECE13-H, ANNEX 9standard or ADR 35 or applicable locallegislation.

1.14.3 Center of Gravity Height TestProcedure

Measurement

Vehicle shall be loaded according to testspecifications specified in ECE13-H ANNEX 9(Vehicle Mass) or ADR 35 or applicable locallegislation.In order to check the center of gravity height thefollowing described method is proposed.For this test four scales are required. The test ispossible with two scales but this requires morepreparation and it results in lower accuracy.Initially the vehicle weights needs to be measuredin a horizontal position. Afterwards the front islifted and weights measured again. The higher itis lifted the more accurate the results will be. Theheight is restricted by different possible touchconditions, between vehicle parts and roof, groundand environment.In order to improve measurements followingpreparations need to be done:• Fix wheel travel, for example: solid shocks, or

spring fixes.• Increase tire pressure to maximum allowed

value.• It is important to remove all load, for example

moving items, from the car or it should beproperly fixed.

• Doors should be closed.Before measuring the vehicle the engine must beswitched off, after lifting it should be rolled freelyin order to release tension in the tire andsuspension.


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Calculation

In order to estimate the resulting Center of Gravity(CGv) the axle load needs to be measured twice.First one is in the horizontal plane and the secondmeasurement is after the front is lifted. To get aconsistent result this test should be done 3 timesindependently with different heights.

To improve accuracy the test is done additionallythe other way around, where the rear end is lifted.

E145328

MeasurementVariables, to be measured, calculated or known3rd2nd1st

mmWBWheelbasekgmVFront Axle Weight

kgmHRear Axle Weight

kgmG = mV + mHTotal Mass

INCLINED VEHICLEkgm'

VFront Axle Weight

kgm'HRear Axle Weight

mmHHeight (Lift)degInclination Angle*mmCenter of Gravity Height Z**

*Inclination Angle:

E146623

**Center of Gravity Height Z:

E146624


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1.14.4 Center of Gravity Height Calculation

Given or measured parameterWBWheelbasemVFront axle weight

mHRear axle weight

HFront height

Calculated and auxiliary parameterZSPCenter of Gravity (CoG) height

mGTotal vehicle mass

XVDistance front axle to CoG (horizontal)

XHDistance rear axle to CoG (horizontal)

WB'Wheelbase (projected in horizontal)

m'VFront axle weight

m'HRear axle weight

X'VDistance front axle to CoG (projected in horizontal direc-

tion)X'

HDistance rear axle to CoG (projected in horizontal direc-tion)

arc sinInclination angleXH1Front part of 'distance rear axle to CoG (horizontal)'

XH2Rear part of 'distance rear axle to CoG (horizontal)'

1.14.5 Formulas

• Masses and lengths. Total vehicle mass is thesum of front and rear axle weight:

• mG= mV + mH

Taking the sum of moments equals zero lawthe distance Center of Gravity and wheelcenter can be calculated as:

E146626

In inclined system the main variable is theinclination angle which is the quotient of thelifting height and the wheelbase:

E146627


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Similar to the equation for the horizontalsystem the distance projected in to theground plane can be determined using thesum of moments around front and rear wheelcenter:

E146628

Trigonometry leads to the projectedwheelbase and analysis of the geometry asshown in the figure E145328 can be used toderive the auxiliary values below:

E146629

Using the rule of proportion leads to theCenter of Gravity height formula:

E146630


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1.15 Towing

1.15.1 Tow Bar Requirements

When a tow bar device is required, the vehicleconverter should use a Ford approved tow bar.

CAUTION: Rear cargo doors may not becompatible with all tow bars andcouplers, check before fitting.

NOTE: Base vehicles ordered without a tow baror underrun bar must order reinforcements andhardware. Contact your local Ford Dealer fordetails.NOTE: Not all vehicles are suitable or approvedto have tow bars fitted. See an authorized dealerfor further information.For further information on Towing a Trailer andTrailer Sway refer to Owner's Manual.Refer to: 1.8 Jacking (page 23).For further information on connecting the Tow bar,Refer to: 4.1 Wiring Installation and Routing Guides

(page 61).

1.15.2 Tow Bar Types

For tow bar devices fitted by the vehicle converterthe following applies:

• Tow bar allowances must not exceed those ofthe standard vehicle.

• For attachment of the tow bar, under run barand steps see figure 186508 - Tow Bar SWBVan 2.9 tonne (GVM) and LWB Van 3.3 tonne(GVM).

• Any modifications to the vehicle must be notedin the owner's handbook or new descriptiveliterature included with the owner'sdocumentation.

• The maximum allowable tow ball static loadis 250kg for 290S SWB Van and 280kg for 330LLWB Van.

• A minimum tow ball static load of 10% oftowed weight is required for Australia and NewZealand.

• Tow bar installations must meet therequirements of the Australian DesignRegulations ADR 62.

• Whenever frame drilling is necessary use tubereinforcement, example shown as green infigure E186508.Refer to: 5.14 Frame and Body Mounting (page

207).Mounting Points and Tubing.

For any further details and advice please consultyour local National Sales Company representative,or Local Ford Dealer. If they are unable to help youthen please contact the Vehicle Advisory Serviceat [email protected]


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Tow Bar SWB Van 2.9 Tonne and LWB Van 3.3 Tonne

E186508

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E186508

DESCRIPTIONITEMTow bar frame assembly12x fixing nuts each side2Reuse 2x bolts (each side) in holes 'G' - Torque 103±15Nm3Reinforcement clamp plate (each side)42x fixing bolts each side in holes 'F' M12 x 75 x 90 - Torque 115±5Nm5177mmA53mmB75mmC35mmD20mmE


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Trailer Sway Control (TSC) Tow Ball Zone - SWB Van and LWB Van

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D

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E214711

DescriptionITEMSWB/LWB = 675mmA*477mmB492mmC15mmD

To ensure functionality of TSC, please make sure that the tow ball is within zone 'D' as shown in figureE214711.* From center of rear axle.


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2.1 Suspension SystemWARNINGS:

Do not modify, drill, cut or weld anysuspension components, specifically thesteering gear system, subframe oranti-roll bars, springs or shock absorbersincluding mounting brackets.Interchangeability (between differentTransit variants) of springs, shockabsorbers and jounce bumpers is notpermitted as the changes in vehicledynamic performance can affect the ESPsystem.CAUTION: Modifications to thesuspension system can cause adeterioration of the vehicle handlingcharacteristics and durability.

NOTE: For detailed information please contactthe Vehicle Converter Advisory Service [email protected]


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2.2 Front Suspension

2.2.1 Springs and Spring Mounting

WARNINGS:Do not modify, drill, cut or weld anysuspension components, specifically thesteering gear system, subframe oranti-roll bars, springs or shock absorbersincluding mounting brackets.Interchangeability (between differentTransit variants) of springs, shockabsorbers and jounce bumpers is notpermitted as the changes in vehicledynamic performance can affect the ESPsystem.

CAUTIONS:When carrying out welding work thesprings must be covered to protect themagainst weld splatter.Do not touch springs with weldingelectrodes or welding tongs.Make sure that components loosened orremoved and reinstalled are properlyreassembled and the torque set inaccordance with manufacturesrequirements.

NOTE: Do not modify the wheelbase or add anytype of frame extension to vehicles fitted withElectronic Stability Control, ESC (also known asElectronic Stability Program, ESP).NOTE: Do not damage the surface or corrosionprotection of the spring during disassembly andinstallation.NOTE: For detailed information please contactthe Vehicle Converter Advisory Service [email protected]


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2.3 Rear Suspension

2.3.1 Springs and Spring Mounting

WARNINGS:Do not modify, drill, cut or weld anysuspension components, specifically thesteering gear system, sub-frame, springsor shock absorbers including mountingbrackets.The rear leaf springs are pre-stressed inmanufacture and should not be alteredfor rate or height in any way duringvehicle conversion. Adding or removingleaves may result in failure or reducedfunction of the spring as well as othervehicle related issues for which FordMotor Company can not be heldresponsible.

CAUTIONS:When carrying out welding work thesprings must be covered to protect themagainst weld splatter.Do not touch springs with weldingelectrodes or welding tongs.Make sure that components loosened orremoved and reinstalled are properlyreassembled and the torque set inaccordance with manufacturesrequirements.

NOTE: Do not modify the wheelbase or add anytype of frame extension to vehicles fitted withElectronic Stability Control, ESC (also known asElectronic Stability Program, ESP).NOTE: Do not damage the surface or corrosionprotection of the spring during disassembly andinstallation.NOTE: Do not add any additional axles.NOTE: For detailed information contact theVehicle Converter Advisory Service [email protected]


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2.4 Wheels and Tires

2.4.1 Wheel Clearance

The distance from the tire to the mudguard orwheel arch must be sufficient, even if snow oranti-skid chains are fitted and the suspension isfully compressed allowing for axle twist as well.Please consult the Vehicle Converter AdvisoryService [email protected] for clearancerequirements and data.NOTE: Make sure that only approved wheels and/or permissible tire sizes are fitted.NOTE: Ensure access to the wheel and wheel jack,and provide sufficient clearance in wheel arch toallow changing the wheels after conversion.

2.4.2 Tire Manufacturers

Replacement tires should be of the same make,size, tread pattern and load rating as the OriginalEquipment Manufacturer. Under these conditionsthe original tire label should be satisfactory,however if the specified tires and/or inflationpressures are changed then a new label should beaffixed over the original label.

2.4.3 Tire Pressure Monitoring System(TPMS)

Ford TPMS is a direct system, using physicalpressure sensors. TPMS is calibrated according tothe tire pressure for the GVM of the vehicle. If thespare wheel is ordered on a base vehicle withTPMS, the tire will not be supplied with a TPMSsensor.If you need to replace a road wheel and tire withthe temporary spare wheel, the system willcontinue to identify a defect. This is to remind youto repair and refit the damaged road wheel andtire to your vehicle. To restore the correct operationof the system, you must have the repaired roadwheel and tire assembly refitted to your vehicle.

E167541

2.4.4 Spare Wheel

When converting or relocating the spare wheel,access must be ensured.

2.4.5 Temporary Mobility Kit

Your vehicle may not have a spare tire. Thereforeyou will have a temporary mobility kit which willonly repair one damaged tire. The kit is located inthe left-hand side of the rear luggagecompartment. For more information and usage ofthe tire repair kit please refer to the Owner'sManual. For information on vehicles with the sparewheel:Refer to: 1.8 Jacking (page 23).

2.4.6 Painting Road Wheels

CAUTION: Do not paint wheel clampsurfaces in contact with brake drum ordisc, hub and holes, or surfaces underwheel nuts. Any further treatment inthese areas may affect the wheel clampperformance and the vehicle safety.

Mask the wheel when changing the color orrepairing paint.


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2.5 Brake System

2.5.1 General

The Brake System must be fully functional whenthe vehicle conversion is completed. The vehiclebrake operating modes must be checked,including warning system and parking brakes.Brakes are certified to 71/320EEC and ECE R13Hrequirements as amended or ADR 35 or applicablelocal legislation.

WARNING: Do not restrict the airflow andcooling to the brake system.CAUTION: Spoilers and wheel coversmust not affect the brake coolingperformance.

NOTE: Do not obstruct the view of the brake fluidreservoir level.NOTE: The donor vehicle brake fluid reservoir istranslucent so that it is possible to check the levelof fluid without opening the reservoir which willreduce the risk of contamination. Do not movebrake fluid reservoir.The brake fluid reservoir must remain accessiblefor servicing and for adding brake fluid.

2.5.2 Kerb Mass Data

NOTE: For further information please contactyour local National Sales Company representative,or Local Ford Dealer. If they are unable to help youthen please contact the Vehicle ConverterAdvisory Service at [email protected]

2.5.3 Brake Hoses General

CAUTION: Make sure that the front andrear brake hoses are not twisted and arecorrectly located away from body andchassis components.

Front and rear brake hoses must not rub, chafe orrest on body or chassis components. There mustbe clearance under all operating conditions,between full compression and extension and fulllock to lock.Brake lines must not be used to support or secureany other component.

2.5.4 Parking Brake

WARNINGS:Do not modify the brakes.

Do not splice into the parking brake cable.

CAUTION: Make sure that a new parkingbrake cable is fitted if modification to thewheel base impacts the existing parkingbrake cable.

2.5.5 Hydraulic Brake—Front and RearBrakes

WARNINGS:Do not modify the brakes.

Do not modify the disc in flow and outflow of cooling air.

2.5.6 Anti-Lock Control — StabilityAssist

WARNING: Do not modify any part of thebraking system, including Anti BrakeSystem (ABS), Traction Control System(TCS) and Electronic Stability Control(ESC), also known as Electronic StabilityProgram (ESP).



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3.1 EngineCAUTION: Make sure to follow theequipment suppliers instructions forsafety, warranty and sometimes legalcompliance.

For electrical supply to auxiliary equipment.Refer to: 4.3 Charging System (page 81).

3.1.1 Engine Selection for Conversions

The vehicle converter is responsible for specifyingthe correct emissions engine to the latestE.E.C/E.U. Regulations or applicable locallegislation depending on the completed vehiclecategory (N1,N2/M1/M2) and weight. The finalweight of a vehicle including the conversion,determines whether a vehicle needs a light-dutyor heavy-duty emissions engine.The weight is based on the Reference Massdefined as the mass in running order, less a 75kgallowance for the driver, add a 100kg uniformmass.

For guidance purposes only, if the Reference Massused for completed vehicle type approval is:• Not exceeding 2,840kg, a light-duty engine may

be specified.• Greater than 2,840kg, a heavy-duty engine

needs to be specified. Note: Heavy-duty enginesare recommended for M2 Bus Conversions.

3.1.2 Engine Power Curves

Front Wheel Drive (FWD)• Common Rail 2.2L TDCi 74kW (100PS) Diesel

Engine.• Common Rail 2.2L TDCi 92kW (125PS) Diesel

Engine.• Common Rail 2.2L TDCi 114kW (155PS) Diesel

Engine.


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FWD Common Rail 2.2L TDCi 74kW (100PS) Diesel Engine

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BE140031

DescriptionItemTorque Curve Nm — Max Torque = 310Nm at 1300-2100 1/min1Power Curve kW — Max Power = 74kW (100PS) at 3500 1/min2NmA1/minBkWC


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3.2 Engine Cooling

3.2.1 Auxiliary Heater Systems

WARNINGS:Ford coolant additives are necessary forthe complete function of the system. Onlyuse Ford approved or equivalentspecification component, to withstandany detrimental effects on the materials.Do not mount components in front of thegrille or in an area of air flow around theengine, which could affect the enginecooling.

CAUTIONS:Only make connections into the heaterhose between the front cab heater andwater pump return inlet.Do not exceed the vehicle's originalcoolant volume (without auxiliary heater)by more than 10%.Maintain a coolant level betweenmaximum and minimum line in coldcondition after fill and de-aeratingoperations.Only use the manufacturer recommended(or equivalent specification) coolantadditives/anti-freeze. Do not mix coolanttypes.

• Coolant flow to cab heater must have priorityover flow to auxiliary heater or hand washfacility.

• Coolant tube routing must be below theminimum line of the degas bottle.

• Use aluminum or plastic 'T' junction withswaged or beaded ends to prevent hose blowoff. Reconnect original coolant tube as shownin view E74570 (in this section) with standardFord water hose clip or suitable equivalentspecification clip. Ensure interference fitbetween hose and 'T' joint.

• Tube routing must be secured to the bodystructure or suitable brackets avoiding electricalcomponents or wires, hot or moving parts andbrake or fuel system components.

• Hose must be heat sleeved with appropriatematerial if within 100mm of exhaustcomponents (for example, manifold or exhaustgas recirculating).

• The vertical clearance between the criticalcooling components (radiator, fan shroud andradiator brackets) and both the hood inner andouter (assembly) panels at design position shallnot be less than 15mm.

• There shall be a minimum clearance of 10mmbetween the engine assembly and flexiblecomponents (for example, hoses or wiringharnesses) affixed to front end sheet metalhardware, under a maximum engine torque rollcondition.

NOTE: For further information please contact yourlocal National Sales Company representative, orLocal Ford Dealer. If they are unable to help youthen please contact the Vehicle Converter Advisoryservice at [email protected]


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Water Hoses for Auxiliary Heating System

E74570

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DescriptionItemConnector (aluminum or plastic)1Heater hose (maintain heater fluid)2Original flow3To ancillary equipment4

3.2.2 Auxiliary Heater Installation

Ensure that the exhaust gas from any auxiliaryheating system can not be re-circulated into thevehicle. The exhaust gases must not pass into theengine intake system or the air intake for thepassenger compartment ventilation. The heatingsystem should be installed outside the passengercompartment. The location of the heating systemshould not be in close proximity to movablecomponents. Any body reworks which damagethe paint must be fully protected againstcorrosion.Refer to: 5.13 Corrosion Prevention (page 206).NOTE: The installation must be in line with theappropriate legal requirements.

3.2.3 Air Flow Restrictions

WARNING: Do not mount components infront of the grille or in an area of air flowaround the engine, which could affect theengine cooling performance.

CAUTION: Over heating within the enginecompartment can seriously compromisecomponent robustness.

NOTE: Please assume under hood environmentis about 130°C when selecting appropriatematerialsNOTE: For further information please contactyour local National Sales Company representative,or Local Ford Dealer. If they are unable to help youthen please contact the Vehicle ConverterAdvisory Service at [email protected]


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3.3 Accessory Drive

3.3.1 Front End Accessory Drives —General Information

When the correct belt is used, tensioning is andremains fully automatic for the life of the belt.

CAUTIONS:Only use the manufacturersrecommended (or equivalentspecification) components.Make sure that the ancillary pulleydiameter is less than the crankshaftpulley diameter.Front End Accessory Drive shields mustbe maintained at all times. If shields areremoved, for example when attaching anancillary unit, they must be replaced sothat it is protected appropriately.

NOTE: No devices can be taken off the crankdamper as this is a tuned device for systemresonance.NOTE: The shields are there to protect the FrontEnd Accessory Drive system from STONE ingressand also protect people from rotating parts underStart-Stop function.NOTE: For further information on systemsrequiring a unique belt please contact your localNational Sales Company representative, or LocalFord Dealer. If they are unable to help you thenplease contact the Vehicle Converter AdvisoryService at [email protected]

The Eigen frequency of the bracket with auxiliaryunit should be above the maximum excitationfrequency of the main excitation order of theindividual engine at engine top speed. On4-cylinder inline engines, this is the second engineorder.

CAUTION: Do not fit an additional beltdriven accessory within the existing beltdrive when the vehicle is already equippedwith an air conditioning compressor. If itis required to retain the air conditioning,then a further belt must be used to drivethe additional accessory, driven from athird crankshaft pulley sheave.

When engineering and installing a new front endaccessory drive i.e. belt driven from the crankshaftpulley, the angular alignment of the belt to anypulleys must be within ±0.5°.When the vehicle is not equipped with an airconditioning compressor, an additional accessorycan be added in its place, and the longer standardoption air conditioning belt can replace thestandard belt if pulley size and position are thesame as the standard option compressor. Thenmaximum power/torque that is available in thatcase at any engine speed is 10kW or 21.6Nm basedon the Ford released variable air conditioningcompressor.For additional information please contact theVehicle Converters Advisory Service,[email protected]• FWD = Front Wheel Drive


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FWD 2.2L Diesel Engine - with Air Conditioning

E145338

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Pulley, Belt Layout, Engine Top Cover and Protective Shields on FWD 2.2L Diesel Engine - With AirConditioning

DescriptionItemIdler1Idler2Alternator3Idler - Not with 150A Alternator4Power Steering Pump5Crankshaft Pulley6Compressor7Auto Tensioner8Front End Accessory Drive Shield - only Start-StopAEngine Top CoverBFront End Accessory Drive ShieldCFront End Accessory Drive ShieldD


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3.4 ClutchThe manufacturer does not offer the option of areinforced clutch system. The axle ratio availableis dependent on the weight of the specified donorvehicle.It is necessary to select the appropriate drive,engine, gear ratio, gross vehicle mass, gross trainmass, axle plates and payloads of the base vehicleto match the customers order.


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3.5 Manual TransmissionThe following manual transmission is availablefor Diesel Engines.Front Wheel Drive (FWD) vehicle— VMT6 Transmission

WARNING: Do not reroute externaltransmission gear shift cables.

NOTE: All VMT6 FWD transmissions aretachograph compatible.

VMT6 - 6 Speed Manual FWD Transmission

Overall Transmission and Differential Drive RatioBase TransmissionRatio

GearVehicles greater than

3000kg GVMVehicles less than or equal to

3000kg GVMStandardEcoStandard

17.57114.67615.6083.7271st8.7867.3387.8041.8642nd5.2864.4154.6951.1213rd3.6793.0733.2680.7804th2.7842.4162.5700.8445th2.2541.9562.0800.6836th17.50415.18916.1541.423Reverse

VMT6 - 6 Speed Manual FWD Transmission

E140559


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3.6 Exhaust System

3.6.1 Extensions and OptionalExhausts

CAUTIONS:Non-standard systems must be tested forengine back pressure and all legalcompliance (noise and emissions).

Make sure that for any pipes that requirebending, the radius of the bend isminimum 2.5 x tube diameter.Make sure that sufficient clearance ismaintained for all driving conditions toall hot and moving components.

NOTE: Where possible all pipe connections shouldbe designed so that the gas flows from smaller tolarger diameter pipes.

Exhaust Pipe Design Principles

E74569

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DescriptionItemdiameterdradius = 2.5dr

3.6.2 Exhaust Pipes and Supports

CAUTIONS:Maintain the original set-up and heatshields.Do not position any components closerthan 150mm nominal (100mm minimum)clearance to the downpipe, the catalyticconverter, the diesel particulate filter andany part of the exhaust system.

3.6.3 Exhaust Heat Shields

Exhaust Heat Shields

• Catalytic converters, in particular, operate athigh temperatures.

• Ensure existing shields are maintained.• Add further shields over exhaust system as

necessary to avoid fire risk.


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Standard Exhaust Heat Shields

CAUTION: Standard heat shields areavailable from your local dealer and caneasily be fitted. Additional heat shieldsmay be required over the modifiedexhaust system, particularly in areas ofclose proximity to the floor.


3.6.4 Diesel Particulate Filter (DPF)

The DPF forms part of the emissions reductionsystems fitted to your vehicle. It filters harmfuldiesel particulates (soot) from the exhaust gas.Regeneration

WARNING: Do not park or idle yourvehicle over dry leaves, dry grass or othercombustible material. The DPFregeneration process creates very highexhaust gas temperatures. The exhaustwill radiate a considerable amount ofheat during and after DPF regenerationand after you have switched the engineoff. This is a potential fire hazard.

Unlike a normal filter which requires periodicreplacement, the DPF has been designed toregenerate, or clean itself to maintain operatingefficiency. The regeneration process takes placeautomatically. However, some driving conditionsmean that you may need to support theregeneration process.If you drive only short distances or your journeyscontain frequent stopping and starting, occasionaltrips with the following conditions could assistthe regeneration process:• Drive your vehicle, preferably on a main road

or motor way, for up to 20 minutes avoidingprolonged idling, but always observing speedlimits and road conditions.

• Do not switch off the ignition.• Use a lower gear than normal to maintain a

higher engine speed during this journey, whereappropriate.

3.6.5 Vehicle Exhaust Systems —Vans with Bulkheads

Vehicle exhaust systems for vans with bulkheadsare available in two lengths; a short lengthexhaust finishing approximately in the center ofthe vehicle, which is standard fit, and a longexhaust finishing at the rear of the vehicle. If youare undertaking any modification to the loadcompartment of the vehicle, especially in thelower half of the vehicle, ensure that the mostsuitable length of exhaust is used to avoid exhaustgas ingress into the vehicle.


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3.7 Fuel SystemWARNINGS:

Do not remove or relocate fuel cooler,where fitted, when modifying vehicle.Do not cut into the original fuel supplylines.Make sure that the modified vehiclecomplies with all relevant legalrequirements.

NOTE: Auxiliary Fuel line comes with Fuel FiredHeater as an orderable option. The Auxiliary Fuelline is available as a service item.For vehicles without auxiliary fuel line that requirea fuel supply for applications (for example:auxiliary heater or fuel fired hand wash facility) itis advisable to use the auxiliary fuel supply port onthe top of the fuel sender unit located on the topof the fuel tank as shown in figure E145336.NOTE: To fit the auxiliary fuel line, the fuel tankwill need to be lowered, see following process:To lower fuel tank:• Drain tank.• Remove filler pipe from tank.• Remove bolts securing the three tank straps.• Lower the fuel tank to gain access to the top,

see Figure E145336 for fitting auxiliary 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 3.7Nm +/- 0.6Nm.

CAUTIONS:Ensure modifications to vehicle do notobstruct airflow to fuel cooler, wherefitted.Make sure that sufficient clearance ismaintained for all driving conditions toall hot and moving components.Make sure that when the port is cut thatit is smooth with no sharp edges or burrs.

NOTE: The tube and/or line must be routedindependently and secured to the body structureor to suitable brackets.NOTE: Ensure that a suitable fuel shut-off is fittedin any unique system.NOTE: Do not fasten anything to existing electricalcomponents, wires or fuel lines.NOTE: To ensure the correct functionality of thefuel cooler, where fitted, sufficient clearances arerequired around the fuel cooler for air flow, seefigure E145335.

Fuel Cooler Clearance Zone for Air Flow

B

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E145335

1 = Center Line Front Wheel Axle, 2 = Center LineB Pillar, A = 580mm, B = 1000mm, C = 1207mm


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Auxiliary Fuel Line - For all vehicles except Campers

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E145336

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DescriptionItemAuxiliary fuel line, part number BK21-9N126-A_1Cut off top of port of diesel delivery module flange leaving 19.64 +/- 0.12mm and carefullyinsert heater tube, part number BK21-9T308-A_

2

Fix quick fit connector of fuel line to heater tube, part number BK21-9N126-A_3Auxillary fuel line has a female connector TI LOCC QC 7.89 fitted as standard. It is recommendedto use a 7.89 male adapter mating part (manufacturer TI Automotive GmbH). For furtherinformation please contact [email protected]

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Auxiliary Fuel Line - For Camper Vehicles

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A

3E201842

DescriptionItemFWD Fuel TankAAuxiliary fuel line, part number BK31-9N126-B1Auxillary fuel line has a female connector TI LOCC QC 7.89 fitted as standard. It is recommendedto use a 7.89 male adapter mating part (manufacturer TI Automotive GmbH). For furtherinformation please contact [email protected]

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4.1 Wiring Installation and Routing Guides

4.1.1 Wiring Harness Information

NOTE: Ford Motor Company has no control overthe modification or installation process of theelectrical content of auxiliary systems andtherefore can take no responsibility for suchinstallations.The following provides an installation guide forany electrical modifications or additional systemsbeing added to the vehicle. The aim is to maintainrobust integration of auxiliary systems withoutcompromising existing systems, in areas such assplicing techniques into existing wiring, modulepackage location and EMC issues. It is alsoexpected that the vehicle converter will test theirinstallation and comply to all legal andhomologation requirements.

4.1.2 General Wiring and Routing

Temperature requirements: Wiring systems in thevehicle interior are expected to function over thetemperature ranges of – 40°C to 85 °C forexposure and – 40°C to 75°C for function. Forengine compartment and underbody, theminimum temperature is - 40°C, while themaximum exposure and operational temperaturesare +125°C for exposure and 105°C foroperational.Make sure that the insulation is compatible withany fluids it may encounter , for example: gasoline,oil, antifreeze, brake fluid, transmission fluid andpower steering fluid.If a connector will be located in a hostileenvironment or wet area use a sealed connector.'Hostile environment' areas include the enginecompartment, wheel wells, underbody and doors.Do not route wires near weld points or weldflashes. A minimum of 15mm clearance to anysheet metal welds under static and dynamicconditions is required. However, it is best to avoidrouting near weld points or weld flashes at alltimes.In general, the distance between retention pointsfor wiring not contained in a rigid shield should beless than 300mm.A minimum 25mm clearance is recommendedfrom all sharp edges and a minimum 35mmclearance of all moving parts of the parking brakeassembly. If these clearances can not be met,protect the wires with a convolute.For conversions with walkthroughs, it isrecommended to provide appropriate protectionon the floor in the walkway.

4.1.3 Connector Pin Out Practices

When designing a harness to componentconnection, it is best practice to put the femaleterminals in the harness side connection and themale terminals in the component side. Whendetermining connector pin outs, make sure thatpower and ground circuits are not in closeproximity, adjacent, to one another. A minimumseparation of 5 mm between power and groundcircuits is required.

WARNING: Do not use connectors whichcut through the outer covering and intothe core wire.CAUTION: Only use Ford approvedconnectors

Cutting into vehicle wiring is not permittedbecause:• The base vehicle specification is unsuitable for

incremental loads except in conjunction withSpecial Vehicle Option Auxiliary Fuse Panel.

• Long term risk of a faulty connectiondeveloping.

• Potential fire risk from over-loading.All connections into existing wiring must bepermanently insulated. Exterior connections mustbe water-proof.When designing electrical circuits, or makingalterations, the following must be considered:• Current rating of wiring, see table 'Current

Rating of Wire Sizes' in this section.• Any voltage drop in the circuit should not lower

the terminal voltage at consumption point tobelow 95% of battery voltage.

• Do not cut into the original harness.• Additional earth returns should be included to

support new equipment.• A supplementary circuit diagram and

accompanying instructions should be addedto the Owner's information or a separatemanual supplied with the vehicle for eachunique component.

NOTE: For further information please contactyour local National Sales Company representative,or local Ford Dealer.Where wires are required to be extended, breakin points and only Ford approved connectorsshould be used.Ford approved jumper harnesses should be used.


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4.1.4 Unused Connectors

The harnesses may have a number of unusedconnectors, which are dedicated to other featuresand options, for example heated seats, but arenot always present depending on level of harnessfitted. Ford do not recommend the use of theseconnectors for any other purpose than thatintended by design.

4.1.5 Grounding

If a new grounding point is required, avoid weatherzones, especially for high current grounds. Groundconnections should be routed back close to thelocation of the +12V supply. This helps to reducethe electromagnetic field particularly generatedby inrush current and improve electromagneticcompatibility.Drill point screws are not to be used for any groundattachments:• Do not ground to moving structures, for

example: doors, deck lids, lift gates, as theground return path through the hinges is notreliable.

• Do not exceed 2 eyelet or crimp terminals perstud connection. For high current applicationsRefer to: 4.4 Battery and Cables (page 93).

• Do not place electrical component attachmentsor ground nuts adjacent to vehicle fuel tanks orfuel lines.

4.1.6 Prevention of Squeaks andRattles

Wiring should be positively retained every 150 to250mm. All connectors should be positivelyretained. Use tapes which do not squeak againstmetal or plastic.

4.1.7 Water Leakage Prevention

Make sure that drip loops are provided to preventwater leakage into the vehicle interior, passengerand cargo compartments, using wiring assembliesthat pass from outside into the vehicle interior. Thedrip loop is a section of wiring that is deliberatelyformed and routed BELOW the point of entry intothe vehicle, so that gravity assists in forming waterdroplets that escape from the lowest part of thewiring.Wiring from door to passenger compartment,should be made such that the door entry point isbelow the passenger compartment entry point,which creates a type of drip loop.

4.1.8 Wiring Splicing Procedures

TYCO-RAYCHEM crimp splices

E131081

Ford Motor Company strongly advises against theuse of wire splicing due to the variable andunpredictable nature of making robust, durableand reliable connections. However, if it is deemedthat a wire splice is absolutely unavoidable, it mustbe made with DuraSeal Heat-Shrinkable,Environmentally Sealed, Nylon-InsulatedCrimp Splices (manufactured byTYCO-RAYCHEM). For example the D406 series.As a further process to improve the splice integrity,the splice should be further sealed with a suitableheat shrink tubing. See Figure E131081.


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4.1.9 Wiring Specification

Current Rating of Wire Sizes

Maximum Continuous current (A)50°C30°CmW/m@20°CCross Sectional Area

4.9754.40.357.71137.10.59.81424.70.7513.51918.5117.02412.71.522.7327.62.529.8424.71438.3543.14651.8731.821069.6981.161691.61290.743251121580.527351401980.368501742450.259702072920.196952443440.153120

NOTE: The maximum continuous current (A)values for 30°c and 50°c is a value below themaximum fuse rating allowed for the cable. Thisis because the fuse/cable system values at thesetemperatures are the continuous usage where asthe maximum fuse also needs to protect for highcurrent short term loadings such as electricmotors.

When designing wire installations for additionalequipment use the cable size recommended bythe equipment manufacturer or select a suitablesize from the 'Current Rating of Wire Sizes' table.


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4.1.10 Electromagnetic Compatibility (EMC) Awareness

E145359

Electromagnetic Compatibility (EMC)Awareness

The installation and routing of Ford wiring,(example of wiring shown in figure E145359), havebeen fully-validated and have passed the requisiteEMC tests. Ford Motor Company, however, are notresponsible for the vehicle’s EMC immunity whennon-Ford-approved systems are installed.

WARNING: Do not route other wiringnear/close to electrical cables with theAnti-Lock Brake System and TractionControl System cables because ofextraneous signal risk. It is generally notrecommended to hang it off existinglooms or pipes.

Wiring must be suitably fixed without anydetrimental effect on other wiring.Single or bunched looms must maintain thefollowing clearances:• 10mm from static components (unless

clamped to it).• 250mm from exhaust system.• 30mm from rotating or moving components.


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4.1.11 Wiring Through Sheet Metal

Dash Panel (Left Hand Drive Shown)

E145360

3

2 1

DescriptionItemDash Grommet Left Hand Side1Dash Grommet Right Hand Side2Only available on vehicles without Tachograph3

WARNING: Harnesses passing throughsheet metal must be through protectivegrommets that also ensure a watertightseal. A windscreen type sealer should beused. Adhesive or tape is not acceptable.

NOTE: Holes must permit the appropriateconnector to pass through.NOTE: The maximum size of additional wirebundle diameter is 6mmThere are three locations in the dash panel whichhave been identified for additional holes to routewires through. See figure E145360 (view fromengine bay) for locations. The number of suitablelocations will depend on the vehicle specification.The grommets in locations 1 and 2, shown in figureE145360, are moulded directly to wire bundles inpolyurethane foam material. It is not possible tofeed extra wires through with the wire bundle. Thegrommets have an 'indent' moulded into thesurface face, engine bay side, which show thepositions where an additional hole can be madeusing the following procedure:

• Check that the immediate surrounding area isfree from obstructions and/or components toprevent damage to critical systems.

• Use a suitable tool, for example: a drill or spikebit.

• Insert the drill or spike bit, horizontal andparallel, through the indent of the grommet ,making sure not to extend further than 25mmthrough the grommet surface, this will helpeliminate any possible damage to items on thepassenger side of the grommet.

Ford released hardware is available to supportfurther installations to the vehicle. Only thishardware and released parts are to be used forthis.


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4.1.12 No Drill Zones — Rear Cargo Area

The areas marked in blue on figures E145339 -E145344 and E166796 - E166798 show the 'NODRILL' zones for the rear cargo area where thereis wire routing and is to be avoided, (for example:when installing cladding and racking). The samecare should also be taken when using self tappingscrews. Not all derivatives are shown but therouting is the same for roof line and wheel basewith regards to B, C and D pillars or roof bows anddoors. Other non electrical systems may also bepresent, for example: fuel tank under floor so it isimportant to check before drilling. For additionalinformation refer to the following links.

CAUTION: Do not drill into the vehiclebefore checking 'No Drill' zones andelectrical wire routing.

Refer to: 5.1 Body (page 174).No Drill Zones -Under the Floor TankRefer to: 5.4 (page 186).Load Compartment Tie DownsRefer to: 5.3 Racking Systems (page 182).Refer to: 5.6 Body Closures (page 190).No Drill Zones - ClosuresFor Wheel Base and Roof Height dimensionsRefer to: 1.1 About This Manual (page 6).

No Drill Zones L1/H1 with Lift Gate (Right Hand Side)

E145339


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No Drill Zones L1/H1 with Lift Gate

E145340

No Drill Zones L1/H1 with Lift Gate (Left Hand Side)

E145341


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No Drill Zones L2/H1 with Rear Cargo Doors (Right Hand Side)

E145342

No Drill Zones L2/H1 with Rear Cargo Doors

E145343


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No Drill Zones L2/H1 with Rear Cargo Doors (Left Hand Side)

E145344

No Drill Zones L2/H2 with Rear Cargo Doors (Right Hand Side)

E166796


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No Drill Zones L2/H2 — Rear Cargo Doors

E166798

No Drill Zones L2 /H2 with Rear Cargo Doors (Left Hand Side)

E166797


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4.1.13 Electrics for Tow Bar

Trailer Tow Module and Harnesses

E145361

43 12

5

2

4

Part NumberDescriptionItemBK2T-19H378-A_Trailer Tow Module1BK2T-13B576-A_Trailer Tow Jumper (with Trailer Tow Module connector 'A'

see figure E151247)2

BK2T-13B576-D_Trailer Tow Socket Jumper - Europe3AMBK3J-15A416-A_Trailer Tow Socket Jumper - Australia and New ZealandBK2T-14406-**Fuel Tank Harness4BK2T-14401-**Main Harness (with Trailer Tow Module connectors 'B' and

'C' see figure E151247)5

Tow bar electrical system may be ordered as a13-pin DIN connector for Europe or 12-pin DINconnector for Australia and New Zealand, as partof the original vehicle build.Where it is required to add trailer towing to anexisting vehicle, and to ensure compliance withlighting regulations, the appropriate wiringaccessory kit can be obtained from your FordDealer.Fitment of non-Ford trailer tow wiring is notadvisable due to Body Control Module control oflighting, and meeting legal lighting regulations.Contact your local Ford dealer for details of aharness that connects to the base vehicle harness.NOTE: For Van tow bars it is necessary to connectinto the rear lamp unit.

NOTE: If tow bar connectors are not used,appropriate fixing and cover must be applied forprotection from water and contaminant ingress.NOTE: The trailer detect circuit is part of the FordTrailer Tow module, it can only be implementedon vehicles with power locking and perimeter orCAT 1 alarms.The Trailer Tow Module (TTM) can support pureLED trailer lamps as long as each circuit exceeds500mA, below this and the system will not detecta trailer has been connected and shuts down alloutputs (sleep mode). It is recommended totarget a 550mA mimimum load to allow forsystem tolerances. This would need to beobtained with a supplemental load resistor, if theLED lighting circuits are below this threshold.


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Each output driver could handle a current of 15Abut it is not recommended to always run to thismaximum. A higher current is interpreted as shortcircuit. If a short circuit is detected the relatedoutput will be switched off. The following tableshows the recommended output maximums percircuit.

Trailer Tow Module Connectors (Figure E151247 and E145361)

Voltage (V)Current (A)FeatureMaxMinMaxMinCircuit NumberComponent

TerminalNumber

Connector A-630.5Right Direction Indicator1

16910-Battery Charge Out2-640.5Stop Left3----Not used4----Not used5-640.5Reverse Lamp6-640.5Stop Right7-620.5Fog Lamp8----Not used9-630.5Left Direction Indicator10----Not usedPin11-670.5Position Lamp12

Connector B----Not used1

16630-Term 30 (Ubat)2Connector C

-60.1-CAN H1-60.1-CAN L2-60.1-Brake Line In (Vehicle -)3-61-Ground4

16-0.1-Trailer Detect Output5


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Trailer Tow Module Connectors

E151247

1 2 5 4 2 13

CB1 2 3 4 5 6

7 8 9 10 11 12

A

The TTM offers a battery charge output. Thisoutput is used for loading a trailer battery with amaximum parameter current of 10A. If the currentexceeds 10A the output is switched off until thecurrent drain goes below 10A. The voltage usedto charge this battery is designed to maintaincurrent charge up to 10A but not fully charge thebattery or let it discharge. This voltage isapproximately 13.5V. Full charge strategy shouldbe performed separately.The maximum total current is 30A of all circuits.If this is exceeded the battery charge output isswitched off.Summary:• Max permanent current: 10A• Switch on condition:

– Power Mode > = Accessory_1– Total power consumption (all lamps +

battery charge) < 30A– Permanent battery charge output current <

= 10A– 9V < TTM power supply voltage < 16V

• Short circuit detection: 30A

If trailer tow system is to be added, the correctwiring and module needs to be ordered. Thevehicle needs to have Central Car Configuration(CCC) programmed to the correct parameters:CCC Parameter 20• 0x1 without trailer tow• 0x5 with trailer towNOTE: It is mandatory that a trailer is detected.Therefore at least one of the following lamps haveto be connected in the on mode or in the standby mode (anti theft mode): Stop right, Stop left,Position lamps or Direction indicator left.If a trailer is detected the trailer detectionhardware output (JP3-pin 5) is set low (opendrain).If a short circuit is detected or an overheating ofthe drivers occurs, the related output remains offuntil an ignition cycle is performed and the engineis restarted.The trailer detection uses a strategy of having a1K ohm resistor if the lights are not actuallyswitched on to detect that the trailer has beenconnected. If a trailer light is already switched onthe related current will be checked.


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4.1.14 Trailer Tow Connectivity

Trailer Tow Connectivity 12 Pin Sockets

12 Pin Trailer Tow Connector - Australia andNew Zealand

14406 Trailer Tow Connector

DescriptionPinColorPinLeft Turn Lamp1Yellow3Reverse2Black11Lamp Ground3White1Right Turn Lamp4Green6Electric Brakes5BlueNot UsedStop Lamps6Red12Park Lamps7Brown13Not Used8Not UsedNot UsedKL30 Power9Pink9Ground10White16Not Used11Not UsedNot UsedNot Used12Not UsedNot Used

Trailer Tow 14406 Interface Connector

E146642

161514131211

109 1

2

345

678

The Body Control Module does not support theincremental load of powering side marker lampson a trailer, if these are required they should alsobe driven using separate relays.


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4.2 Communications Network

4.2.1 CAN-Bus System Description andInterface

WARNING: Do not tamper with, cut intoor connect to any of the CAN-Businterface wiring or connectors. Theaddition of unapproved CAN-Basedmodules could impact the safe operationof the vehicle.

CAN, Controller Area Network, uses proprietymessage sets to communicate between thedevices shown, via Medium Speed (MS), HighSpeed (HS), Private and Public Buses. In additionthere is localized application of Local InterconnectNetwork (LIN) and ISO 9141 K-line serial links.

CAN-Bus System

E145366


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Communication Network System (Figure E145366 references)

DESCRIPTIONITEMDESCRIPTIONITEMBody Control ModuleBCMHigh Speed CAN -500kb/s1Battery Backed-up SounderBBSMedium Speed CAN -125kb/s2Interior Motion SensorIMSHigh Speed iCAN - 500kb/s3Battery Monitoring Sensor (Start Battery)BMS#1Local Interconnect Connector (LIN)4Battery Monitoring Sensor (AuxiliaryBattery)

BMS#2International Standards Organization(ISO)

5

Rain Sensing ModuleRSMProprietary6Windscreen Wiper Motor (driver sidewiper)

WWMmaster

DIS BUS (Private CAN)7

Windscreen Wiper Motor (passenger sidewiper)

WWMslave

Audio Control Module - Radio/CDACM

IPMA Steering Wheel Haptic Device (LaneDeparture Warning)

SWVAFront Control/Display Interface Module(MFD 2,3,5)*

FCDIM

Steering Wheel ModuleSWMIntegrated Control PanelICPLight Switch ModuleLSMSync Gen1APIM G1Remote Keyless Entry/Tire PressureMonitoring System Receiver

RKE/TPMS

Rx

Instrument Panel ClusterIPC

Passive Anti-Theft SystemPATSTachographDTCOSteering Angle Sensor ModuleSASMGlobal Positioning System MonitorGPSMImage processing Module A (Lane Depar-ture Camera)

IPMAAuxiliary Heater Control ModuleAHCM

Parking Aid ModulePAMTrailer Module (Trailer Tow)TRMHeadlamp Control ModuleHCMImage processing Module B (Rear View

Camera System)IPMB

Restraints Control ModuleRCMCamera Module RearCMRAnti-Lock Brake System Control ModuleABSEngine Control ModuleECM

Starter/Generator Control Module(Alternator)

SGM

*Either low, medium or navigation kb/s - Kilo bytes per second


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4.2.2 Body Control Module (BCM)

BCM - as viewed in-car position

E145367

DescriptionItemLabel PositionA

WARNINGS:Unapproved and/or incorrect connectionto any of the mating wiring can causeeither the associated systems to shutdown (overload protection), orpermanent damage to the BCM itself.

Vehicle BCM configuration must NOT bemodified once the vehicle has left a Fordproduction plant, except for any changesthat may be carried out using dealershipintegrated diagnostic systemsequipment.

The BCM is the prime control module in thevehicle’s electrical architecture. It is responsiblefor management of most of the vehicle’s lighting,locking and security systems.


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BCM Functionality

FunctionalityLow Series - BK2T-14B476-A*

Dual Battery Relay ControlDipped BeamHigh Speed and Medium Speed CAN GatewayMain BeamEngine Run SignalPosition LampsFuel Pump ControlLicence PlateFront Wash WipeBrake LampsClimate Control Fan Relay ControlRear Fog LampsSwitch Back light Illumination (dimming withheadlamp switch fitted)

Daytime Running Lamps

Vehicle HornDirection Indicators and Hazard LampsBase Remote LockingCourtesy LampsBrake Pad Wear IndicationBattery Saver Timer-Tire Pressure Monitoring System

Mid Series - BK2T-14B476-B* (incremental over Low)Power Fold mirrorsPerimeter AlarmRear Screen Wash WipeAuto WipeAuxiliary Heater (PTC)Auto LampFront Fog LampsHeated Front ScreenConfigurable Locking (set at time of order)Heated Rear ScreenPark Aid Module Power SupplyHeated Mirrors-Washer Fluid Level Sensor

High Series - BK2T-14B476-C* (incremental over Mid)Category 1 Alarm (CAT1) includes:Interior Motion Sensor (IMS)Battery Backed Sounder with Inclination Sensor (BBS)


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BCM Output InformationOverload ConditionMax. LoadLoad TypeComponentFunction

Output Shutdown55WBulbHigh Side Pulse WidthModulation

Dipped Beam Left


Dipped Beam Right

Blown Fuse — if bigger fuse fitted,relay and/or Printed Circuit Boarddamage

2x55WBulbHigh Side DriverMain Beam


Day Time Running Lamps(if enabled)


Position Lamps Left


Positions Lamps Right


2x55WBulbInternal RelayFront Fog Lamps

Output Shutdown63WBulbHigh Side DriverTurn Indicators Left

Output Shutdown63WBulbHigh Side DriverTurn Indicators Right


License Plate Lamps

Output Shutdown42WBulbHigh Side DriverReverse Lamps


Rear Fog Lamp


Stop Lamp Left


Stop Lamp Right


Center High Mount StopLamp

Output [email protected] Side Pulse WidthModulation

Switch Illumination

Output Shutdown105WBulbHigh Side DriverBattery Saver Supply

Output Shutdown75WBulbLow Side Pulse WidthModulation

Front Cabin Lamps

Output Shutdown90WBulbLow Side Pulse WidthModulation

Rear Cargo Lamps

Output Shutdown4A normal, 8A10msec in-rush

Electro Mechan-ical Horn

High Side DriverAlarm Siren

Output Shutdown3.5A/50msecRelayLow Side DriverTwin Battery DisconnectRelay

Output Shutdown250mARelayLow side Relay DriverEngine Run Status Relay


8AMirror MotorHigh Side DriverPower Fold MirrorsUnfold


8AMirror MotorHigh Side DriverPower Fold Mirrors Fold


15A (fuselimited)

Latch MotorHigh Side DriverLock/Double Lock


5ALatch MotorHigh Side DriverUnlock Relay

Repeated overloading of circuits can result inoutput lock-out requiring dealer reset. Repeateddealer resets can result in permanent loss of afunction.


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BCM Fuse OverviewFunctionRatingSeriesFuse

Central/Configuration Locking 215ALow/Mid/HighF1

Central/Configuration Locking 115ALow/Mid/HighF2

Ignition Switch Supply15ALow/Mid/HighF3

Parking Aid Module Source5AMid/HighF4

Rain Sensor Supply5AMid/HighF5

Water Pump Supply15ALow/Mid/HighF6

Mirror Supply7.5AMid/HighF7

Fog Lamps Front Supply15AMid/HighF8

Main Beam Right Supply10ALow/Mid/HighF9

Main Beam Left Supply10ALow/Mid/HighF10

Exterior Lamp Right / position Lamp Left25ALow/Mid/HighF11

BBS Supply, Security Horn20AMid/HighF12

On Board Diagnostic II Supply, Battery Saver Supply15ALow/Mid/HighF13

Turn Indicator Supply, Daytime Running Lamps, Fog lamp RearSupply

25ALow/Mid/HighF14

Exterior Lamp Left / position Lamp Right / Central High MountedStop Lamp

25ALow/Mid/HighF15

Radio/CD Navigation Supply20ALow/Mid/HighF16

Hybrid Electronic Cluster Supply7.5ALow/Mid/HighF17

Light Switch Module, Steering Wheel Module Supply, Stop LampSwitch Supply

10ALow/Mid/HighF18

Instrument Control Panel, Multi Function Display Supply5ALow/Mid/HighF19

Ignition Passive Anti-Theft Supply5ALow/Mid/HighF20

Radio, Hybrid Electronic Cluster, Navigation KL75 Supply3ALow/Mid/HighF21


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4.3 Charging System

4.3.1 General Information and SpecificWarnings

The Transit electrical system is a 12-Volt supplywith a negative ground return. The alternator andbattery equipment used as standard are designedfor normal operations with the type of enginefitted. Higher capacity batteries are available asstandard production options and special vehicleoptions offer AGM technology for heavy PTO anddeep cycling applications. Before installingadditional electrical equipment check that thebattery capacity, technology type, harness loadcapability, and alternator output are suitable forthe extra load.The battery capacity, technology and chargeavailable from the alternator must be adequateto ensure engine cranking in unfavorable climaticconditions.

The Transit utilizes multiplexed vehicleelectronics, it is recommended that theappropriate Ford proprietary accessory systemsare used. Inappropriate or incorrect connection ofadditional equipment could cause mis operation,or damage to the vehicle, and so invalidate anywarranty.Additional connection points are providedspecifically for customer use, and are located onthe outside of the driver's seat pedestal. A 60Amp fused connection is provided as standard.Do not jump-start the vehicle directly from thebattery. Use designated jump-start points. Referto the Owner's Manual. The wiper motor bracketmust not be used as a ground as it is isolatedfrom the body.


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4.3.2 System Operation and Component Description

System Diagram

E140418

1

2

4

5

3

DescriptionItemPower Control Module (PCM) or Engine Control Module (ECM)1Body Control Module (BCM)2Battery Monitoring Sensor (BMS) — Where fitted3Battery — For Start-Stop application there will be two batteries4Electrical consumers5Alternator6


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System Operation - Smart RegenerativeCharging (SRC) Except Camper

The largest element of the SRC strategy is storedin the Body Control Module (BCM). It receives allof the important information relating to thebattery condition sent by the Battery MonitoringSensor (BMS) via the Local Interconnect Network(LIN) data bus.Using the information received, the BCM thensends the set value needed for the alternatorcharging voltage via the HS CAN (Controller AreaNetwork) data bus to the PCM/ECM. This thenadjusts the value received if necessary and passesit on the alternator via the LIN. The chargingvoltage is adjusted depending on variousparameters, such as the current level of engineefficiency. The smallest possible set value for thealternator voltage (V) is 12.2V, while the maximumcharging voltage may be anywhere between 14.5Vand 14.9V. However, when the battery is in arefresh phase, the voltage could occasionallyreach up to 15.2V. These refresh phases arerequired as the battery charge status is 80% overlong periods of time.Refer to: 4.4 Battery and Cables (page 93).

Comparison of SRC and ConventionalCharging

The following figure E140419 demonstrates thedifference between SRC and conventional batterycharging. Conventional charging aims to chargethe battery to the highest possible levels. Duringthis process the battery temperature is monitored(inferred temperature) and the battery must notbe overcharged. By comparison SRC uses theinformation from the battery monitoring sensor(voltage, current and direct temperature) tomaintain, more accurately, the battery at acalibrated state of charge. This means that thebattery has a certain amount of extra chargingcapacity at all times. If the BCM detects that thecharge status is above the calibrated value thealternator charging voltage is reduced, in order todischarge the battery. If the opposite occurs andtoo low a value is detected, the charging value isincreased in order to return the battery to thecalibrated value.


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Smart Regenerative charging and Conventional Charging

80

0

1

D

A

E F

3

B C

2

E140419

DescriptionItemState of Charge — SOCAConventional ChargingBRegenerative ChargingCCharging continuouslyDCharging during decelerationEDischarge during normal drivingFHigh SOC control target1Partial SOC control2Charging continuously3

4.3.3 Start-Stop Override andConfigurable Charging

There are two control methods to switch thepower supply system to Conventional Charging.This maybe required for converters requiringbattery voltage that is being charged by thealternator in the range of 14.0 to 14.9 volts. Suchapplications include boost or supplemental batterycharging, compensation for volt drop or highAmpere electrical loads whilst the engine isrunning.

1. ECO Switch - Manual Operation

The ECO functions are OFF when the ECO switchis pressed and the LED is ON (ConventionalCharging). It can be reactivated if the ECO switchis pressed again or the ignition key is set toAccessory or OFF (Normal Charging) see Summaryof the Available Charging Modes table.


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Summary of the Available Charging Modes

Approximate Charging Voltages(Measured at Jump Start post)

Charge Mode

Minimum 12.8 - Maximum 14.9Smart Regenerative Charging - normal chargemode.

SRC

Minimum 14.0 - Maximum 14.9Conventional Charging - applies a strong chargingvoltage until the battery is full and maintainsalternator voltage above 14V unless batterytemperature >40degC. The actual voltage at thebattery will vary depending on the alternator load.

CC

Not ApplicableStart-Stop - there is a 5 second delay from whenthe CC/SS inhibitor is activated to when SS isinhibited. *

SS

The voltages in the above table are approximate as the charging system is dynamic and can vary thevoltage at any time.For further information on Start-StopRefer to: 4.8 Electronic Engine Controls (page 114).

2. Hardwire Input

NOTE: Only available on Body Control Modules(BCM) with software version BK2T-14C184-AGor later. Not available before September 2013.This is a pin in the BCM that the customer canconnect to and switch between open circuit andground to change between Normal Charging andConventional Charging modes.The Hardwire Input can be accessed in three ways:

• Pre-installed as part of a Camper Donorvehicle.

• Pre-installed as part of the High SpecificationVehicle Interface Connector (A608) and a linkfrom the Hardwire Input to the chosen switchand ground point, but must not be a permanentground. The grounding should only occur for aduration of the third party system needing acertain functionality and performance whichcan only be met by turning off the fuel savefeatures of Smart Charging and Start-Stop.Grounding permanently might invalidate theemission and homologation of the vehicle andthe vehicle could need to be re-homologatedas part of the approval process by theconverter. A mating 43 way connector withthree meters of wiring (with all wires) isavailable as a kit (KTBK2V-14A411-D_) fromyour local Ford dealer. For information on HighSpecification Vehicle Interface ConnectorRefer to: 4.17 Electrical Connectors and

Connections (page 142).• As a kit to install the additional pin in the BCM

connector pin C3-38. The kitKTBK2V-14A411-E_ is available from your localFord dealer.


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Installation of Converter Pin to BCM Connector C3

Jumper Kit KTBK2V-14A11-E_

E169178

DescriptionItemKTBK2V-14A11-E_ contains spare connector, 3 meter fly lead with pre-crimped terminal andcable tie.

JumperKit

To access the BCM refer to the Workshop ManualRemoval and Installation instructions.

BCM C3 Connector Location

E169177

1. Disconnect the C3 connector from the BCM bypulling back the grey lever mechanism.


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C3 Connector

E169179

2. Remove the black connector cover - 2x clipseach side.

Cut Cable Tie

E169180

3. Cut cable tie on brown cable guide side ofconnector.


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Insert Converter Pin

E169181

11937

183654

38

37

54

1

18

4. Insert converter pin into connector pin 38. Thepin will only fit one way. Once inserted, gently pullback the terminal to ensure that it is latched inposition.

Wire Routing

E169182

5. Route the wire through the harness retainer withthe rest of the loom and fix in place with a cabletie.


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Reassemble Connector

A

BE170009

6. When reassembling the connector into the BCMthe latch (A) must be in the fully open positionand the sliders (B) on both sides must be levelwith the front of the connector, see figureE170009.7. To reconnect the connector to the BCM pushthe grey lever to engage the connector and clickinto position.8. Route the harness to required switch mountingpoint,Refer to: 4.2 Communications Network (page 75).BCM section. Reinstall trim using reverse of theremoval procedure. Verify BCM function byoperating the vehicle horn.

Test Functionality: Start-Stop Inhibit -for vehicles with Start-Stop

1. Check Start-Stop functions as intended, referto Owner's Manual for details.

2. While driving the vehicle, close the HardwareInput Switch, if safe to do so, and check thatthe Start-Stop no longer operates.

3. Open the Hardware Input switch and checkStart-Stop functionality is restored.

Test Functionality: SRC Inhibit, ChargingMode Control

1. Ensure batteries have good charge. Whencharging, use the jump start point and enginebay ground point. Refer to the charginginstructions in the Owner's Manual.

2. Measure voltage between jump start point andengine bay ground point with engine runningand SRC inhibit switch open. Refer to theRoadside Emergencies section of the Owner'sManual.

3. With the engine running, close Hardwire InputSwitch and measure voltage. The voltageshould be in the ranges shown in the table'Summary of the Available Charging Modes'.

4. Open the switch again and check voltage levelreturns to the original level measured in Step2. SRC is active.

Note:There will be a delay between closingHardwire Input Switch and change of voltageoutput. The voltage may depend on many factorsincluding total electrical load, which loads areactive, battery condition and others. The rate ofcharge between modes varies depending on whichloads are active.

4.3.4 Power Management Settings

WARNING: The only method to return thevehicle to Transport mode is by using aFord diagnostic service tool with thecorrect level of security clearance. TheFord dealer has the correct tools andlevel of security to do this if required.

There are four power management settingsavailable; Factory, Transport, Normal and Crash.Factory and Transport modes are only active withthe engine not running (for example: ignition offor with ignition on and engine not running); withengine running, the vehicle operates with fullfunctionality. When in Transport mode, the interiorlights, clocks, and power locking and alarms(where fitted) do not work.It is possible to switch from Transport mode toNormal mode without the use of any ancillaryequipment, but not vice versa. To change mode,the brake pedal must be depressed five times,and the hazard warning switch operated twice (inany combination) within 10 seconds.


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If a vehicle is received from the dealer wheremodules do not seem to be functioning correctly,please contact the dealer as the vehicle may stillbe in Transport Mode. Transport Mode is mainlyused to conserve battery life/warranty. The normalprocess is for the pre delivery phase to change thevehicle from Transport Mode to Normal Mode.

4.3.5 Electrical Conversions

WARNING: The fitting of voltage boostersor other devices to enhance alternatoroutput are not allowed. The fitting of suchdevices will not only invalidate vehiclewarranties, but could damage either orboth, the alternator and EngineManagement System/Power ControlModule, and possibly affect vehicle legalcompliance. Check local legislation.

Operator requirements for additional andspecialized electrical equipment varies. The vehicleconverter/modifier must, therefore, consider thefollowing points when designing the installation:• Legality and regulatory conformity of the base

vehicle.• Drive-ability and serviceability of the base

vehicle.• The effect of regulations governing the

proposed conversion including NationalLegislation in the country of sale.

• The method of integrating the circuit into thebase vehicle.

• No additional circuits are to be run alongsidethe electrical circuits (shown in blue in figureE146305) associated with the EngineManagement System (shown in green in figureE145305), due to the possible inductive orelectrostatic coupling of electrical interference.

• The base vehicle is equipped with either a singleor twin battery system (with battery disconnectswitch). Additional batteries can be fitted inconjunction with a battery disconnect switch(cut-off relay), described in the section 'Batteryand Cables'. It is important to also read relativeinformation on Start-Stop and SRC.Refer to: 4.4 Battery and Cables (page 93).

• When auxiliary electrical systems are added tothe vehicle, it is recommended that theadditional circuits are designed to be used withthe Special Vehicle Option Auxiliary Fuse Panelto maintain the integrity of the electricalsystem.Refer to: 4.15 Fuses and Relays (page 134).

• The materials and installation must meet thequality standards described in this section.

• Any additional equipment or components mustbe designed such that they have no adverseElectro Magnetic Compatibility - EMC effect onthe vehicle.

• The alternator and Engine Management System(EMS) — Also referred to as Powertrain ControlModule (PCM) are interdependent.

• The alternator is LIN controlled. It does not havea conventional D+ (engine start) signal line.Refer to: 4.8 Electronic Engine Controls (page

114).• Take special care with the routing of existing

electrical harnesses within the vehicle to avoiddamage when fitting additional equipment.Also see section concerning installation ofequipment containing an electric motor.


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Electrical Circuits Associated with Management System

E146305

For additional third part gound and +12V powercable connections to the Ford systemRefer to: 4.4 Battery and Cables (page 93).Camper vehicles: When fitting an additionalbattery, this must be connected to the auxiliarybattery circuit. If high loads are to be supplied,exceeding the customer connection point suppliesor high in general, especially at ignition off loads,an isolation switch disconnect relay should befitted. This is to protect the vehicle start batteryfrom a failed start. Suitable capacity in the wiring,fuses and alternator will be required. If unsure ofwhich battery to interface with or what systemrequirements are needed, please contact yourlocal dealer who can advise.Refer to: 4.4 Battery and Cables (page 93).NOTE: Before disconnecting the battery, checkavailability of radio key code.NOTE: When auxiliary electrical systems are tobe added to the vehicle it is mandatory that theadditional circuit design includes the necessaryfuses.The Auxiliary Fuse Panel is recommended.Refer to: 4.17 Electrical Connectors and

Connections (page 142).

Safety

Increased use of comfort and safety electronicsin modern motor vehicles also requires thegreatest attention to be paid during body work.Over-voltages produced during welding and inalignment work during body shell rectification maycause electronic systems to be damaged. Inparticular, the safety instructions for performingwelding / cutting work on vehicles with airbagsystems must be adhered to.NOTE: After disconnecting the power supply andbefore performing further work, a wait time of upto 15 minutes must be maintained, depending onthe vehicle. Work on airbag systems may only beperformed by persons who have a relevantcertificate of competence.Pay attention to the following points:• Disconnect all the batteries, including ground

and insulate the negative battery terminal(s).• Disconnect the electrical connector at 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 removedbefore hand.

• Never connect the negative cable of the weldernear an airbag or a control module.

• Connect the negative cable of the welder closeto the location of the weld.


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4.3.6 Fitting Equipment ContainingElectric Motors

WARNING: When electric motors are tobe fitted, account must be taken of thepotentially high in rush currents that amotor can draw.CAUTION: The following must beobserved:

• All motors must be driven via relays withcontacts rated at least 3 times the maximumrated current of the motor.

• All motor supply circuits must be individuallyfused with the proper fuse rating for the motor.

• All power wiring must be rated for at least 3times the rating of the motor and installed asfar away as possible from any existing vehiclewiring.

• All motors fitted should be fully suppressed toEuropean or applicable local Legislation relatingto Electromagnetic Compatibility to ensureelectrical interference does not affect thevehicle systems.

• Add EMC emissions statement to CE approval.

4.3.7 Vehicle Electrical Capacity —Alternator

WARNING: Do not cut into the alternatorwires. The alternator is LIN controlled. Itdoes not have a conventional D+ (enginestart) signal line.

4.3.8 Charge Balance Guidelines

The base vehicle is fitted with a 150A alternator.It is recommended to conduct a charge balancecalculation in case the conversion comprises ahigh number of electrical consumers or highelectrical consumption is expected.

4.3.9 Circuit Diagrams

For circuit diagrams for Auxiliary Fuse Panelconnections and standard Ford relays.Refer to: 4.17 Electrical Connectors and

Connections (page 142).Refer to: 4.15 Fuses and Relays (page 134).Full vehicle wiring and circuit diagrams are in theFord Workshop Manual.NOTE: For further information please contact yourlocal National Sales Company representative, orLocal Ford Dealer. If they are unable to help youthen please contact the Vehicle Converter AdvisoryService at [email protected]


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4.4 Battery and Cables

4.4.1 High Current Supply and GroundConnections

WARNINGS:A self locking crimp hexagonal nut MUSTbe used for high current terminal studconnections, for battery positive andnegative or chassis ground. Do not uselocking, split washers or nylon lock typenuts.It is recommended to only use one eyeletper stud for high current applications. Ifmore than one eyelet per stud isunavoidable, the highest current eyeletfeed should be connected closest to thesupply terminal. Do not exceed twoeyelets or crimp terminals per studconnection.

For additional informationRefer to: 4.17 Electrical Connectors and

Connections (page 142).Customer Connection Points.

Self Locking Crimp Hexagonal Nut

E171315

A

B

C

DescriptionItemLarge flange for maximum surface areacurrent flow and large clamp force area.

A

Crimp / locking feature is obtained bydeformed female thread only

B

Finish must be a low resistance materialwhich complies with the RestrictedSubstance Management Standards(RSMS).

C

4.4.2 Battery Information

WARNINGS:For electrical power take-off thatrequires deep discharge and cycling fromthird party systems, High PerformanceDeep Cycle AGM batteries (A736) mustbe ordered on the base vehicle, for moreinformation refer to 'Power andConnectivity Usage Recommendations'table later in the section. If option A736is not on the base vehicle they can befitted by your local Ford Dealer. See tablein Single and Twin Batteries Section.If serviceable batteries are fitted, it isessential that regular checks are madeto determine that the electrolyte (acid)levels are correctly maintained. There isa level indicator in each cell.Take necessary safety precautions whenhandling batteries, for example:protective clothing, eye and handprotection.Ensure batteries are charged in adesignated charging area that is correctlyventilated.Vehicles with Start-Stop require anenhanced battery. You must replace thebattery with one of exactly the samespecification and technology or upgradeto a High Performance Deep Cycle AGMbattery if adding a deep cycle system.Make sure that the battery box iscorrectly sealed including any additionalcables routing in and out of the box. Afterconversion, always check that the draintubes have not been dislodged.

NOTE: If a converter intends to add systems oraccessories that will add load at key off or enginerun, then twin batteries should be specified inparticular AGM battery type. There are alsoalternator upgrades and other options that arerequired for Power Take Off requirements. Referto the table “Power and Connectivity UsageRecommendations” in this section of the BEMMfor your vehicle. Heavy Power Take Off may inhibitStart-Stop but only for the duration of the thirdparty load. This is normal functionality.In order to protect the battery system from directground shorts or continuous high current loads, a470A main fuse is fitted in the Pre Fuse Box underthe driver’s seat. Converter fit peripherals mustnot use this fuse as its sole purpose is protectionof the starting and charging system.This fuse is not repairable — Use only a Fordreplacement part.


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Following battery disconnection, there is no needto reprogram the vehicle. It retains its ‘normal’power management settings and configurations.However, the central locking latches may cycle ifone of these was opened manually in theintervening period. With regard to the radio, all ofthe settings are retained.There is no longer a need to re-program theelectronic security code, as it is tied into the VINof the factory fit Transit system. The clockinitializes to 12:00 and will need to be reset tocorrect time in accordance with the customerhandbook procedure. After reconnecting, theBattery Monitoring Sensor (BMS) requires at leastthree hours quiescent period to re-calibrate to thecorrect battery state of charge, see also BMSinformation later in this section.

The Ford SureStart® system (battery disconnectrelay) prevents inadvertent discharge of the starterbattery to ensure the vehicle will crank. The vehiclestart battery is only connected to the rest of thesystems when the engine is running. During a warmengine auto stop, the vehicle start battery isisolated until auto restart is performed.During a system warm re-crank the battery voltagewill drop as low as 7V for 100ms. Followed by aperiod of voltage ripple providing an output to bringthe voltage back to 12.3V. This can be up to 5seconds. All third party fit modules must be robustto handle warm re-cranking waveform.

Warm Re-crank Waveform

E242177

DB C EA A

DescriptionItemEngine OnAFuel Cut OffBEngine Off (auto-stopped)CEngine CrankDEngine On (alternator ramping up)E

After market battery management systems arenot required unless for converter fit equipment orthird party battery low voltage protection.


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WARNING: Where a battery guard isfitted, the supply from a non-deep cycletwin standard flooded battery system(2x80Ah) should not be set below 12V atopen circuit voltage. If a battery guard ismonitoring a supply from a deep cycletwin AGM battery system (2x80Ah), it isrecommend not being below 11.8V atopen circuit voltage. If the supply hasdifferent configuration, it isrecommended to test the Low VoltageThreshold to ensure crank capability.There will be volt drop if the system isunder load. It is recommended to test thevolt drop under the load and compensatefor the volt drop to avoid earlydisconnect. For example: loads above20A will cause approximately 0.3V dropin the twin AGM battery system. If thesystem is under load above 20A, LowVoltage Threshold can be set to 11.5V. Ifa battery guard is required becauseequipment can be active at engine off,then it is recommended to fit deep cyclebatteries as standard. See also 'Powerand Connectivity UsageRecommendations' table later in thissection. A battery guard high voltage setpoint should also not be below 15.3V asthis is the normal operation voltage of anSRC system, when in refresh mode. Forfull peripheral robustness, it isrecommended that equipment canhandle up to 24V to allow for accidentaljump start by extra 12V supply in seriesand not parallel.

Any peripherals added to the power supply mustbe connected via the Customer Connection Points,from dedicated fuses such as the Auxiliary FusePanel (A526) or the High Specification InterfaceConnector (A608). For loads greater than 180A,see 'Third Party +12V Power Take Off for LoadsExceeding 180 Amps' in this section of the BEMM.Where twin batteries are required on vehicles witha single battery installation, the batterydisconnect relay (SureStart® relay), associatedwiring and hardware should be fitted and alignedto Ford architecture. The extra battery must beof the same technology and performance ratingas the existing battery. Alternatively both batteriescan be upgraded to the High Performance DeepCycle AGM batteries (A736).If the battery type on a vehicle is changed to othercompatible derivatives (see battery configurationtable) it is required to reconfigure the vehicle tothe new battery types from the dealer. Central carconfiguration can be updated at a dealership.For special conversions requiring a third partybattery, a further disconnect switch isrecommended. This should be controlled via theengine run signal to a normally open relay. Aschematic of this architecture can be found laterin this section.Refer to: 4.8 Electronic Engine Controls (page 114).andRefer to: 4.3 Charging System (page 81).

Battery Voltage Requirements andTesting

As part of the Converter process and to maximizebattery life and prevent premature failure of theFord Batteries, the converter should protect andprevent battery discharge during any conversionor whilst the vehicle is in storage. This may include,leaving the vehicle in ‘Transport’ mode as long aspossible, reducing the amount of crank cyclingaround the facility, door ajar events and duration.It is recommended to check voltage whenreceiving and before shipping. Recharge with anappropriate proprietary battery charger if thevehicle battery voltage is below 12.4V for standardand enhanced flooded or 12.3V for AGM. Measureconnected to the vehicle at ignition off and noloads active including interior or exterior lights inOFF status.All voltages are to be measured with an accuracyof: ± 5% of values published using calibratedmeters. Measure the voltage by using theCustomer Connection Point (CCP) or the batteryplus terminal for positive connection and batteryground or battery minus terminal for negativeconnection.For EU5 vehicles starter and auxiliary battery needto be checked separately. Use the jump startconnection points in the engine compartment tocheck the starter battery and use the CCP andbattery minus terminal to check the auxiliarybattery.

Surface Charge Dissipation

Prior to carrying out manual voltage checks, it isnecessary to establish that the battery does nothave any damage and the battery voltage is stableand free from surface charge which occurs afterengine run.To ensure surface charge is not present measurethe battery voltage after the vehicle has beenstanding, with the ignition off and no loads active,for a prolonged period of 24 hours. If this is notpossible an estimate can be made using thefollowing method:1. To dissipate whatever surface charge is present

in the battery turn on the head lamps (mainbeam) for 5 seconds or turn on the parkinglamps for 15 seconds if the head lamps will notturn on with the key in the off position.

2. Turn off the lights and allow the key off loadsto reach their steady value. This typically takes10 - 15 minutes.


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Delayed Vehicles

Vehicles held at the vehicle convertor premisesand not in use for longer than 7 days, should havethe battery's negative cable disconnected. Beforeshipping to the customer, the battery negativecable must be re-connected and the voltagere-checked. A complete recharge is required forbattery voltage below 12.4V for standard andenhanced flooded or 12.3V for AGM or for no-crankvehicles by using an appropriate charger.For additional informationRefer to: 1.11 Vehicle Transportation Aids and

Vehicle Storage (page 26).

Usage of Electrical Loads DuringConversion

If electric loads are used during conversion, forexample multiple crank cysles or door ajar, checkthe battery voltage more frequently than every 7days and recharge the battery if necessary.For additional informationRefer to: 1.11 Vehicle Transportation Aids and

Vehicle Storage (page 26).

Battery Charging Procedure

WARNING: Do not connect to any Groundor +12 volt potential points other thanthat specified in the Owner's Manual.There is a dedicated charge point underthe hood. Failure to comply may lead tohigh current paths that may damageperipherals and ECU's especially in a jumpstart condition.

1. Cold batteries will not readily accept a charge.Therefore, batteries should be allowed to warmup to at least 5°C (41°F) before charging. Thismay require four to eight hours at roomtemperature depending on the initialtemperature and battery size.

2. A battery which has been completelydischarged may be slow to accept a chargeinitially, and in some cases may not accept acharge at the normal charger setting. Whenbatteries are in this condition, charging can bestarted by use of the dead battery switch orboost charge on chargers that have this facility.

3. To determine whether a battery is accepting acharge, follow the manufacturers instructionsfor the charger, for use of the deadbattery/boost charge mode.

Battery Cable Fixing Torque

The battery cables should be fixed to the terminalpost with a torque of 8.0Nm ± 1.2Nm for battery+v/-v connection with/without BMS. For additionalinformation see BMS later in this section.

Battery Options

Any additional or different batteries must bechecked for correct functionality on a Start-Stopor Smart Regenerative Charging (SRC) vehicle.Refer to: 4.8 Electronic Engine Controls (page 114).Start-Stop and SRCRefer to: 4.3 Charging System (page 81).NOTE: If wrong batteries or incorrect configuration,Start-Stop or SRC may not function correctly.

Battery Part Numbers and UsageSizeQuantityTypeBattery Part

Number

Single Battery (without Start-Stop) Battery Configuration A

T71700 CCA (80Ah @20 hour rate) Standard FloodedBattery

6C16-10655-C_*

Twin Battery (without Start-Stop) Battery Configuration B

T72700 CCA (80Ah @ 20 hour rate) StandardFlooded Battery

6C16-10655-C_ *

Twin Battery (with Start-Stop)*** Battery Configuration C

T72700 CCA (75Ah @ 20 hour rate) EnhancedFlooded Battery

CC1T-10655-B_ **

T72700 CCA (75Ah @ 20 hour rate) EnhancedFlooded Battery

DK2T-10655-A_ ^

High Performance Deep Cycle AGM Batteries*** Battery Configuration D

H72800 CCA (80Ah @ 20 hour rate) Absorbent GlassMat Battery

DV6T-10655-B

* Can be replaced by 8G9N-10655-P_ in service.** Can be replaced by BV6N-10655-B_ in service.*** Compatible with SRC and Start-Stop vehicles only, pending availability in markets.See Battery Configurations^ Turkey Markets Only.


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4.4.3 Battery Rules

• Batteries in parallel must be of the same typeand capacity when using the SureStart ®system and listed in the Ford battery table.

• Third party batteries and loads are to beisolated from the standard Ford system at keyoff.

• For External charging of batteries ensure thatthe maximum voltage of 15.2V is not exceeded.Normal proprietary charging equipment shouldoperate below this voltage.

NOTE: Charge balance calculations are requiredwhen adding additional systems taking intoaccount alternator size and battery capacity.Important Factors for Battery Choice• Battery specification capability in ampere hours

for continuously loading until empty. Forexample an 80Ah fully charged battery cansupply 4 Ampere over a 20 hour period at 20degrees centigrade until it is fully discharged.

• The Cold Crank Ampere (CCA) rating is themaximum rating for cold start requirements.

• For deep cycling and micro cyclingrequirements (engine off loads) the deep cyclebattery system (A736) is recommended.

Always observe circuit set-up outlined in diagramE74522 - Battery Disconnect Relay (Split ChargeRelay) Circuit, later in this section. Extra batteriesadded to the power supply should be connectedas shown at the end of this section.

4.4.4 Battery Configurations

Battery Configurations (always in the driversseat pedestal)

1

1

2

1

2

2

1

K

K

J

J

E145368

A

B

C

D

Battery ConfigurationDescriptionItem

Vehicle Start Battery1

Auxiliary Battery2

Single standard battery system — Without Start-StopA

Twin standard battery system — Standard Duty — Without Start-StopB

Improved flooded standard order battery — Start-Stop (K)C

Twin special vehicle option battery system — With and without Start-Stop (J)D

Arrow = Front of vehicle direction

4.4.5 Battery Configuration,Additional Loads, Start-Stop andSmart Regenerative Charging (SRC)

Start-Stop and SRC will operate withinspecification only if a correct battery configurationis installed in the vehicle.NOTE: The following battery configurations areNOT compatible with Start-Stop and SRC:• Mixed battery types - for example: 1 x AGM and

1 x Flooded.• Mixed sizes - for example: 1 x 60Ah, 1 x 80Ah.• Battery types other than those listed in the

'Battery Part Number and Usage Table.• Extra batteries than factory fit - for example:

3 or more, if not isolated from existing powersupply at Key off.

• If twin Ford battery configured only fittingsingle Ford battery.

• If single Ford battery configured, fitting twinFord battery.

Start-Stop and SRC system functionality cannotbe guaranteed with these configurations. If sucha battery configuration is required, it isrecommended not to equip the vehicle withStart-Stop in the factory so the vehicle should beoriginally ordered without. It will not be possibleto decommission the Start-Stop and SRC featuresdue to Homologation, Vehicle Tax and ExciseRequirements.If the battery type on a vehicle with Start-Stop orSRC is changed to other compatible derivatives(see battery configuration table) it is required toreconfigure the vehicle to the new battery typesfrom the dealer. Central car configuration can beupdated at a dealership.The feature content of the vehicle must stillremain an Start-Stop or SRC vehicle to be in linewith the Homologation, Vehicle Tax and ExciseRequirements.


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Convert Fit Additional Third PartyBatteries

If additional batteries are added, a disconnect relayor main manual switch system is advised to isolatethe converter fit battery from the Ford fit batteries.It is recommended to only connect the third partybattery to Ford fit batteries and alternator atengine Run. The third party battery should beconnected to the auxiliary battery side of thesystem via the customer connection points for the+12V supply. If the third party battery and addedsystem requirements exceed 180A of current,connection to the battery positive 6mm stud ispermissable, as detailed in the 'Third Party +12VPower Take Off for Loads Exceeding 180A' sectionof this manual. This ensures the vehicle startbattery is untouched. If supplemental chargers areadded for the third party converter fit battery,direct connection of such chargers to this batteryis required. Connection to the auxiliary battery alsoreduces the number of crank micro cycling that athird party battery will be exposed to on aStart-Stop variant. This is because the startermotor in an auto start condition, only uses energyfrom the vehicle start battery, the rest of the powersupply is isolated until the engine is running. Gelbatteries in particular are vulnerable to multiplestarter cycles, see next figure E147211 for anexample of converter fit third party batteryinstallation to existing Ford power supplyarchitecture.

The Charge can also be applied to the Ford fitbatteries, all relays/switches connected, but onlyfor an emergency charge.When changing from an incompatible batteryconfiguration to a compatible system, Start-Stopand SRC functionality will take some time (ignitionoff overnight and multiple ignition run cycles) tore-establish full functionality.Refer to: 4.3 Charging System (page 81).System Operation


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E147211

A

L

M

N

BK

E

D

J

H

C

F

G

DESCRIPTIONITEM

Converter Fit — LoadsA

Body Control Module — Provides Engine StateB

Pre Fuse Box — Drivers Seat PedestalC

Converter Fit — Normally open Third Party Battery Control RelayD

Converter Fit — Third Party BatteryE

Ford Fit — Auxiliary BatteryF

Ford Fit — Vehicle Start BatteryG

Ford Fit —SureStart® Battery RelayH

Ford Fit — Loads (from Auxiliary Battery)J

Switched Ground Engine Run Signal (200mA)K

Converter Fit — +12V Fused KL30 SupplyL

Converter Fit Power Supply FuseM


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Third Party +12V Power Take Off for LoadsExceeding 180 Amps

Third party +12V power take off connectivityshould be made to the Customer ConnectionPoints (CCP) where possible. In the event ofgreater than 180A current power requirements butless than 250A peak loading (maximum fuse valuethird party installed), connecting to the rear battery+12V clamp, 6mm stud, is permitted.The following fusing principles must apply:• If for a long duration (greater than one hour

continuous), the fuse must be no higher ratingthan the alternator fitted to the vehicle. Forexample: vehicles fitted with a 150A alternator,a maximum 150A fuse can be fitted, vehiclesfitted with a 210A alternator, a maximum 210Afuse can be fitted. Conversion example: 2 kWInverter installation.

• For short term loads such as one minute peakloads, a 250A fused cable can be installed.Conversion examples: Crane, Tipper, Tail-Lift.

This is only allowed if testing by the converterconfirms that there are no issues (documentationmust be held to confirm the tests) and thefollowing criteria is met:• No movement before full tightening of the nut

(no risk of rotation). The third party eyelet mustbe a tight fit within the battery clamp slot andhave a maximum Cross Sectional Area (CSA)for current flow.

• The cable CSA must be oversized,Refer to: 4.1 Wiring Installation and Routing

Guides (page 61).Wiring Specifications table. For example: 245Ahas 70mm CSA cable.

• The third party conductor is mounted directlyto the battery clamp with the BatteryMonitoring Sensor (BMS) last, see figureE224111.

• No deformation to the Ford BMS can occur. Theconductor terminal/eyelet may need to beinverted, see item 4 in figure E224111.

• Only one termination (third party conductor)can be added to the 6mm stud in addition tothe BMS.

• The Ford 6mm self-locking nut is to be re-usedand torque to 9Nm ±10%. Separate lockingwashers are prohibited.

• A Mega inline fuse must be fitted as close tothe 6mm stud as possible. Not to exceed 250Afor short duration applications such as onTippers, Cranes or Tail Lifts.

• For long duration continuous powerapplications such as High Power Inverter, theMega fuse must not exceed the rating of thealternator fitted to the vehicle. The alternatorsaturation voltage must be above 13.0V whentesting full load. AGM battery twin system(A736) must be fitted to the derivative. See'Single and Twin Battery System' and 'Powerand Connectivity Usage Recommendation'table in this section of the BEMM.

• A higher amphere alternator must be fitted iflong duration (greater than one hour) high loadsare required. See 'Single and Twin BatterySystem' and 'Power and Connectivity UsageRecommendation' table in this section of theBEMM.

• The SRC override feature must be used forEngine Run applications.Refer to: 4.3 Charging System (page 81).Start-Stop Override and Configurable Charging.

• Efficient isolation of third party equipment,when not required, to minimize batterydischarge/deep cycling.

• Testing for end customer usage, including dutycycle, at a range of temperatures and drivecycles, worst case.

• Testing of vehicle converters system mustconfirm no heating of Ford or third party cablesor any junctions utilized.

• Testing of vehicle converters +12V conductormust demonstrate no loosening possible toFord battery cable clamp.

• No detriment to Ford systems from Voltdrop/Inrush current by third party system(functionality or Warnings).

• If Engine Off can still operate the third partysystem then testing also required in this vehiclestate.

• A Charge Balance must also be performed toconfirm system has correct battery andalternator ratings.

• If Idle loading can saturate the alternator (fullyload and go below 13.0V) then Engine RPMspeed control system must be utilized toincrease alternator output at idle.

• The return ground cable is recommended,routed in parallel to +12V supply for EMCcompliance.

• When in Engine Run, unrequired systems shouldbe turned off to help the alternator supply themain load of the third party system. Thisinformation should be passed onto the end userby the vehicle converter.

• The BEMM is adhered too in all relevant areas.This document allows connectivity to Fordbattery clamp if the above criteria is met.

For further information please [email protected]


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Third Party +12V Power Take Off Assembly

E224111

1

2

3

4

41

23

A B

DescriptionItemAssembly sequenceAAs installedB+12V Battery Clamp 6mm Stud1Third Party Eyelet and Cable - Must be a tight fit to the battery clamp2BMS Fuse3Self Locking Crimp Hexagonal Nut - Re-use and torque to 8.0Nm ± 1.2Nm4

4.4.6 Additional Loads and ChargingSystems

NOTE: Auxiliary customer electrical loads mustonly be made via the Customer Connection Pointsprovided, the Auxiliary Fuse Panel or the HighSpecification Vehicle Interface Connector. Forloads greater than 180A see 'Third Party +12VPower Take Off for Loads Exceeding 180A' sectionin this BEMM. Contact your local Ford Dealer orNational Sales Company representative for adviceon which system for your application.NOTE: Do not make any additional connectionsto the Engine Junction Box (EJB) terminals, asover-torquing could cause damage to the EJB.Any electrical loads should be taken from thecustomer connection point. For applications thatrequire a permanent installation to gain power forjump start requirements for example recoveryvehicle conversion, contact your National SalesCompany representative.

For additional information on number of availableCustomer Connection PointsRefer to: 4.17 Electrical Connectors and


EJB Terminal Studs

E176677


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All loads that exceed 80mA continuous key offload must be fitted with an isolation switch ordisconnected relay. In general all loads shouldhave some form of isolation. A supplementalbattery may be required to power systems, forexample: GPS vehicle tracking systems, that pullhigh key off loads continuously.. This is to protectfrom discharging batteries at ignition off andinterfering with the BMS correlation of batterystate of charge. This supply should also have adedicated protection fuse of the correct value.High loads should also be grounded directly to thevehicle body and not the negative battery terminal.Connecting to the negative battery terminal willbypass the BMS and affect the correct assessmentof the battery state of charge. Refer to BMS sectionin this manual.If separate charging systems are added, the groundside of the charger must also be connected to thebody. An auxiliary ground stud eyelet, see figureE176720, can be ordered, part numbersDU5T-14436-G_ for single battery orBK2V-14301-F_ for twin battery systems. FromOctober 2014 this will be standard when preordered with Special Vehicle Options, A526, A606,A607,A608, A736 and A652. For additionalinformation on order codesRefer to: 1.4 Conversion Type (page 15).

Each battery must also have a separate chargeras the batteries are isolated at Ignition off and twominutes after Key-on if the engine is not running.For additional informationRefer to: 4.17 Electrical Connectors and

Connections (page 142).Customer Connection Points.

Auxiliary Ground Stud Eyelet

E176720

2

1

DescriptionItem6mm Auxiliary Ground Stud for ConverterEquipment - Torque 8Nm +/- 0.8Nm

1

Battery Ground Jumper Cable part numberBK2V-14301-F_

2


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4.4.7 Battery Monitoring Sensor (BMS)

E146298

7

152

3 4

6

DescriptionItemBattery Monitoring Sensor (BMS) AV1T-10C652-A_. Used with Start Battery on twin batterysystems.

1

Plug-in connection — Local Interconnect Network (LIN) and Battery Positive +12V (B+) Feed.2Connection to Negative Terminal of Main Battery Post — See 'Battery Cable Fixing Torque'.3Jumper Cable (BK2T-14301-A_) only with twin batteries.4Second BMS (CC1T-10652-A_). Used with Auxiliary Battery on twin battery systems. Used withStart Battery on single battery systems.

5

2x M8 nuts. Do not loosen or remove.6Front of vehicle direction7

CAUTION: Do not permanently removejumper cable (BK2T-14301-A_) from BMS.

The BMS continuously monitors the condition ofthe main battery (or twin batteries on a Start-Stopvehicle). To do this, it is bolted directly to thenegative terminal of the battery. It isrecommended that this is not removed. However,if removal is required, please refer to the ETISworkshop manual, local Ford dealer or customerservices.The BMS re-calibrates itself at regular intervals.This occurs during a rest period at key off, whenthe battery closed-circuit current is less than100mA. The rest period must last for at least threehours. If the system cannot carry out are-calibration then it is unable to establish thecorrect state of charge of the battery. In this case,the Start-Stop system may be deactivated.

It is recommended that the total Ampereconsumption, in sleep mode, from the auxiliarybattery, does not exceed 100mA. This is becauseBMS will not be able to accurately correlate thebattery state of charge. Note there isapproximately 20mA of key off load from existingFord fit systems so the additional maximum is80mA of converter fit system. Any third partyinstallations should ideally be activated viaIgnition or engine RUN. However, a sleep mode of100mA is still high and will lead to deep discharge.The High Performance Deep Cycle AGM batteriesoption should be pulled if greater than 5mA insleep mode of additionally fitted systems.Regardless of battery system, it will still berequired to frequently charge when at long periodsof engine off.


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After Converter system is installed, it isrecommended to measure total key off load tobattery with a clamp on ammeter calibrated andsensitive to milli ampere's (mA). Perform this testafter 10 minutes of key off with all doors shut sothat the vehicle remains in sleep mode.NOTE: If the key off load only drops to theexpected lower value after 30 minutes, itsprobably because a feature is still active,controlled by the battery saver timer. This couldbe because any door is ajar, interior lamp isswitched on or a peripheral is plugged into one ofthe power sockets.

If the BMS system has been changed, removed orretro fitted the following DTC's (DiagnosticTrouble Codes) can be set in relation to the BMS• 0xD007 - 87: Lost Communications BMS 1.• 0xD00F - 87: Lost Communications BMS 2.• 0x91DB - 49: BMS Hardware fault 1.• 0x93AE - 49: BMS Hardware fault 2.

4.4.8 Single and Twin Battery Systems

Battery Disconnect Relay (Split Charge Relay)

E74522

5

6

7

A C

D

E

G F

4 3 1 2

B

Battery Disconnect Relay(Split Charge Relay)Relay Pin 1 — Supply +12V (KL30)1Ignition Switch Supply, Fuse KL30 — Fuse F3

(BCM)A

Relay Pin 2 — Ground Switched (to closerelay)

2Battery Disconnect RelayB

Relay Pin 3 — Ground Switched (to openrelay)

3Ignition Switch Supply, Fuse KL30, Fuse F2 (PFB)C

Relay Pin 4 — Supply +12V (KL30)4Vehicle Start BatteryDBCM Output — Pin C3-135Auxiliary BatteryEBCM Output — Pin C3-306Pre Fuse BoxFBCM Output — Pin C4-657Body Control Module (BCM)G


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Battery Disconnect Relay (Split ChargeRelay)

Where a vehicle is equipped with a single battery,the system can be updated to a twin system. Thisrequires updating to a split charge relay, insteadof the shorting bar. This ensures that auxiliarycircuits are isolated from the vehicle start batteryat key off, ensuring the engine can be cranked.The battery disconnect relay is controlled fromthe BCM using a pulsed change of state strategy(coil not continuously energized) and is alwaysfactory fit for twin systems. Reconfiguration ofthe BCM software by the Ford dealership isrequired to support this feature. It will also berequired to update the system to include a secondBMS and wiring, also requiring dealership batterytype reconfiguration. An update list of parts isshown at the end of this section.Refer to: 4.3 Charging System (page 81).SRCRefer to: 4.8 Electronic Engine Controls (page 114).Start-Stop.

Wiring of Batteries in Parallel for HighCurrent Applications

For vehicles equipped with a twin battery system,wiring of the two batteries in parallel without abattery disconnect relay is not recommended. Ifhigher current is required a third party battery canbe added as shown in the proposed interfaceschematic. In this case the engine run signal isused to control relay "D", see figure E147211, toallow the third party battery to be charged whenthe engine is running.

Single to Twin Battery Conversion

Any additional or different batteries must bechecked for correct functionality on a Start-Stopor SRC vehicle, please refer to BatteryConfiguration, Additional Loads, Start-Stop andSmart Regenerative Charging (SRC) and also:Refer to: 4.3 Charging System (page 81).Refer to: 4.8 Electronic Engine Controls (page 114).

If a requirement exists, it may be viable to ordervehicles installed with a single battery, a batterydisconnect relay, and a kit of harnesses to befitted by the installer. See following table forbattery cables and components.NOTE: A vehicle ordered with a single batterycannot be converted into a Start-Stop derivative.

Battery Cables and Components

A vehicle ordered with a single battery can beconverted to twin standard batteries or to HighPerformance Deep Cycle AGM batteries. Whenconverting to the standard option it is necessaryto order an additional single battery to the samespecification as the original fit. Alternatively whenconverting to the High Performance Deep CycleAGM batteries it is necessary to replace theoriginal battery with two AGM batteries of thesame type. The battery part numbers for eachoption is shown later in this section.The shorting bar needs to be removed and theSureStart® relay added in its place. Dealersupport is also required to update the central carconfiguration for twin and specification of the newbatteries.Number of batteries are in parameter 40• value 0 x 01 is single• value 0 x 04 is twinBattery values are in parameter 210• value 0 x 0B = T7 75Ah standard Start-Stop

Only• value 0 x 03 = T7 80Ah standard SRC only• value 0 x 13 = H7 80Ah High Performance Deep

Cycle AGM for SRC or Start-StopThe start battery is to be packaged at the front ofthe drivers seat pedestal, the auxiliary is to bepackaged at the rear. NOTE: when attaching thetwo BMS's to the 14301 cable, care is needed toavoid damage to the BMS sensor with the M8 nutbeing torque. Contact the National CompanySales representative for these torques andschematics for layout and package.

Generic items when converting from Single to Twin Batteries

QuantityDescriptionPart Number1SureStart® RelayBK2T-10B728-A

_1BMS Jumper CableBK2T-14301-A_

1*Left Hand Drive positive cable to pre fuse boxBK2T-14300-A_1*Right Hand Drive positive cable to pre fuse boxBK2T-14300-D_1BMS for Auxiliary Battery (also used for Single Battery System)CC1T-10C652-A_1BMS for Vehicle Start BatteryAV1T-10C652-A_

B_2M8 Nut for fixing BMS to 14301 (1 each BMS)W520102 -S442

*only one battery pending on drive.


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Replacing with Twin Basic System – Same as Single Fitted

QuantityDescriptionPart Number1Lead Acid 80Ah Standard Battery6C16-10655-C_

Replacing with High Performance AGM System

QuantityDescriptionPart Number2High Performance Deep Cycle 80Ah AGM BatteryCC1V-10655-A_1Bracket Battery ClampBK2V-10A721-A_1Dual Drain TubeYC1T-10A818-B_2Battery Positive Isolation CoversBK2V-14277-A_1Foam MatBK2V-V13002-A_

4.4.9 Power and Connectivity Usage Recommendations

Recommended Specification (order code inbrackets)

Power Usage

Standard Power Supply with the vehicle, single ortwin batteries, with standard 150A Alternator isacceptable.

Occasional electrical loads less than 30A at enginerun, and less than 5mA at key off. For example:Courier Van or Hotel Transfer Bus where occupantsuse interior lamps and power points for charginglaptops, phones or portable navigation systems.

Twin Batteries (NLX), with standard 150 AmpereAlternator.

Frequent electrical loads less than 30A at enginerun, and less than 5mA at key-off. For example:Service Engineer's Van with additional lighting andbeacons.

2 High Performance Deep Cycle AGM batteries(A736), with standard 150 Ampere Alternator. Note:if loads used over a long duration with the enginerunning, then recommend the 210 Ampere Altern-ator 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 tools,water heater, and additional lighting.

2 High Performance Deep Cycle AGM batteries(A736), with 210 Ampere Alternator option (HFL)Note: for loads greater than 190A, supplementalbatteries may be required.

High electrical loads for short duration (100 - 250Arequirements). For example: Ambulances with rearlift gate, medical equipment, communications,beacons

RPM Speed Control (A003).Power Take Off applications which require elevatedidle engine speeds. For example: Mobile Tire FitterVan.

Recommended Specification (order code inbrackets)

Connectivity Usage

Auxiliary Fuse Panel (A526) optionAdditional fused relay outputs. For example: ServiceEngineers Van.

Beacon Preparation Pack (A606)/Utility VehicleSwitch Pack (A607)* Note: includes Auxiliary FusePanel (A526)

Roof Beacons/Additional switches. For example:Highway Maintenance Vehicles.

High Specification Vehicle Interface Connector(A608)* Note: includes Auxiliary Fuse Panel(A526).

Conversions using various vehicle signals arerequired, such as indicators, stop lamp, door ajar,handbrake on. For example: Police Vehicles andAmbulances.

*Utility Vehicle Switch Pack (A607) and High Specification Interface Connector (A608) can not beordered together.


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WARNING: If the lifetime vehicle usageregarding frequency cycles of discharge,total current drain or real time batterystate of charge, cannot be defined, asmentioned below, then the Conversionmust default to AGM battery technology.

Standard Flooded Lead Acid Batteries can beutilized, though prior to choosing StandardFlooded over High Performance AGM batteries,the following parameters should be considered.Taking account of standard vehicle operation overa 3 year period, the following Ah capacity cyclingis available:• Standard Flooded Battery = 30 times the

battery Ah capacity• AGM = 600 times the battery Ah capacityFor example: For an 80Ah Standard FloodedBattery, 30 x 80Ah = 2400Ah of battery turnoveris available for the converter to use during thebattery life (3 years)The following are examples (in an engine offcondition, using this battery size) of equivalentloading:• 8Amp draw for 1 hour and 300 times during

battery life• 20Amp draw for 10 minutes and 720 times

during battery life

• 60Amp draw for 1 minute and 2400 timesduring battery life

• 160Amp for 1 minute and 900 times duringbattery life

When calculating the available capacity it is alsorecommended the battery state of charge doesnot fall below 50% at any time.NOTE: With Twin Battery systems, only theAuxiliary Battery should be considered in IgnitionOff applications.NOTE: Use AGM Batteries for deep cycleapplications i.e. charge and discharge on a regularbasis.NOTE: • When considering battery discharge, theconverter needs to consider the current drawnwhen the added system is in operation, plus anycontinuous key off loads even when not in use.For example, an inverter fitted will consume powereven with no load connected.NOTE: • Where possible, engine run operation ofelectrical equipment reduces battery discharge;both Vehicle Start and Auxiliary Batteries areutilized in conjunction with the charging system.NOTE: • User training and appropriate batterymaintenance on a regular basis will assist inensuring correct battery operation.

4.4.10 Generator and Alternator

Torque Curve of Alternator - 150A

E75871

00

2

4

6

8

10

12

2 000 4 000 6 000 8 000 10 000 12 000 14 000 16 000

A

B


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Diagram E75871 shows the torque in Nm which isrequired 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).

NOTE: For equivalent engine revs per minute(RPM), the alternators revolutions, axis (B) shouldbe divided by the following factor: 2.66 for 2.2Ldiesel.NOTE: These alternator curves do not show spareoutput capacity as this would be dependant onoriginal vehicle features and options.

Output Performance of Alternator - 150A

00102030405060708090100110120130140150160170180

2 000

E75873

4 000 6 000 8 000 10 000 12 000 14 000 16 000

A

B

5

4

3

2

1

DescriptionItemTemperature 0°C — Voltage 14.1V1Temperature 27°C — Voltage 13.8V2Temperature 60°C — Voltage 13.5V3Temperature 93°C — Voltage 13.1V4Temperature 115°C — Voltage 12.9V5

Diagram E75873 shows the alternator outputperformance at five different temperatures Inaccordance to Ford specification at five differenttemperatures. The vertical axis (A) shows outputcurrent (Amps) and the horizontal axis (B) showsAlternator speed in revolutions per minute (1/min).


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Torque Curve of Alternator - 210A

E146659

00

2

4

6

8

10

12

14

2 000 4 000 6 000 8 000 10 000 12 000 14 000 16 000

A

B

Diagram E146659 shows the torque in Nm whichis required to drive the alternator. The vertical axis(A) shows the torque (Nm) and the horizontalaxis (B) shows the alternators revolutions perminute (1/min).


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Output Performance of Alternator - 210A

00

20

40

60

80

100

120

140

160

180

200

220

240

260

2 000

E146660

4 000 6 000 8 000 10 000 12 000 14 000 16 000 18 000 20 000

A

B

1

2

5

4

3

DescriptionItemTemperature 0°C — Voltage 14.1V1Temperature 27°C — Voltage 13.8V2Temperature 60°C — Voltage 13.5V3Temperature 93°C — Voltage 13.1V4Temperature 115°C — Voltage 12.9V5

Diagram E146660 shows the alternator outputperformance at five different temperatures Inaccordance to Ford specification at five differenttemperatures. The vertical axis (A) shows outputcurrent (Amps) and the horizontal axis (B) showsAlternator speed in revolutions per minute (1/min).NOTE: Vehicles fitted with SRC and Start-Stopwill switch off the alternator if the batteries are ata high state of charge when at engine idle.Requirements for full alternator charge voltagefor functions such as; charging a third party battery,jump starting, inferred engine run status and highvoltage to counteract volt drop in systems, willneed to switch on the alternator. This can be doneby turning on the hazard switch in conditions whereit is convenient and legal to do so. Contact yourlocal Ford Dealer or National Sales Companyrepresentative.


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4.5 Climate Control SystemWARNING: Do not use propylene glycolbased coolant.

• Never secure hoses or tubes to thetransmission fill or dip stick or to any fuelsystem or brake component.

• Do not route heater or refrigerant lines near ordirectly over any exhaust system component,including the exhaust manifolds.

• Avoid routing of hoses in the wheelhouse orstone kick-up arch. If routing is required in theseareas, shield against stone pecking asappropriate.

• Do not route hoses near sharp edges. Utilizeguards to protect against cutting or chafing.

Climate Control System Pin-Outs

DescriptionPinKL58 - Backlight Illumination Power SupplyJ1-1Temp Door PowerJ1-2Air Disribution Door PowerJ1-3KL31 - GroundJ1-4AC Request (only BK2T-19980-**)J1-5PTC - Auxilary Heater Request (only BK2T19980-E* and BK2T-18518549-B*)J1-6Air Distribution Door AJ1-7Air Distribution Door BJ1-8Air Distribution Door CJ1-9Air Distribution Door DJ1-10Spare - GroundJ1-11Spare - GroundJ1-12Spare - GroundJ1-13KL30 - Battery VoltageJ1-14KL15 - Switch Battery VoltageJ1-15Reserved for Supplier DiagnosticJ1-16KL31 - GroundJ1-17REC Out 1 - DC Motor Power/Ground ToggleJ1-18REC Out 2 - DC Motor Power/Ground ToggleJ1-19Temp Door AJ1-20Temp Door BJ1-21Temp Door CJ1-22Temp Door DJ1-23Spare - GroundJ1-24Spare - GroundJ1-25Spare - GroundJ1-26Blower Stage 1J2-1Blower Stage 2J2-2Blower Stage 3J2-3Blower Stage 4J2-4Blower GroundJ2-5


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4.6 Instrument Panel Cluster (IPC)WARNING: Do not tamper with, cut intoor connect to any of the CAN-Businterface wiring or connectors.

Most of the functions are managed over theCAN-Bus interface.

Instrument Cluster

Wire ColorDescriptionConnectorPin (C1)

TwistedViolet/OrangeMS CAN -1Grey/OrangeMS CAN +2

-RedPower3TwistedViolet/GreyMS CAN Low4

Blue/GreyMS CAN High5-White/BrownCluster Signal Ground6-YellowCluster Signal7-Green/VioletCluster Set8--Automatic Transmission9-Black/VioletGround10-Grey/BlueTachograph11-White/GreenCrank Detect12


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4.7 HornA dual horn may be fitted to the vehicle in placeof the single horn.Any other aftermarket horn (for example an airhorn) will need to be driven by a separate relayenergised by the horn circuit.


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4.8 Electronic Engine ControlsCAUTION: Do not make any additionalconnections to the electrical circuitsassociated with the engine managementsystem.

NOTE: It is not necessary to disconnect or removeengine management modules.

4.8.1 Start-Stop

WARNINGS:The engine may restart automatically ifrequired by the system. It will onlyautomatically restart when one of thepedals is pressed. If no pedal is pressed,the Start-Stop indicator will flash and amessage will be shown in the display.Switch the ignition off before opening thehood or carrying out any maintenance.Always switch the ignition off beforeleaving your vehicle, as the system mayhave shut down the engine but theignition will still be live.The system may not function if you leaveadditional loads connected with theignition off.

It is very important not to make any modificationsto the shielding around exposed moving parts onthe engine, for example the drive belt.

General Information

Start-Stop is designed to improve fuel economyand reduce CO2 emissions by automaticallystopping the vehicle's combustion engine duringidle phases when it is not required for motivepower, and restarting it when required.

Start-Stop Logic

Automatic engine stops and restarts are controlledby the Start-Stop logic within the ECM (enginecontrol module), known as the Start-Stopscheduler. This is connected to a number of vehicleand powertrain signals, sensors and switches anddecides when to shut down and when to restartthe engine, based on the particular Start-Stopstrategy employed. Stop-in-Neutral is a Start-Stopstrategy applicable to manual transmissions whichstops the engine, subject to inhibitors, wheneverthe vehicle is stationary AND neutral is selectedAND the clutch has been fully released. The engineis restarted on clutch pedal press in neutral.

Inhibitors

Sometimes the engine may not shut down orrestart, due to one or more system inhibitors beingactive. The engine will shutdown only once allinhibitors are cleared, which maybe some timeafter the transmission is shifted to neutral and theclutch pedal is released.Typical examples of inhibitors are:• If the ambient temperature is below the lower

limit and above the higher limit for Start-Stop.• Engine coolant temperature not warmed up

(value dependent on ambient temp).• Heated screens are on.• Insufficient battery charge to sustain a stop

event or too high a current drain or battery iscold or battery failure.

• Driver's door has been opened and vehicle hasnot been driven over 5 kph since.

• Engine management reason, for example:during a DPF regeneration event.

• The ABS warning lamp is on or the vehicle is ona steep gradient

• High electrical load where total vehicle currentA drain exceeds 50 Ampere.

• Ford Engine RPM (Revs Per Minute) SpeedController System is active.

• Un-recognized batteries fitted or BMS damagedor removed.

• ECO button is pressed (LED illuminated).• Accelerator pedal or clutch pedal is not

released.• Greater than 100mA continuos load on each

battery at ignition off. The BMS will be unableto correctly assess battery state of charge.

• Vehicle in Factory or Transport mode.

Stall Recovery/Start Abortion Recovery

Stall recovery is an additional feature availablewith Start-Stop, and is active even if Start-Stopitself has been deselected or is inhibited. Understall recovery, an automatic engine restart isinvoked if the clutch pedal is fully depressedimmediately following a vehicle stall, thus enablingthe driver to quickly recover from a stall conditionwithout needing to cycle the ignitionkey/start-button. Stall recovery is only availablefor 5 seconds following a stall.


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Start-Stop De-selection (ECO button withLED illuminated)

The Start-Stop function may be deselected bythe driver by means of the "ECO" button on thedash panel. An integral amber LED in the buttonilluminates to indicate that the function isdisabled. After ignition OFF and ON, Start-Stopwill be re-enabled. This switch also overrides the110kph speed limiter. Pressing the ECO button(LED illuminated) will inhibit the auto Start-Stopfeature and allow the vehicle to drive to maximumspeed or a higher speed limit value if also fitted.Pressing the button again (LED not illuminated)will make auto Start-Stop active and vehicle willbe limited to 110KPH. These are part of the fuelsaving features.

Vehicle Modification Considerations

There are two main considerations: impacts toStart-Stop behavior as a result of vehiclemodifications and impacts from the Start-Stopsystem.

Impacts to Start-Stop Behavior

Inhibitor occurrence may be increased by vehiclemodifications. For example the 12V energymanagement system on the vehicle is designedto allow the engine to shutdown only if the currentdrain is less than 50A. High current loads(attached to the secondary battery) may lead tothis threshold being exceeded. In addition enginestops will be inhibited if the battery state of chargeis below 68%, which may occur if added electricalloads are active during key-off periods. Wheninstalling extra peripherals, be aware of thecontinuous / quiescent current drain of suchequipment, even when in Off or Standby mode.Any module should not load more than 5 mA(milliamps) in electrical load when off. If currentdraw is high at key-off, a different battery systemshould be considered instead of the standard fitbattery system. The AGM 2 x 80Ah twin systemwhich has been engineered to work withStart-Stop, should be considered if electricalloads will be high at Engine Run and Off but totalkey off load including Ford systems must notexceed 90mA. Please contact your local Forddealer to enquire about this option.NOTE: Regardless of the battery configuration,key-off load in excess of 100mA for 7 days or morewill cause Start-Stop to inhibit.For additional informationRefer to: 4.4 Battery and Cables (page 93).Battery Monitoring Sensor.

The Start-Stop system on Transit employs amodified version of Ford's patented SureStart®twin battery system to isolate the vehicleelectrical system from the effects of the voltagetransients from increase starter motor warm crankcycles. This means, when the engine is restarted,the auxiliary battery is connected with a delaytimer to isolate the load connected to it from thevolt drop. Therefore extra electrical loads shouldalways connect to the auxiliary battery to reducethe equipment's exposure to these transientvoltage drops (Customer connection points).Start-Stop is only designed to operate with twobatteries that are calibrated by the system. Fittingadditional batteries or the incorrect type will causeincorrect state of charge assessment leading toStart-Stop becoming permanently inhibited andtherefore the fuel saving features lost. This is thesame as for a Smart Regenerative Charging (SRC)vehicle.Refer to: 4.3 Charging System (page 81).SRC.The driver's door switch is used to help identify ifthe driver has left the vehicle and prevent engineshutdowns. If any modifications are made to thedoor or switch then this functionality may beaffected. If the driver's door is not used thenensure this switch is permanently closed (inputgrounded).The system uses signals from switches/sensorson the clutch, brake and accelerator pedals alongwith and the transmission shift mechanism. Toavoid compromising the safety of the system, noelectrical connection should be made to any ofthese signals.

Impacts from Start-Stop System

Start-Stop is designed to shut down the enginewhen it would otherwise be idling. Somemodifications may rely upon a running engine tooperate. Ford's RPM speed controller willautomatically inhibit Start-Stop from shuttingdown the engine when the vehicle is stationary.Aftermarket systems do not have this facility sothe driver may need to use the ECO button todisable Start-Stop when such devices are beingused. The starter relay should never be bypassedor driven directly.With the Ford-fit RPM controller, please be awarethat the throttle pedal functionality is different.For instance, if RPM is active, pressing the throttlepedal will stall the engine. If an RPM controller isrequired – it is recommended to use the Fordengineered system as this is developed with theStart-Stop System. An aftermarket fit systemmay still have the engine switch off when notexpected.


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The Special Vehicle Option feature Engine Runsignal, which is a switched ground signal, on aStart-Stop vehicle is only active when the vehicle'sengine is actually running (for example: not activeduring an auto-stop). Any equipment connectedto the Engine Run signal will therefore experiencemore cycles than on a conventional vehicle. Suchequipment must ensure that it can handle alifetime of 300,000 cycles. A quiet or silent typerelay may also be required as these increasedcycles may be audible to occupants duringStart-Stop Events. Alternatively, considerpackaging the control system away from theoccupants.All converter fit loads should be connected toeither customer connection points or to theauxiliary battery. Converter fit loads must not beconnected to the vehicle start battery, on a twinbattery system.

4.8.2 Engine RPM (Revs Per Minute)Speed Controller (A003)

System Overview

This feature enables the engine in the vehicle tobe run at elevated RPM speeds. The power fromthe engine can then be used to drive ancillaryequipment. The ancillary equipment may bepowered via a Front End Accessory Drive (FEAD)layout (in a similar fashion to the air conditioningcompressor).The maximum power that is available for front endaccessory drive applications at any engine speedis 6kW (in lieu of the 26Nm air conditioningcompressor). For additional information pleasecontact the Vehicle Converters Advisory Service,[email protected] converter should consider any increasedengine cooling requirements due to the conversionand running the vehicles engine under load forextended periods while the vehicle is stationary.

3 Modes of Operation

There are 3 principle modes in which this featurecan operate, they are:1. 3 Speed Mode this provides the end user a

choice of up to 3 preset RPM values of 1100,1600 and 2030rpm to select from. The end usercannot easily override these values so there isminimal risk of damage to ancillary equipmentdue to it being run at speeds it was not designedfor. Very limited vehicle speed is allowable whilein this mode (up to 2.5mph approx)

2. Variable Speed Mode this provides the enduser with RPM speed ramp up and downbuttons. The end user is free to select RPMvalues between 1300-3000rpm in 25rpm steps.

A single press results in a 25 rpm jump. If a rampbutton is held depressed by the end user thenthe rate of change is 250rpm/sec. Very limitedvehicle speed is allowable while in this mode(up to 2.5mph approx).

3. Idle Up Speed this mode allows the enginesnormal idle to be increased (in 25 rpm steps)in the range 900-1200rpm. There is not avehicle speed restriction in this mode as theintended use is to raise the engine idle to reducethe likelihood of engine stall when ancillaryequipment is being run from the engine duringnormal drive operations. For example:Refrigerator units used to keep the cargo baycool.

System Availability

This feature is built into the latest PowertrainControl Module (PCM) software on all dieselengine variants, except EU6 2.2L Heavy Dutyengines.By default the feature is not enabled unless thevehicle is specifically ordered with the feature fromthe factory.Vehicles which have not been ordered with thisfeature may have the feature enabled at a dealervia the IDS diagnostics system. There is a dealercharge for this service.Vehicles fitted with Start-Stop technology maybe converted to RPM speed control, however, thecustomer should turn Start-Stop off prior tostarting RPM speed control. For more informationRefer to: 4.8 Electronic Engine Controls (page 114).Impacts from Start-Stop System.

How to control this feature

A loop of wire (green/white) is provided in themain electrical harness to permit control of theRPM Speed Control software. Cutting this loopwill provide two wires to connect a control box tothe PCM.The control box needs to switch resistors into thecircuit across the two green/white wires whichformed the loop prior to being cut. This sort ofcircuit is known as a resistance ladder, see figureE88295. The PCM software monitors thegreen/white wire circuit and when certainresistance's are detected they are interpreted asvarious inputs which control the feature. Theswitch box can be located where it is ideallyrequired for the vehicle conversion in question,rather than having to be mounted on theInstrument Panel (IP). If the converter chooses tolocate the switch box in a location which is subjectto an adverse environment then the convertershould design the switch box to withstand withthese conditions.


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Green/White Loop — Right Hand Drive Shown

E146658

1

The harness is loosely taped in this location, sothe green/white loop should be easy to extract.Figure E146658 shows the location of the greenand white loop.

Resistance Ladder

Resistance Ladder Circuit

65432E88295

1

1

DescriptionItemTo Green/White Wire1Stop Engine2RPM 1 on/off or Variable Control 'Idle'3RPM 2 on/off or Variable Control 'Negative (-)'4RPM 3 on/off or Variable Control 'Positive (+)'5RPM Control Armed or Increased Idle on/off6


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The resistance ladder circuit acts as a potentialdivider. The PCM has an internal reference voltageof 5 volts. Current passes through an internal 320ohm resistor (not shown above) prior to passingthrough the resistance ladder. There is also a(second) 220 nF capacitor internally within thePCM between the 320 ohm resistor and ground(not shown above) and this is to reduce EMCeffects.With all the switches open there is a totalresistance in the green/white loop of approx 4310ohms and this corresponds to normal drivingoperation (the condition prior to the loop beingcut).To ensure robust operation, it is recommended forall switches that a switch de-bounce specificationis chosen as close to zero ms (milli seconds) aspossible.Starting from the right of the diagram, when thekey switch is closed only 2110 ohms is in the circuitand the PCM software recognizes this as the RPMmode being armed and ready for operation (Keyswitch closed = on, open = off). A key switch isrecommended in this position for a couple ofreasons:• If the control box is located externally on the

vehicle, the requirement for a key avoids anypassers by being able to put the vehicle intoRPM Speed Control mode by simply pressinga button.

• Using a key switch where the key can beremoved in either the on or off condition couldbe used as an aid to anti theft. If the operatoruses a key to put the vehicle into RPM Speedcontrol mode and then removes the key, thenthe vehicle cannot quickly and easily be takenout of RPM speed control mode. If a foot pedalis pressed while in either the 3 speed or variablespeed modes, the vehicles engine will stall andtherefore the vehicle can not easily be drivenaway and stolen.

When in 3 speed mode pressing any of the middle3 switches (with the feature armed) results in theengine RPM jumping to the corresponding RPMvalue held in memory (defaults of 1100, 1600 or2030rpm) for the 3 switch positions. A secondconsecutive press of the same button returns tonormal idle.When in variable speed mode the same 3 buttonsact as ramp up, ramp down and return to idleselections respectively.The software in the PCM responds to the changeof state, so it is recommended that these 3 middleswitches be non-latching push button microswitches. When going from idle to an elevatedRPM the execution of the command will occur asthe button is released. When going to idle theexecution of the command occurs as the buttonis pressed.The final button (the one on the left in figureE88295) acts as an emergency vehicle enginestop. It is recommended that this be a red andoversize non-latching micro switch button. Theexecution of this command will occur as thebutton is pressed.

All wiring connecting the PCM to the resistanceladder control box should be shielded and twisted(33 twists/m) to reduce EMC effects.All resistors should have a tolerance of +/- 5% orbetter.Switch contact, connectors and loom (loombetween the green/white wires and the controlbox) total resistance must be no greater than 5ohm max.The PCM to resister ladder control switch box loomshould not come within 100mm of any otherharness, especially any carrying heavy loads.Designs which do not require all the buttonswitches must still have the complete resistornetwork with the switches positioned correctlywithin the network.A suitable two way quality connector should beused to connect the control box to the twogreen/white wires.

How to change the default settings

NOTE: It is not possible via either method below,to change the step value of 25 rpm per press orthe 250 rpm per sec for a held down button, in thevariable rpm speed.By default, when the feature is first enabled (eithervia factory order or via dealer IDS tools), it will beset to the 3 speed mode of operation with presetRPM values of 1100, 1600 and 2030rpm for the 3speeds.There are two methods by which these defaultscan be modified:1. Via the IDS diagnostics system at a Ford dealer

(there may be a charge for this).Via the IDS system the mode of operation canfreely be changed between any of the 3 principlemodes of operation, the feature can even be turnoff (disabled). The 3 default RPM speeds can alsobe modified within the allowable range for themode of operation as detailed in this section.Via IDS the RPM Speed Controller menu is underthe tool box tab, then Powertrain, then ServiceFunctions, then PCM. The IDS on screen menuswill guide the dealer through the options andsetup.2. Via an inbuilt vehicle ‘learn mode’.Via the vehicle 'learn mode', it is possible to switchfrom the default 3 speed mode to variable speedmode, however it is not possible to switch backusing this method.

How to enter vehicle ‘Learn mode’

1. Make sure that the RPM Speed controller switchbox is connected but turned off.

2. Start the engine (vehicle out of gear and no footpedals being pressed, handbrake on).

3. Wait a couple of seconds for the instrumentpanel start up diagnostic lamps to extinguish.

4. Press and release the clutch pedal.


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5. Press and release the brake pedal.6. Repeat steps 4 and 5 a further four times

(clutch & brake pressed a total of five timessequentially each).

NOTE: Steps 4 to 6 have to be started within 10seconds of the engine start.The vehicle should now be in ‘learn mode’.

How to Select between modes

NOTE: If the engine stalls out at the initial brakepedal input then the vehicle was not in, or hasdropped out of learn mode and you will have torestart the learn procedure.1. Enter learn mode (see directions above).2. Arm the RPM speed controller (turn the key

switch to ON).If the vehicle is already in 3 speed mode (the initialdefault):3. Press and release the brake pedal five times.The vehicle should now be in variable speedmode. The new settings can be saved and learnmode exited (see below).or4. Press and release the brake pedal once.The vehicle should now be in 3 speed mode. Thenew settings can be saved and learn mode exited(see below).Using this method it is easy to change betweenthese two modes of operation for the RPM speedcontroller.

How to change the 3 pre-set default RPMvalues in the 3 speed mode

NOTE: If the engine RPM responds to the initialRPM button press, then the vehicle has notentered ‘learn mode’ correctly and you will haveto restart the procedure. If the engine stalls outat the brake or accelerator pedal inputs then thevehicle was not in, or has dropped out of ‘learnmode’ and you will have to restart the procedure.1. Enter ‘learn mode’ (see directions above).2. Arm the RPM speed controller (turn the key

switch to ‘on’).3. Press and release the brake pedal once.4. Press and release the RPM button that requires

re-programming.5. Use the accelerator pedal to rev the engine to

the new desired RPM speed and hold at thisspeed (only speeds between 1200 to 3000rpm can be selected in 3 speed mode).

6. Press and release the same RPM button toreset the stored RPM speed to the currentengines RPM.

7. Release the accelerator pedal.8. Repeat steps 4 to 7 for the remaining RPM

buttons.

The 3 RPM speeds should now be re-programmedto the new RPM speeds. The new settings can besaved and 'learn mode' exited (see below).

How to save new settings and exit from‘Learn mode’

NOTE: The engine stalling indicates that thesettings should have been saved and the vehiclehas exited from ‘learn mode’. Learn mode howeveris very specific that the exact steps are taken inthe correct order and within certain time limitsotherwise the learn procedure fails and it maytake several attempts to get this order and timingcorrect and a successful modification from thedefault settings.1. From within the 'learn mode' and with the RPM

Speed Control switch box 'armed', fully press& release the clutch pedal at least five timesin quick succession. The engine may stall outon the last depress which is normal, howeverif the engine does not stall out after at least 5clutch pedal depresses, then you can key offafter the sequence of rapid clutch depresses.

2. Restart the engine and test the new settings,repeat above procedures if necessary.

Reasons why RPM speed Controloperation may stop or fail

The RPM Speed control software monitors vehicleinformation during operation in RPM speed controlmode and will drop out of RPM speed controland/or stall the engine should any adverse signalsbe detected. For example:• If the engine temperature becomes too hot

then RPM speed control will stop in order toprotect the engine.

• If the engine oil lamp illuminates then RPMspeed control will stop in order to protect theengine.

• If the low fuel level lamp illuminates then RPMspeed control will stop so that the vehicle canbe driven to a refueling point.

• If the vehicle speed exceeds approx 2.5 mphwhile in 3 speed or variable speed modes, thenRPM speed control may stop. RPM speedcontrol should normally be operated with thehand brake on, but some uses may require alow level of vehicle ‘creep’ during RPM speedcontrol operation.

• The software monitors for ‘stuck on’ buttonson the control switch box, this may result inRPM speed control being halted. A button thatis held down for too long may be registered bythe software as a ‘stuck’ button.

• The software monitors the foot pedals, ifdepressed these may stall the engine if in 3speed mode or variable speed mode (does notapply to idle up speed).


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• If the control switch box circuitry significantlyexceeds 2110 ohms or there is a short circuitthen RPM speed control will not be possible.

• If a PTO conversion has been attempted on avehicle with a non anti braking system (ABS)then RPM speed control will fail due to vehiclespeed being registered via a transmission speedsensor and / or the need to press the clutch inorder to put the vehicle in gear while in RPMspeed control mode.

4.8.3 DPF and RPM Speed Control

The Diesel Particulate Filter (DPF) captures sootin the exhaust fumes to improve vehicle exhaustemissions. The condition of the DPF is monitoredby the vehicles electronic systems. Under normaldriving conditions a regeneration feature istriggered to clean the filter. If the DPF becomesfull, a red engine warning lamp illuminates on theinstrument cluster and the vehicle will need to betaken into the local Ford dealer to have the DPFspecially purged.Vehicles fitted with DPF, running under RPM SpeedControl with the engine running under load atelevated idle, may produce soot build up over time.With the vehicle stationary, the DPF is unable tostart a regeneration event. It is thereforerecommended that vehicle converters adviseoperators to break up any long periods under RPMSpeed Control operation with some normal drivingto permit the DPF to regenerate. When operatingRPM Speed Control, it is recommended that theidle speed is limited to 1600rpm to avoid soot buildup over long periods.For additional information on DPFRefer to: 3.6 Exhaust System (page 56).

4.8.4 Changing Vehicle SpeedMaximum Setting

The Vehicle Speed Maximum Setting can bechanged via the Integrated Diagnostic System(IDS) menu under the following tabs: Toolbox,Powertrain, Service, Functions, PCM. The IDS onscreen menus will guide the dealer through theoptions and setup.


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4.9 Information and Entertainment System - GeneralInformation—Specifications

4.9.1 Audio Head Unit (AHU) - Multimedia In Car Entertainment (ICE) PackSummary

The Multimedia System you have, as a standardfit, will depend on the market region, body styleand model of the vehicle.NOTE: Depending on the vehicle upgrade you areplanning it is important to order the right levelparts that include new Instrument Panel Harness,Instrument Panel Bezel and Hood.

NOTE: Pre Equipment Pack (less speakers) doesnot have wiring between the roof-mountedAM/FM/DAB antenna and the co-axial cable thatconnects to the AHU. If planning to retrofit an AHUyou will need to order the Pre Equipment Pack.

AHU/Multimedia ICE Packs

DescriptionAHU/ICEPack

Pre Equipment Pack (less speakers) - no audio*Pre Equipment Pack - no audio**MyConnection Radio2MyConnection Radio with DAB3Mid Radio with SYNC Gen 14Mid Radio with DAB / SYNC Gen 15Low Navigation (NAV) SYNC Gen 111


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AHU/Multimedia ICE Pack Content

115432***Description-----XXLess ICE----X--MyConnection Radio AHU/AM/FM + USB + Bluetooth---X---MyConnection Radio AHU/AM/FM DAB + USB +

Bluetooth--X----ICE - Low Audio (LOC)XX-----ICE - Low Audio (LOC) with DAB---XXXXLess Multi Function Display (MFD)-XX----Mid MFD - 3.5" Dot MatrixX------Low NAV MFD - 5" TFT with NAV---XXXXLess Integrated Control Panel (ICP)-XX----ICP Mid - ExtendedX------ICP NAV - Extended with NAV------XLess Speakers---XXX-2 Front Speakers + 2 Rear Speakers*XXX----4 Front Speakers (2 woofer/2 Tweeters) + 2 Rear

Speakers*--X-XXXSingle AM/FM AntennaXX-X---Single AM/FM/DAB Antenna-XXXXXXLess GPS AntennaX------GPS Antenna---XXXXLess GPSMXXX----GPSM-XXXXXXLess NAV DataX------NAV Map Data-----XXLess Radio ControlsXXXXX--Radio Controls on Steering WheelXXX----MFD Controls on Steering Wheel---XXXXLess SYNCXXX----SYNC GEN 1-----XXLess MicrophoneXXXXX--Microphone-----X-Less Auxiliary HeaterXXXXX--Aux Input Jack (AIJ)XXX----Accessory Media Hub 1 x USB

* Rear Speakers are dependent on body style.

4.9.2 MyConnection Radio andMyConnection Radio with DAB

Audio Head Units (AHU) are connected to theinstrument panel wiring via a single 24 pinconnector, see figure E145370 and table.NOTE: There is a black co-axial cable for theroof-mounted AM/FM/DAB antenna that goes tothe side of the AHU.

NOTE: MyConnection Radio variants do not acceptMulti Function Display (MFD) or Integrated ControlPanel (ICP)NOTE: Power for radio - do not switch thepermanent battery feed (KL 15) and ignition feed(KL 30) on the radio connection. The ignition feed15 is only used to 'wake up' the radio.


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24 Pin Connector ICE (8475-1 / 544127-1)

E145370

1

2

14

13

12

24

24 Pin Connector ICE

TypeDescriptionPinTypeDescriptionPinInputAudio Ground13InputBattery1Input/Output

Illumination + (PWM VIH)14OutputSwitched B+ Power2

Input/Output

Illumination -15InputIgnition SW Crank Position3

OutputAudio Shield (AIJ)16InputRun/Accessory4InputAIJ Left +17InputStarter Motor Control Sense5InputAIJ Right +18InputAux IN Jack (AIJ) Common6InputMicrophone -19*InputMicrophone +7*InputSteering Wheel Control -20InputSteering Wheel Control +8OutputLeft Rear Speaker+21OutputLeft Rear Speaker -9OutputLeft Front Speaker +22OutputLeft Front Speaker -10OutputRight Front Speaker +23OutputRight Front Speaker -11OutputRight Rear Speaker +24OutputRight Rear Speaker -12

* Pins 7 and 19 are for external microphone. Check availability with your Local Ford Dealer.

4.9.3 Mid-Radio and Mid-Radio withDAB

NOTE: AHU/ICE Pack 4,5 and 11 are connectedto the instrument panel wiring via a 24 and 26 wayconnector, see figures E145370 and E146212.NOTE: There is a black co-axial cable thatconnects the roof-mounted AM/FM/DAB antennato the back of the AHU. If the vehicle has anavigation display, the black co-axial cable goesinto the back of the navigation display and asecond co-axial cable connects the navigationdisplay to the AHU. There is also a thin blackco-axial cable for the global positioning systemantenna that goes to the navigation display.NOTE: All vehicles, except those ordered with aPre Equipment Pack or Pre Equipment Pack (lessspeakers) and all MyConnection Radios, have 3variants of a Multi Function Display (MFD) andIntegrated Control Panel (ICP).

NOTE: Power for radio - do not switch thepermanent battery feed (KL 15) and ignition feed(KL 30) on the radio connection. The ignition feed15 is only used to 'wake up' the radio.

24 Pin Connector (8475-1 / 544127-1)

E145370

1

2

14

13

12

24


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24 Pin Connector

TypeDescriptionPinTypeDescriptionPinInputGround13InputBattery1Input/Output

CAN - High14OutputSwitched B+ Power2

Input/Output

CAN - Low15-Not used3

OutputAudio Shield for AIJ16InputNavigation Audio In +4InputAIJ Left +17InputNavigation Audio In -5InputAIJ Right +18InputAuxiliary Input Jack (AIJ) -

common6

OutputAudio Shield for Aux219-Not used7-Not used20-Not used8OutputLeft Rear Speaker+21OutputLeft Rear Speaker -9OutputLeft Front Speaker +22OutputLeft Front Speaker -10OutputRight Front Speaker +23OutputRight Front Speaker -11OutputRight Rear Speaker +24OutputRight Rear Speaker -12

26 Pin Connector (8476-1 / 544128-1)

E147212

1

14

13

26

26 Pin Connector

TypeDescriptionPinTypeDescriptionPin-Not used14-Not used1-Not used15-Not used2OutputAudio Shield Aux 116-Not used3OutputAuxiliary Out 1 -17OutputAuxiliary Out 1 +4Input/OutputAE_CD 118-Not used5-Not used19-Not used6-Not used20-Not used7InputAlert In -21Alert In +8-Not used22-Not used9-Not used23-Not used10-Not used24-Not used11InputStereo In 1 Left -25InputStereo In 1 Left +12InputStereo In 1 Right -26InputStereo In 1 Right +13


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Multi Function Display (MFD) 12 PinConnector

123456

789101112

E147213

12 Pin MFD Connector

TypeDescriptionPinTypeDescriptionPin-Stalk Switch7InputBattery1Input/Output

MFD — LIN Bus8Input/Output

MS Body CAN +2

Input/Output

Ground9Input/Output

MS Body CAN -3

-Stalk Switch Return/AlarmSense

10Input/Output

CAN — High4

Input/Output

Ground11Input/Output

CAN — Low5

OutputAudio Out -12OutputAudio Out +6

Integrated Control Panel (ICP) 6 PinConnector

E167585

61

DescriptionItemBattery +1PADI Voltage Ignition2PADI ON3PADI OFF4LIN5Ground6

4.9.4 Additional Rear Speakers

Rear speaker wiring is always present in theinstrument panel harness 14K024, but notnecessarily in the harnesses 14401 and14405/14A005 that then take the signals to therear speaker locations.When the rear speakers are not present at thebody harness 14401/IP harness 14K024 in-lineconnector on low series variants the rear speakersmay be spliced into the Audio Jumper Harness atthe rear of the Audio Head Unit, see next table fordetails.


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Rear Speakers - Spliced into the Audio Jumper Harness

Wire ColorSpeakerPinBrown/WhiteRight Rear +24Brown/BlueRight Rear -12White/GreenLeft Rear +21Brown/YellowLeft Rear -9

Rear Speakers - In-line connector14401/14K024

40

43 42

41

E146834

DescriptionItemRear Speaker Left + (White/Green)Pin

40Rear Speaker Left - (Brown/Yellow)Pin 41Rear Speaker Right - (Brown/Blue)Pin

42Rear Speaker Right + (Brown/White)Pin

43


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4.10 Cellular PhoneWARNING: Installation of anynon-Ford-approved system is notrecommended and operation withassociated systems cannot beguaranteed. Any resultant damage willnot be covered under warranty.

Ford offer hands-free and wireless technology(Bluetooth) phone systems (including voicerecognition) as factory-fit options, these will alsobe available as aftermarket accessory kits fromyour Ford dealership.These use the Ford MS CAN multimedia bus tooperate in conjunction with the Ford audio andnavigation systems.


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4.11 Exterior LightingWARNING: Make sure that the modifiedvehicle complies with all relevant legalrequirements.

4.11.1 Reversing Lamps

Reversing lamps are activated by the reversingswitch on the transmission and sensed by the BodyControl Module (BCM) which is controlled by theBCM high side driver.

4.11.2 Additional External Lamps

All power for additional exterior lamps must betaken through the Auxiliary Fuse Panel with asuitable switch and/or relay as required.Refer to: 4.15 Fuses and Relays (page 134).Refer to: 4.17 Electrical Connectors and

Connections (page 142).The load on the reversing lamps should not exceeda total of 3A (42W).

Lighting Loads

VehicleMax. LoadControlling DeviceBCM Outputs2x5W46WHigh Side DriverLicence Plate and Marker Lamp Supply **2x5W23WHigh Side DriverPosition/Parking Lamp Left (Front and Rear)2x5W23WHigh Side DriverPosition/Parking Lamp Right (Front and Rear)21W + 5W63WHigh Side DriverDirection Indication Front Left*21WDirection Indication Rear Left*21W + 5W63WHigh Side DriverDirection Indication Front Right*21WDirection Indication Rear Right*2x15W30WHigh Side DriverDaytime Running Lamp Left /Right

*Turn Indicator Supply, smaller load will cause double flashing (bulb outage detection).**Licence Plate and Marker Lamps not to exceed 46W. LED Markers are recommended where available.

Lighting FusesFront Fog Lamp15AF8High Beam - Right Hand Side10AF9High Beam - Left Hand Side10AF10Exterior Lamp - Right Hand Side, Side Lamp - Left Hand Side25AF11Turn Signal Indicator, Rear Fog Lamp, Day Time Running Lamps25AF14Exterior Lamp - Left Hand Side, Side Lamp - Right Hand Side, Central HighMounted Brake Lamp

25AF15

4.11.3 Lamps – Hazard / DirectionIndication

The maximum permissible load with the standardsystem is:• 1 x 21W — front indicator, 1 x 21W rear indicator

+ 1x 5W side repeaters (Left hand side).• 1 x 21W — front indicator, 1 x 21W rear indicator

+ 1x 5W side repeaters (Right hand side)* 63W per side maximum load.

4.11.4 Lamps – Front and Rear Fog

National Regulations regarding inter-connectionwith other front and rear fog lamps must bechecked before designing the wiring circuit. Themaximum permissible load with the standardsystem is:

• Front fog lamps - 2 x 55W (relay controlled).• Rear fog lamps - 2 x 21W (high side driver

controlled).For trailer tow, rear fog lighting, relating to thatsystem.Refer to: 4.16 Special Conversions (page 137).

4.11.5 Electrically Operated DoorMirrors

WARNING: Do not tamper with the basesystem (controlled by Body ControlModule and multiplex architecture) andany feeds taken from the associatedwiring or controller.

NOTE: These options are not suitable foraftermarket or converter fit.


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4.12 Interior Lighting

4.12.1 Additional Internal Lamps

Additional cabin interior lighting may be obtainedby directly accessing the connector inside thedome lamp in the cabin.Additional load space interior lighting may beobtained by directly accessing the connectorinside the load space lamps in the load spacearea.

CAUTION: The maximum total internallamp load must not exceed 11A (150W).

Power for the Interior Lamps - Cabin and cargoareas come from the battery save system, BodyControl Module (BCM) pin C2-9. The courtesylamps for each area (front and rear) are controlledby seperate pins on the BCM:• Front (cabin) lamps, pin C2-2• Rear (cargo) lamps, pin C2-1For additional information on BCMRefer to: 4.2 Communications Network (page 75).The battery saver system provides power for theinterior lighting for a limited time.Maximum loads for all interior lamps (vanity, map,courtesy) 150 total. Courtesy lamps havemaximum loads of:Van• Front cabin lamps - 75W max.• Rear load space lamps - 75W max.• Combined total including vanity and map

lamps not to exceed 150W max.Kombi• Front cabin lamps, including 2nd row seat lamp

and entrance lamps - 75W max.• Rear load space lamps - 75W max.• Combined total including vanity and map

lamps not to exceed 150W max.Bus• Front cabin lamps including entrance and

luggage lamps - 75W max.• Rear over seat lamps - 75W max.• Combined total including vanity and map

lamps not to exceed 150W max.Each of these pins on the BCM can take a load of75W. Lamps that are controlled by the batterysave circuit will extinguish 30 to 180 minutes afterignition off (dependent on vehicle configuration).If fluorescent lighting is required it must not beconnected to the existing interior cabin or cargolighting as it is not compatible with the pulsewidth modulated (PWM) lighting circuit and maycause premature failure of the Fluorescentlighting. If Florescent lighting is required, it shouldbe connected to the Auxiliary Fuse Panel.

If enhanced bright lamps are required for the cargoarea of a van, it is recommended to fit the FordEnhanced Load Space Lighting. Option A080 andLED lamp part numbers 2x front BK2V-13776-A*and 2x rear BK2V-13773-A*, jumper wires mayalso be required for updates. This is variantdependant part numbers BK2T-14334-A* or C* .These are controlled from the side load or reardoor being ajar or manual demand from the domelamp in the front cabin. The default setting is 30minutes from the battery saver system but thiscan be changed up to 180 minutes. For furtherinformation on required parts and configurationsto order contact your Local Ford Dealer.

4.12.2 Additional 'Theater Lighting'for rear of vehicle interior

Where higher wattage installations are required,these should be taken through the Auxiliary FusePanel with a suitable switch and/or relay asrequired. For additional informationRefer to: 4.17 Electrical Connectors and



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4.13 Cruise Control

4.13.1 Adaptive Cruise Control

CAUTION: For converted vehicles fittedwith adaptive cruise control, wherevehicle mass or geometry is significantlyaltered it is recommended that the radarvertical alignment and systemfunctionality is checked by a Ford dealer.For further information refer to WorkshopManual or Owner's Manual.

NOTE: Do not obstruct the cruise control radar,see clearance zone 2 in Figure E184124NOTE: Do not paint the front grill of the vehicle asthis may affect the functionality of the cruisecontrol radar.

Adaptive Cruise Control Radar

E184124

1 2

DescriptionItemAdaptive Cruise Control Radar1Adaptive Cruise Control Radar clearance zone2


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4.14 Handles, Locks, Latches and Entry Systems

4.14.1 Door Removal or Modification

For derivatives requiring no doors, to ensure doorajar warnings do not appear on the instrumentcluster and the interior lamp does not stay on, forany doors that are not fitted the Body ControlModule (BCM) must be connected in the followingway:• C3-44 Front Left -ground• C3-34 Front Right - ground• C3-50 Ajar lift gate switch - not connected

• C3-35 Ajar left side cargo switch - notconnected

• C3-51 Ajar left side cargo switch - notconnected

4.14.2 Central Locking

Locking is controlled by the BCM. There is currentsensing on certain locking circuit pins as part ofthe security system – if these are tampered with,locking cannot be guaranteed.

Function14A631 in-linePassenger Side

14A631 in-lineDrive Side

BCM

Lock Left88C2-18Lock Right88C2-27

Driver Door unlock-17C2-39Deadlock Left55C2-40

Lift gate release--C2-41Deadlock Right55C2-42

Rear Cargo Door unlock--C2-44Passenger Door unlock17-C2-45

Locking Configurations The following list detailsspecific locking scenarios that have been notedby customers:1. Raid locking or drive away locking for taxi and

parcel van usage – this is a configurableparameter in the BCM (Ford Dealerships canset this). There is also the option to configurevia the instrument cluster once theconfigurable parameter has been set.

2. Slam locking – this is a configurable parameterin BCM (dealerships can only switch off thisfeature, but not switch on).

3. N1 lock reconfiguration into no deadlocks – thiscan be reconfigured to be central-locking onlyby a Ford Dealer (via Dealership hotline).

4. Auto unlock - There is an option to configurecentral unlock where the drivers door, whenopened, will automatically unlock all doorsexcept any doors controlled by the third buttonon the key fob.

Drive-Away Locking DisableThe following parameter (automatic locking byspeed) is configured as follows:• IDS parameter 32 - Change 0x02 [on] to 0x01

[off].


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Pins to Control Additional Door Locks

18

4544

39

27

404142

E145374

DescriptionItemLeft Lock SupplyPin 18Right Lock SupplyPin

27Driver Door Unlock SupplyPin

39Dead Lock Left Door SupplyPin

40Lift Gate Latch ReleasePin 41Dead Lock Right Door SupplyPin

42Rear Cargo DoorPin

44Passenger Door Unlock SupplyPin

45

4.14.3 Remote Keyless Entry/TirePressure Monitoring System Receiver(RKE/TPMS Receiver)

WARNING: For best performance theRKE/TPMS receiver must be a minimumdistance of 25mm from any metal objectsand 100mm from high switch loads.

NOTE: It is recommended that the RKE/TPMShas a dedicated ground wire and ground stud, donot splice with other modules.

The RKE/TPMS Receiver is fed via a connectionto the 14A005 Harness and then earthed at theground point located on the A-Pillar. For Groundpoint locationRefer to: 4.18 Grounding (page 171).E145385.For additional informationRefer to: 2.4 Wheels and Tires (page 44).


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E169304

12

3

DescriptionItemRKE/TPMS Receiver1Harness 14A0052Ground point location3


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4.15 Fuses and Relays

4.15.1 Fuses

WARNING: No increase in existing vehiclestandard fuse capacity is allowed underany circumstances. There are no sparefuses in the Engine Junction Box (EJB),Standard Relay Box (SRB) or BodyControl Module (BCM). The vehicleconverter/modifier must provideadditional fuses as required. Please referto below chart.

NOTE: Only use Ford fuses as shown in belowtable. Other fuses may interfere with the validatedfusing strategy.

Ford Fuses

ColorAmpere RatingPart NumberMini Fuse

Grey2A1L3T-14A094-A_Violet3A1L3T-14A094-B_Pink4A1L3T-14A094-C_Tan5A1L3T-14A094-D_Brown7.5A1L3T-14A094-E_Red10A1L3T-14A094-F_Blue15A1L3T-14A094-G_Yellow20A1L3T-14A094-H_

Maxi FuseYellow20A6EST-14A094-A_Green30A6EST-14A094-B_Orange, Amber40A6EST-14A094-C_Red50A6EST-14A094-D_Blue60A6EST-14A094-E_

J-Case FuseBlue20A6EST-14A094-A_Pink30A6EST-14A094-B_Green40A7T4T-14A094-D_Green40A6EST-14A094-C_Red50A7T4T-14A094-E_Red50A6EST-14A094-D_Yellow60A7T4T-14A094-F_Yellow60A6EST-14A094-E_


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Engine Junction Box

E146639

Smart Relay Box

E146640

4.15.2 Relays

Ford Relays

ColorAmpere RatingPart NumberMini Relay

Grey70A5M5T-14B192-E_Black40A5M5T-14B192-C_Black40A5M5T-14B192-D_

Micro RelayBlack20A5M5T-14B192-A_Grey20A6X4T-14B192-A_*

*Silent/Low Noise Relay

NOTE: Only use Ford Relays shown in table.Ford standard relays have a nominal coil currentof 300mA (max) at 25°C. Relays with higher loadsshould not be used.For maximum switching currents please refer toRelay Figures E75017—E75021.

Micro Relay

E75017

142

5 3

1 2 3

5 4

Micro Relay Parameters20 AmpsOpen contacts16 AmpsClosed contacts300 mA (max)Nominal coil current

Medium current changeover relay - Part number: 6G9T-14B192-B*Medium current normally open relay - Part number: 6G9T-14B192-A* (pin 4 not present)


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Mini Relay

E75018

12

3

4

5

1 2 3

5 4

Mini Relay Parameters40 AmpsNormally open contacts20 AmpsNormally closed contacts300 mA (max)Nominal coil current

Medium current changeover relay — Part number: 6G9T-14B192-D_Medium current normally open relay — Part number: 6G9T-14B192-C_ (pin 4 not present)

Battery Disconnect Relay

E75021

4 3 12

BA

Battery Disconnect Relay Parameters260 Amps @ 25°CNormally continuous rated current (B-A)3.3 Amps @ 25°C for 60msNominal 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 tamperedwith (controlled by BCM and multiplex architecturewith LIN technology).NOTE: Power to wiper motors is limited by thesize of the wiring and associated relays. If anyalternative wiper installation is made, it must havea specification equivalent to Ford components.Refer to: 5.9 Glass, Frames and Mechanisms (page

198).


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4.16 Special Conversions

4.16.1 Special Vehicle Options (SVO)Harnesses and Aftermarket Kits

WARNING: Only Ford release wiringshould be used to support added vehiclefunctionality. If the implementation ofwiring other than this is required, Fordguidelines must be followed. Please also

Refer to: 4.15 Fuses and Relays (page 134).Refer to: 4.18 Grounding (page 171).

In addition to the Auxiliary Fuse Panel alreadymentioned, a number of other kits are availableto meet customer needs see next table.

Special Vehicle Option Harnesses and Aftermarket KitsPart NumberAuxiliary Fuse Panel Harness LHDBK2V-14517-A*Auxiliary Fuse Panel Harness RHDBK2V-14517-B*C1 Connector Jumper Harness (for Auxiliary Fuse Panel)KTBK2V-14A411-A*C2 Switch Connector Jumper Harness (for Auxiliary Fuse Panel)KTBK2V-14A411-B*Vehicle Interface ConnectorKTBK2V-14A411-C*High Specification Vehicle Interface Connector Jumper HarnessKTBK2V-14A411-D*BCM C3 Connector Jumper (for Start-Stop Override and ConfigurableCharging)

KTBK2V-14A411-E*

Utility Pack Connector Jumper HarnessKTBK2V-14A411-F*Beacon Connector Jumper HarnessKTBK2V-14A411-G*Beacon Preperation Pack (Rear Beacon Harness)BK2V-10A933-A*Beacon Preperation Pack (Front Switch Harness)BK2V-14A303-A*Utility Vehicle Switch Pack (Front Switch Harness)BK2V-14A303-F*Utility Vehicle Switch Pack (Rear Harness)BK2V-14659-A*Trailer Tow JumperBK2T-13B576-A*Trailer Tow Socket JumperBK2T-13B576-D*Trailer Tow ModuleBK2T-19H378-A*

4.16.2 Additional VehicleSignals/Features

WARNING: When interfacing withspecific lighting high side driver outputs,additional supplemental signal access,relays and peripherals fitted, must becompatible with a Pulse WidthModulation (PWM) frequency of 200Hz.

For list of lighting circuits that are PWM supplied:Refer to: 4.2 Communications Network (page 75).Body Control Module (BCM) Output Informationtable.

Reverse Signal

A reverse signal is available on the tail lampconnector. In order to avoid electrical issues dueto leakage, and to ensure connector compatibility,a mating connector with seals/plugs andpre-crimped wire and terminal should be used.

NOTE: It is not recommended that reverse signalis used to drive auxiliary equipment directly – arelay (max 300mA) should be used. The existingreverse lamp load is close to the threshold and ishard-wired through the BCM for current sensingand other feedback systems.

Reverse Signal / Rear Lamp Connector

E151248

6

5

4

3

2

1


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Reverse Signal / Rear Lamp Connector - Van, Bus and Kombi

ColorWireCSA

FunctionPinRightLeftRightLeft

Green/BrownGreen/Brown0.75Reverse Lamp25Green/OrangeGrey/Orange0.75Direction Indicator61White/OrangeViolet/Green0.5Position/Park Lamp42Grey/VioletWhite/Green0.5Brake Lamp53Black/GreenBlack/Grey1.5Ground16White/BlueBrown/Green0.5Fog Lamp34

Reverse Signal in BCM C2 Connector

11

E151619

DescriptionItemReverse SignalPin 11

In addition, the reverse signal is also availabledirectly from the BCM (max. 300mA), but there isno free pin available. The only way to access thissignal at this location would be via a spliceinto the existing wire.Refer to: 4.1 Wiring Installation and Routing Guides

(page 61).

Splicing procedures andRefer to: 4.2 Communications Network (page 75).BCM, figure E145367(connector C2) and thefollowing Figure E151619 pin 11.Pin 11 can be accessed from either male or femaleconnector between harnesses 14401 to 14A005or 14401 to 14405 (Green/Brown wire).


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Third Brake/Stop Lamp

Third Brake/Stop Lamp Connectors

E151249

5

10

A

B

DescriptionItemLeft Connector Pin 5 on 14405 Harness - Yellow/GreyARight Connector Pin 10 on 14A005 Harness - Yellow/GreyB

A signal for a third brake/stop lamp is alsoavailable on the tail lamp connector.In order to avoid electrical issues due to leakage,and to ensure connector compatibility, a matingconnector with seals/plugs and pre-crimped wireand terminal should be used.For connectivity, see following Figure E151249 andthe details given in the section for reverse signal.The third brake lamp feed can be accessed fromthe body side connector of 14405 harness (left,pin 5) or 14A005 harness (right, pin 10) whichconnects to the door harness 13B472. Theseconnectors are located at the rear of the vehiclenear the interface of the rear door or lift gatewiring. This circuit can only have a relay added(maximum 300mA) to control additional lighting.Check with your local Ford dealer or NationalCompany Sales representative for conversioncompatibility.The use of the trailer tow connector is notrecommended. In situations where it is necessary,please see the following figure E151250. Thisconnector can be found at the 14406 interfacewith the 13B576 harness. Pin 6 is the stop lightfeed. The trailer tow module BK2T-13B576-A_ willneed to be fitted to get the system active. For full

trailer tow kit, BK2T-13B576-D_ is also required.For additional information on electrics for towbars:Refer to: 4.1 Wiring Installation and Routing Guides

(page 61).

Trailer Tow Connector

E151250

6

DescriptionItemStop Light FeedPin 6


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Additional Position Lamps at the Rear ofthe Vehicle

Lighting Connector

E151251

2

DescriptionItemPosition LampsPin 2

The feed for position lamps can be taken from thelighting connector, at the rear of the vehicle on13B472 harness, pin 2, see figure E151251 or directfrom the licence plate feed connector, see figureE151252, which is located in the door. The dealerwill need to reconfigure this output for themaximum rating 46W total.NOTE: Lighting connector shown in E151251 willrequire a local ground.For Lighting LoadsRefer to: 4.11 Exterior Lighting (page 128).

Licence Plate Connector

E151252

1

2

DescriptionItem12V Feed1Ground2

The position and parking functions operateindependently.When the position lamps are extinguished, the sidemarker and end-outline markers turn offsimultaneously, in line with Inter Regs No 48, whichstates the following:The electrical connections must be such that thefront and rear position lamps, the end-outlinemarker lamps (if they exist), the side-markerlamps (if they exist) and the rear registration platelamp can only be switched on and offsimultaneously. This condition does not applywhen using front and rear position lamps, as wellas side-marker lamps when combined orreciprocally incorporated with said lamps, asparking lamps and when side-marker lamps arepermitted to flash.

Fog Lamp Connector

Connectors are already part of the wiring if thevehicle is medium or high specification, (forexample with electrical side mirrors). The mainlamp switch will need to be changed for one thatincludes this feature. (There are switches with andwithout front fog lamp function).

Connecting to Lighting Information

Additional turn indicators must be poweredthrough relays (max 300mA), driven by existingturn lamps. The maximum load that the BCM candrive is 3 x 21W per side (front, rear).


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4.16.3 Auto Wipe and Auto Lamp for vehicles with large overhangs

E147777

2 1

3

DescriptionItemConversion or Installation rearward (zone 1) where Auto Lamp and Wipe feature will functioncorrectly.

1

Conversion or Installation forward (zone 2) where Auto Lamp and Wipe feature will NOTfunction correctly — The feature is not to be specified with the donor or configured OFF by theFord dealer.

2

Auto sensor location.3

NOTE: The Auto Wipe, Auto Lamp feature shouldnot be ordered for vehicles that are to be builtwhere the installation covers any part shownforward of the vehicle see figure E147777. This willaffect the auto sensors ability to detect light ormoisture to the defined calibration and it will notfunction correctly.In the event that a donor vehicle has beensupplied with these features, the dealer canconfigure the vehicle to manual lamp and wipewith the following settings.• Set Central Car Configuration parameter 24 –

With Rain sensor to 01: (Without Rain Sensor)• Parameter 88 for Auto Lamp should be set to

01: (Without Auto Lamps)

It is also recommended that the Auto Lamp mainswitch is changed for a non auto switch. If notchanged when selecting auto position (A), thedipped beam will remain on (due to a not validcondition) and the system will run in fail safemode. Dipped beam will be operated at Ignitionon and with Engine RUN. If the wiper is selectedwith the lamp switch in (A) the wiper will work asif intermittent mode has been selected. A FordDealer can help advise which switch should beordered and fitted, starting with part numberBM5T-13A024-** (depending on the specificationof the vehicle).


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4.17 Electrical Connectors and Connections

4.17.1 Connectors

Cutting into the Original Wiring System

WARNINGS:Under no circumstances should the CANBus be tampered with. This may lead tofailure of safety critical components suchas Anti-Lock Brake System.Do not use connectors which cut throughthe outer covering and into the core wire.CAUTION: Only use Ford approvedconnectors.

It is not recommended to cut into vehicle wiringbecause:• The base vehicle specification is unsuitable for

incremental loads except in conjunction withAuxiliary Fuse Panel or the High SpecificationVehicle Interface Connector.

• Long term risk of a faulty connectiondeveloping.

• Potential fire risk from over-loading.All connections into existing wiring must bepermanently insulated. Exterior connections mustbe water-proof and with a drip loop.Where wires are required to be extended, break inpoints should only be at existing connector points.If splicing into existing wiring is unavoidable, seewiring splicing procedures in this manual.Refer to: Wiring Installation and Routing Guides

(page ?).NOTE: Ford approved jumper harnesses shouldbe used.

4.17.2 Customer Connection Points (CCP)

E145358A

C3C2C1F14F13F12Battery/BatteriesSpareCCPSpareSpare60A

FuseSpareSingle Battery - Without Aux Fuse Panel

CCPCCPCCP60AFuse

60AFuse

60AFuse

Single Battery - With Aux Fuse Panel

CCPCCPCCP60AFuse

60AFuse

60AFuse

Twin Battery - Without Aux Fuse Panel

CCPCCPCCP60AFuse

60AFuse

60AFuse

Twin Battery - With Aux Fuse Panel

Customer Connection Point CoverA

WARNING: Only use the Ford approvedkit for adding fuses to the CCPs.


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CAUTION: When connecting to the CCP,it is recommended to disconnect thebattery ground so as to avoid a shortcircuit. The fixing torque (M5) is 3.5–4.5Nm.

NOTE: When fitting additional power wiring feedsthe protective cover will need to be revised toallow routing for the extra wires. The cover is premarked with the relevant areas so that they canbe easily removed.NOTE: There is a maximum of three CCPs, eachcapable of supplying a max current of 60 A(Ampere). These points are always located onthe driver's seat pedestal and are protected by acover.NOTE: Vehicles with Single Battery without AuxFuse Panel will only have one CCP fitted, theremaining two can be used after fitting the CCPkit KTBK2T-14B475-A*.NOTE: Camper Vehicles will have three CCP, oneof them is used for the Camper Central Connectorwhich means only 2 CCP are available to use.Contact your local Ford dealer or National SalesCompany representative for details of the kit.E145358 shows the left hand drive situation. Ona right hand drive vehicle the pre fuse box isrotated 180 degrees. Therefore C1/F12 will be atthe bottom and C3/F14 at the top connections.For High Current Supply and Ground ConnectionsRefer to: Battery and Cables (page ?).

4.17.3 Camper Central Connectors

WARNING: If multiple systems are to usethis supply, the total system load mustnot exceed the 60A short term loading.

Camper conversions are fitted with a dedicatedmain wiring loom BK2V-14401-J*/K* including 3customer connection points, as well as adedicated instrument panel wiring loomBK2V-14K024-A*/D*. There is no customerinterface, instead, three connectors are locatedwithin the passenger seat pedestal to supportcamper installations. The connector to power upthe 2-way connector underneath the passengerpedestal is securely taped back to the main wirebranch running behind the front seats and wouldneed to be connected by the converter during theinstallation. See customer connection points inthis section for further information. The converteris responsible for good protection of the exposedwire to the customer connection point, protectingthe wire against chafing.For a Camper Van on a Kombi derivative rearspeaker wiring and Camper speaker connectivityis provided at 2.5mm CSA. It is recommended toonly connect one 4 ohm speaker to each channeleither from the Camper interface connector or thebody wiring. If twin speakers per channel arerequired then each value must be 8 ohm.For additional informationRefer to: Electrical Connectors and Connections

(page ?).Wiring Specification table for characteristics oncontinuous loads versus temperature.


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E201841

1 4

63

1

3

13

15

CBA

A

B

C

1 2

DescriptionItemC2-1 - 15 way connector (face view)AC2-2 - 6 way connector (face view)BC2-3 - KL30 connector (face view) 60A Fed from Pre Fuse Box + GroundC

Tyco and Ford part numbers that are used for vehicle connectors, and suggested matingconnectors.

Mating ConnectorsVehicle ConnectorsTyco TerminalTyco ConnectorTyco TerminalTyco ConnectorConnector926883-1 (pin)1-480710-0926882-1 (socket)0-926647-115 way (C2-1)926883-1 (pin)1-480704-0926882-1 (socket)0-480705-06 way (C2-2)MTA TerminalMTA ConnectorMTA TerminalMTA ConnectorConnector

17.0768544.4040011.0766044.403002 way (C2-3)


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CommentsColorWire CSAFunctionPinConnector C2-1 (Figure E169183 - Item A)

21W maxYellow/Grey1.5Stop lamp (CHMSL)1300mA,Ground switchingBrown/Yellow0.5Engine Run2138Hz@100KPH, 50% duty cycleViolet/Orange0.5Vehicle Speed Output3Ford lock set (+ve pulse)Grey/Yellow1.5Lock^4Ford lock set (+ve pulse)Violet/Grey1.5Unlock^5300mA maxBrown/Violet0.5Rear Door Ajar6300mA maxViolet/Green0.75Interior light feed^^7300mA maxYellow/Grey0.75Interior light ground8

Not used9Not used10Not used11

300mA (nominal)Violet0.75Air Conditioningrequest

12

10A/F21 (SRB)Blue/Grey1.5Ignition (KL15)13Ground=SRC/Start-Stopdisabled

Violet/Grey0.5SRC/Start-Stop Inhib-itor

14

300mA maxGreen/Brown0.75Reverse signal15Connector C2-2 (Figure E169183 - Item B)

Not used1Twisted pairWhite/Green0.75Rear Speaker Left +2

Brown/Yellow0.75Rear Speaker Left -3twisted pairBrown/White0.75Rear Speaker Right +4

Brown/Blue0.75Rear Speaker Right -5300mA (nominal)Yellow/Grey0.5Instrument Panel Illu-

mination6

Connector C2-3 (Figure E169183 - Item C)60A Fed from Pre Fuse BoxBrown/Red6.0B+ (KL30)1 (A)GroundBlack/Grey6.0B-2 (B)

^ The lock and unlock signals are intended to operate with Ford lock sets, or components with equivalentfunction and operational characteristics: – Central Locking: 1.0s pulse; followed by 0.25s pulse forDouble Locking, – Unlocking: 0.25s pulse followed immediately by 1.0s pulse.^^ Battery saver default time is 30 minutes (alternative configurations: 180 minutes).Note:There are no additional ground wires in either C2-1 or C2-2 auxiliary devices and systems; localgrounds should be used.


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4.17.4 Vehicle Interface Connector

E152877

2

4

1

3

3

6

1

4

A

B

The Vehicle Interface Connector is on every vehicleexcept Camper Vans and Business Bus derivativesand provides a direct interface to signals. Seefigure E152877 for location and the following tablefor signals.

NOTE: There are two versions of Vehicle InterfaceConnector depending on the build date of thevehicle, connector A or connector B.

Vehicle Interface Connector Signals

6 Way - Connector B4 Way - Connector AVehicle Speed1Vehicle Speed1Switch Illumination only, not for relay as pulsewidth modulated (PWM)

2Switch Illumination only, not for relay aspulse width modulated (PWM)2

Engine Run - Ground3Engine Run - Ground3Ignition4Ignition4_5---6--

WARNINGS:Signals 1 to 3 on the Vehicle InterfaceConnector are for sensing purposes onlyand not to be loaded by high currentconsumers. The max current rating forsignal 4 is 10A and not to be exceeded inany situation.

Unused wires in the service kit must havecable ends insulated to avoid shorting onany ground points.

A service kit can be ordered from your local FordDealer, the kit contains the mating connector toaccess these signals, and 3 meters of wiring. Checkwith your local Ford Dealer which Vehicle InterfaceConnector you have on your vehicle before orderingthe kit.

KitMating ConnectorConnector A or BKTBK2V-14A411-CB*4S7T-14489-VD*4 Way - Connector AKTBK2V-14A411-C*4S7T-14A459-VGA6 Way - Connector B

When the Auxiliary Fuse Panel is fitted to thevehicle, the Interface Connector is occupied by theattached wiring harness. In this case these signalsand some additional features are available throughthe C1 connector. For more details refer to AuxiliaryFuse Panel section.


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Vehicle Speed

Square Wave CharacteristicsSpecifications

Battery VoltageMax High Signal

3.67 VoltsMin High Signal

1.1 VoltsMax Low Signal

- 1.1 VoltsMin Low Signal

+/- 1.0 VoltsMax Ground Offset

10µ sec <= tr <= 250µ secRise Time

10µ sec <= tf <= 250µ secFall Time

50% +/- 10%Duty Cycle

2.2 Hz/MPH (1.3808 Hz/KPH)Pulse Rate

WARNING: Do not interface with the CAN(Controller Area Network) for vehiclespeed.

Pin 1 - Vehicle Speed signal is a direct currentcoupled square wave that varies in frequency inproportion to vehicle speed. This provides a squarewave-form (50% duty cycle) signal, where afrequency of 138Hz equates to 100km/h.

Switch Illumination

Pin 2 - Switch Illumination signal is only to be usedfor sensing or to control a relay. It is a PWM singnalonly for low current illumination that can bedimmed and not to drive a relay.

Engine Run

WARNING: Do not cut into the alternatorwires or use the alternator as a source toobtain a 'D+ Signal'.

Pin 3 - Engine Run signal will only support a senseline or relay control.This engine run signal is ground switching (maxcurrent sink 250mA), it provides no positive output(open circuit) and is only active when the engineis running regardless of vehicle variant, forexample Start-Stop or SRC.The signal will not be present when:• Key states - OFF (0), Accessory (1), Run but

Engine OFF (2), Crank (3).• Key in Run position, where Start-Stop vehicle

has auto stopped the engine.• Engine running but load is greater than 250mA

(driving two or more relays in error).

Due to Start-Stop vehicles, the signal may switchup to 300,000 times. Provision is required forcontrol relays switched by this signal to meet thisdurability cycle.The fitment of the Auxiliary Fuse Panel will providea power +12V side for the relay (althoughconnection to the engine run pin is still required).This allows up to 15A output on the C1 connectorwith the manual demand switch Aux 2, see SVOAuxiliary Fuse Panel circuit diagram later in thissectionIf a positive (+12V) engine run signal is required,it can be done by using the switched ground tocontrol an ignition fed relay, to give this output.

Ignition

Pin 4 - Ignition signal is protected by a 10A fuse.It is +12V active at ignition positions: Accessory(1) and Run (2). It is not active at Ignition OFF (0)or Crank (3). Whilst it can drive equipment directlyit is recommended to use this feed to control aconverter fitted relay, especially for high currentapplications.

4.17.5 Auxiliary Fuse Panel (A526)

The Auxiliary Fuse Panel is recommended forvehicle converters where access to fused powerconnections are required (for example, additionallighting), see figures E152948 and E152949. Adedicated wiring harness (BK2V-14517-A*/B*) isused to implement the Auxiliary Fuse Panel to thevehicle. This fuse panel is located within thedrivers seat pedestal as part of the Pre Fuse Box(PFB). The Auxiliary Fuse Panel uses the VehicleInterface, shown in figure E152877, and providesan advanced customer access point (C1)connector as well as a (C2) interface connectorto further switch installations and a power andground supply.


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Auxiliary Fuse Panel (A526) - Left Hand Drive

E152948

X

5

12

3

4

6X

DescriptionItemC1 Connector1C2 Switch Connector2Vehicle Interface Connector3Ground4C3 — 2 Way Radio Connector5Auxiliary Fuse Panel within the Pre-Fuse Box (lid not shown)6


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Auxiliary Fuse Panel (A526)- Right Hand Drive

E152949

X

2

5

6

1

X3

4

DescriptionItemC1 Connector1C2 Switch Connector2Vehicle Interface Connector3Ground4C3 — 2 Way Radio Connector5Auxiliary Fuse Panel within the Pre-Fuse Box (lid not shown)6


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C1 Connector

E102527

S

J

H

A

DescriptionItemRelay 2 Output (5A)ARelay 7 Coil OUTBRelay 7 Coil INCRelay 7 Output (10A)DGroundERelay 6 Coil INFRelay 5 Coil IN AGRelay 3 Output 1 (15A - F5 Fuse Shared)HRelay 2 Output 2 (15A)JKL30 20AKRelay 4 Output (15A)LKL15 Ignition SwitchMRelay 2 Coil IN ANRelay 6 Output (15A - F7 Fuse Shared)PRelay 5 Output (15A - F7 Fuse Shared)RVehicle Speed SignalS

The C1 connector is a major interface to the vehicle,providing various signals and control circuits. It iswired to the Auxiliary Fuse Panel, see figuresE152948 and E152949. The mating connector forthe C1 is DELPHI 15326956. The fuse ratings, relaysand circuits are shown in figure E152950 and table.A service kit (KTBK2V-14A411-A*) can be orderedfrom your local Ford dealer, this kit contains themating connector, and 3 meters of wiring.

C2 Switch Connector

E152952

3 10

1

DescriptionItemRelay 1 Output (20A)1Ground2Switch Illumination Supply3Relay 3 Coil IN4Relay 4 Coil IN5Relay 1 Coil IN6Relay 3 Output 2 (F5 Fuse Shared)7Relay 2 Coil IN B8KL30 (3A)9Relay 5 Coil IN B10

C2 Mating Connector — KTBK2V-14A411-B*

C3 - 2 Way Radio Connector

E152951

2 1

DescriptionItemKL30 20A1Ground2

C3 Mating Connector - 6S6T-14A459-HK*


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Auxiliary Fuse Panel Circuit Diagram

E152950


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DescriptionItemDescriptionItemR7 Coil OUTC1-BVehicle SpeedAR7 Coil INC1-CSwitch IlluminationBR7 OutputC1-DIgnition SwitchCGroundC1-EKL30DR6 Coil INC1-FEngine Run Signal - GroundER5 Coil IN AC1-GBusbarD1R3 Output 1C1-HB-ZR2 Output 2C1-J3A FuseF1KL30C1-K20A FuseF2R4 OutputC1-L20A FuseF3Ignition Signal / KL15C1-M20A FuseF4R2 Coil IN AC1-N15A FuseF5R6 OutputC1-P15A FuseF6R5 OutputC1-R15A FuseF7Vehicle SpeedC1-S10A FuseF8R1 OutputC2-120A FuseF9GroundC2-25A FuseF10Switch IlluminationC2-315A FuseF11R3 Coil INC2-4Not UsedF12R4 Coil INC2-520A Relay (Beacon^)R1R1 Coil INC2-620A Relay (Ignition^)R2R3 Output 2C2-720A Relay (Aux 2/Water Heater^)R3R2 Coil IN BC2-820A RelayR4KL30C2-920A Relay (LHS Indicator/Aux 1^)R5R5 Coil IN BC2-1020A Relay (RHS Indicator^)R6KL30C3-120A relayR7GroundC3-2R2 Output 1C1- A

^When specified on Ford options


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4.17.6 Beacon Preparation Pack (A606)

A606 - Vehicles built before February 2016

E145352

1

2

DescriptionItemFront beacon harness on BK2V-14A303-**1Rear beacon harness on BK2V-14A303-**2

Figure E145352 shows the routing for front andrear beacon wiring installations and location ofconnectors for the beacons, which should beviewed in conjunction with the fitment of thebeacon switch, BK2V-13D768-A*, see figuresE152953 and E152954 for Switches and see figuresE152948 and E152949 for Auxiliary Fuse Panel,shown in this section.The beacon wiring circuit is fused at 20A. Anyincrease in this current demand should be metwith the use of an external relay.Contact your National Sales Companyrepresentative or Local Ford Dealer for availabilityand options.

12

E118455

DescriptionItemGround1Beacon Supply2


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A606 - Vehicles built after February 2016

1

1

1

2

2

2

A B

C

E226737

DescriptionItemVehicles with a bulkheadALow Roof vehicles (without bulkhead)BHigh Roof vehicles (without bulkhead)CFront Beacon harness on BK2V-14A303-**1Rear Beacon harness on BK2V-14A303-**2

Figure E226737 shows the routing for front andrear beacon wiring installations and location ofconnectors for the beacons which should beviewed in conjunction with the fitment of thebeacon switch, BK2V-13D768-A*, see figuresE226739 and E152954 for Switches and see figuresE152948 and E152949 for Auxiliary Fuse Panel,shown in this section.The beacon wiring circuit is fused at 20A. Anyincrease in this current demand should be metwith the use of an external relay.Contact your National Sales Companyrepresentative or Local Ford Dealer for availabilityand options.

12

E118455

DescriptionItemGround1Beacon Supply2


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4.17.7 Utility Vehicle Switch Pack (A607)

A607 - Vehicles built before February 2016 - Right hand drive shown

E146657

54

1

2

3

DescriptionItemFront Beacon Connector1Rear Beacon Connector2Aux 2 Connector (Limited availability, check local National Sales Company representative)3Aux 1 Connector4Mating C1 Connector5

The Utility Vehicle Switch Pack has BeaconPreparation Pack and an additional harnessBK2V-14659-B*. The beacon wiring is always onthe right hand side of the vehicle and connectsinto the C2 connector of the switch harnessBK2V-14A303-**.

Harness BK2V-14659-B* is always on thepassenger side of the vehicle and connects to theC1 connector of the switch harnessBK2V-14A303-**, see E152948 and E152949 forC1 connector location and also figures E152953and E152954 for Switches.


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A607 - Vehicles built after February 2016 - Right Hand Drive shown

E226738

54

1

2

3

12

3

1

3

3

2

1

2

A B

C

D

DescriptionItemDescriptionItemFront Beacon Connector1Vehicles with BulkheadsARear Beacon Connector2Low Roof vehicles (without bulkhead)BAux 2 Connector*3High Roof RHD vehicles (without bulkhead)CAux 1 Connector4High Roof LHD vehicles (without bulkhead)DMating C1 Connector5--

* Limited Availability, check with local National Sales Company Representative.The Utility Vehicle Switch Pack has Beacon Preparation Pack and an additional harness BK2V-14659-**.The beacon wiring is always on the right hand side of the vehicle and connects into the C2 connector ofthe switch harness BK2V-14A303-A* and harness BK2V-14659-** is always on the passenger side ofthe vehicle and connects to the C1 connector of the switch harness BK2V-14A303-A*, see E152948 andE152949 for C1 connector location and also figures E226739 and E152954 for Switches.


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4.17.8 Auxiliary Switches

Vehicles built before February 2016

E152953

2 3

4

A

B

1

1

DescriptionItemLeft Hand Drive locationARight Hand Drive locationBC2 Connector1BK2V-14A303_** Harness (see E152954 and switch table)2Front Beacon Connector3Over Head Console - Containing Switches4


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Vehicles built after February 2016

3

2

E226739

A

1

B

1

DescriptionItemLHD locationARHD locationBC2 Connector1BK2V-14A303-F* Harness, see figures E152954 and Switch table2Over Head Console - Containing Switches3


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Switch Locations

E152954

A B

1 1

1231 2 3

DescriptionItemLeft Hand Drive Switch optionsARight Hand Drive Switch optionsBBeacon1Aux 1 — Part of Utility Vehicle Switch Pack (A607)2Aux 2 — Part of Utility Vehicle Switch Pack (A607)3

Switches and Harness Part Numbers

Aux 2 (12V)Aux 1 (12V)BeaconHarness--BK2V-13D768-A*BK2V-14A303-A*

BK2V-13D734-B*BK2V-13D734-A*BK2V-13D768-A*BK2V-14A303-F*

There are a combination of switch packs availableto order for specific conversions. The 'BeaconPreparation Pack' or 'Utility Vehicle Switch Pack'are high current latched switches that controlrelays in the Auxiliary Fuse Panel. When theswitches are pressed (light on) the switchesprovide a +12V/20A output.NOTE: The Aux 2 switch must have the enginerunning before it will give an output. The outputwill be switched off during an engine auto-off(Start-Stop vehicle). The other switches (Beaconsand Aux 1) are fed directly from the battery. It isimportant to switch these off when not required,as the battery charge level will be depleted.

If heavy loads are required, controlled via theseswitches (especially at engine off) it isrecommended to install the High PerformanceDeep Cycle AGM Battery option (A736). Theswitches are illuminated red when the lights are:side, dipped, full beam or auto lights on. Theyswitch +12V and can switch up to 8A directly.


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4.17.9 High Specification Vehicle Interface Connector (A608)

E145355

1

2

3

6 5

4

DescriptionItemC1 Connector1Fuse Box — For High Specification Vehicle Interface Connector2Fuse Box Bracket3High Specification Vehicle Interface Connector4The connections are taped back to the harness under the carpet, behind the Drivers Seat Pedestal560A fuse Connections on Drivers Seat Pedestal6

The standard system includes the Auxiliary FusePanel and a supplementary Fuse Box, it is poweredby two fuses from the Customer Connection Pointsat the driver's seat pedestal (item 6 in figureE145355), therefore on these high-specificationvehicles there will only be one remaining customerconnection point available for customer to use.See also Fuse Rating table.


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The High Specification Vehicle InterfaceConnector (43 way connector), see E145357, isan order only option (A608) for production fit andcan not be updated after the vehicle is built. Theconnector is located behind the glove box asshown in E145355. It provides access to multiplesignals, power and ground. These signals includethose required for Police /Emergency Serviceconversions. The part numbers of the dedicatedharnesses are BK2V-14401-A*/D* andBK2V-14K024-A*/D*.A standard mating connector, with only a link wirebetween cavity 36 and 39, is provide (no otherwires). A mating 43 way connector with 3m ofwiring (with all wires) is available as a kit(KTBK2V-14A411-D*) from your local Ford dealer.

WARNING: This link wire provides a 'nostart function'. If the connectionbecomes 'Open Circuit' by removing themating connector or link wire the vehiclewill not Crank/Start.

E145357

7

19

31

43

1

8

20

32


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High Specification Vehicle Interface ConnectorNominal

RatingFuse

RatingFuseCommentsSignalWireCavity

---Licence Plate SupplyKL582.001

16A20A17GroundKL31-20A max.2.502





8A10A1Battery SupplyKL301.007





6A7.5A6Battery SupplyKL301.0012


6A7.5A8Battery SupplyKL300.7514

4A5A9IgnitionKL151.0015




---Ground = Door OpenRear Door Ajar Switch0.519

300mA--Pulse Width Modulation Signalfrom BCM

IP+Switch Illumination0.7520

NA--AC Active = Ground (<50 ohms)AC Active0.5021

3A--<= 13V DC, > Pulse Width Modula-tion Signal from BCM

Stop Lamp Signal0.7522

---Ground = SRC/Start-Stop deactiv-ated.

SRC/Start-Stop Inhibit0.5023

NA--Door Open = Ground (<50 ohms)LHS Sliding Door Ajar0.5024

NADoor Closed = Ground (<50 ohms)Passenger Door Ajar0.5025


Parking Lamps0.5026

NA--Door Open = Ground (<50 ohms)RHS Sliding Door Ajar0.5027

12A--Fuse and Relay located in Aux FusePanel in seat pedestal

Turn Indicator LHS1.0028

--Turn Indicator RHS1.0029

300mA--Relay Output from Smart RelayBox 1

Horn Signal0.5030

NA--To be used as input to ElectronicControl Units only

Vehicle Speed0.7531


Reverse Signal0.7532

300mA--Output from BCMHigh Beam0.7533

300mA--Output from BCMLow Beam0.7534

300mA--Output from BCMFog Lamps0.7535

300mA--Bridged with 39 - Open Circuit willinhibit Crank ^

KL500.5036

NA--Handbrake Activated = Ground(<50 ohms)

Handbrake Signal0.5037

NA--Engine Running = Ground(<50ohms)

Engine Run0.5038

NA--Bridged with 36 - Open Circuit willinhibit Crank ^

No Start Function0.5039

---12VKey In^^1.0040


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NominalRating

FuseRating

FuseCommentsSignalWireCavity

NA--Door Closed = Ground (<50ohms)

Driver Door Ajar0.5041

NA--Lock Request = Ground 500mS.Lock0.5042

NA--Unlock Request = Ground 500mS.Unlock0.5043

^ Bridged via circuit on mating connector to enable crank/start. If mating connector is removed, vehicle will not start^^ Ignition Switch 3M5T-11572-A* is required for Key In Signal. To replace the Ignition Switch refer to the Workshop ManualRemoval and Installation for Steering Wheel and Column Electrical Components - Ignition Switch.

KL Terminology

Ignition - Position 2KL15

B+ (Always +12V)KL30

Chassis or Body GroundKL31

Crank/Start Position 3KL50

Side Marker and Licence Plate LightingKL58

Accessory - Position 1KL75

Supplementary Fuse Box - for High Specification Interface Connector

E146641


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Fuse Ratings

Part NumberFunctionColorRating (A)TypeFuse1L3T-14A094-F_Battery KL30Red10MiniF11L3T-14A094-D_Battery KL30Tan5MiniF21L3T-14A094-G_Battery KL30 STDBlue15MiniF31L3T-14A094-G_Battery KL30 STDBlue15MiniF41L3T-14A094-F_Battery KL30 STDRed10MiniF51L3T-14A094-E_Battery KL30Brown7.5MiniF61L3T-14A094-F_Battery KL30Red10MiniF71L3T-14A094-E_Battery KL30Brown7.5MiniF81L3T-14A094-D_Ignition KL15Tan5MiniF91L3T-14A094-D_Ignition STDTan5MiniF101L3T-14A094-F_Ignition KL15Red10MiniF111L3T-14A094-D_Ignition KL15Tan5MiniF121L3T-14A094-H_Fused GroundYellow20MiniF131L3T-14A094-H_Fused GroundYellow20MiniF141L3T-14A094-H_Fused GroundYellow20MiniF151L3T-14A094-H_Fused GroundYellow20MiniF161L3T-14A094-H_Fused GroundYellow20MiniF17

-Spare---F18

WARNINGS:The fuse ratings and nominal ratingswithin the table should be followedstrictly. Any deviation could insecurelyinterfere with the validated fusingstrategy and wiring architecture. Someinputs are provided via electronicmodules and any overloading could causeserious vehicle malfunction and mayconflict with legal requirements.No increase in existing vehicle standardfuse capacity is allowed under anycircumstances.

On high-spec vehicles the C1 connector is notavailable as a customer interface and only the 43way connector should be used. The connector toadd wiring for switches and beacons is stillavailable.

125kb/s MS CAN Access Interface

WARNING: It is not allowed to transmitDATA on any of the CAN lines. The systemprovided to splice into the 125kb/s MSCAN Bus is for modules that will readonly. If messages are transmitted from athird party fit module, vehiclefunctionality can be compromised andlead to serious failure. It is vital that anyCAN stubs added must comply to thetwisted rate, length, correct parity, withrouting away from any high EMP devices.

NOTE: Please contact your National SalesRepresentative or your local Ford Dealer foravailability.The High Specification Interface Connector optionA608 has a 125Kb/s MS CAN interface EDSconnection point that can have third party CANwires spliced into. This is designed to provide FordCAN Bus interfacing for third party fit moduletelematics and logic controller systems. For furtherinformation on splicingRefer to: Wiring Installation and Routing Guides

(page ?).Modules to be installed are only allowed to be readONLY of the Ford system CAN Bus data and mustbe CE marked. After installation, functional testingof Ford systems connected to the same CAN Busis expected. These include Trailer Tow, RearCamera, Tachograph, Body Control Systems, FuelFired Heater and Cluster Systems. The systemshould also receive a health check DTC read toensure no failures are present after the installationand ignition cycle has been performed. Theconverter is also responsible for legal complianceto EU EMC requirements of the finished systemand ensure no adverse impact has been generatedto the existing Ford systems. Please refer toSection 1 of the BEMM for responsibility and EMCcompliance.


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The CAN Interface loop wire, see figure E212562,is located near the 43 WAY interface connector,behind the glove box and outboard to the wheelarch. The half way loop point can be spliced intowith third party twisted pairs of at least 3 twistsper 50mm and a minimum of 0.3m to a maximumof 2m stub length to module. CAN Low is theGrey/Orange wire. CAN High is the Violet/Orangewire.

CAN Bus Interface Loop Wire Location

E212562

D

DescriptionItemSplice into mid point of loopD


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Third Party Fit CAN Read Module

E212563

B

D

A

EC

DescriptionItemConverter Fit Read ModuleAConverter Fit Stub WiringBSpliced Interface ConnectionCFord CAN Loop Wire - CAN Low (Violet/Orange wire), CAN High (Grey/Orange wire)DC22-ABE

Can bus network stubs must comply with thefollowing standards:• Originate at the CAN bus backbone.• Have a final length of between 0.3m and 2m,

see dimension 'X' in figure E212566.

• Have at least 3 twists per 50mm of wire.• follow the splice guidelines, shown later in this

section.Stub length added must exceed 0.3m but be lessthan 2m, at least 3 twists per 50mm of wire andnot be less than 50mm of untwisted wire to theadded module or splice.

Physical Interface of spliced in EDS Requirements

UnitsMaximumNominalMinimumParameterOhm132120108Impedancemilli Ohm/meter175--Resistancenano Second/meter

5.5--Signal Speed

Twisted/50mm--3^Twistingnano Second3.4--Phase ShiftVolts0.5--Differential Mode Offset

^ The Twisted circuits shall have a minimum twist rate of 3 twists (4 wire crossovers) per 50 mm. One"twist" or "turn" = 180 deg. Rotation. Twisting shall be maintained to within 50mm of any in-line orcomponent connector.

The twisted pair that forms the CAN Bus shall betwisted throughout the total run of the vehicleexcept for a maximum of 50mm from connectorsor harness splices. At splices an additional 50mmof untwisted wire is allowed between the CAN Hand CAN L contact points


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Twisted Circuits - all values are maximum limits (dimensions shown in mm)

E212564

A B

C

DescriptionItemConnectorASpliceBTypically taped to backboneC

Maximum CAN Bus Length Series ChainMethod - all values are maximum limits(dimensions shown in mm)

E212565

100

It is allowed to connect modules to the backboneusing a series chain method instead of a stub. Ifthe series chain method is selected, the untwistedwire on each side of the double crimp in theconnector cannot exceed 50mm. See figureE212565The two terminating ECU's shall be placed the'furthest' distance apart on the CAN Bus. Themaximum wiring length for each type of networkis defined in the following table

Maximum CAN Network Lengths

SAE J1962 Connector to 'Furthest'Terminating ECU^

Between terminatingECU's

Network Speed

45m50m125 kbps28.5m33.5m500 kbps

^ This allows for an off-board tester cable of up to 5m.

NOTE: Exceeding the permitted CAN networklengths will result in data transfer issues and couldcause serious vehicle error.

Cable Stub Length: Must be a final length ofbetween 0.3m and 2m, see dimension 'X' in figureE212566. It is acceptable for any stub, except theterminating ECU stubs, to be open circuit andunterminated, i.e. harness variants are not requiredto support option fit ECU's.


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Cable Stub Circuit

E212566

DescriptionItemStub 1AStub 2BStub - Final length between 0.3m and 2mX

Stub Splices:The general rule is that there shallbe at least 50mm of twisted wire between anyseries of the following connections: splice – splice,connector - splice, connector - connector, Splicesinclude wire to wire splices and splice blocks.Two stubs may be connected to the same stubconnection point at the CAN backbone only on a125 kbit/s (MSCAN) bus. In this case the stubsmust differ in length by at least 10%. Example: Ifone stub is 1m long the second can be less than0.9m or between 1.1m and 2m.

Stub Topologies: Stubs connected to stubs arenot allowed. If multiple nodes need to beconnected to a single stub then the nodes mustbe series chained. This can be accomplished bydouble crimping if only two pins (CAN H & CAN L)are available or making the CAN Bus connectionthrough the module if four pins are available (2 xCAN H & 2 x CAN L).The maximum number of ECU's on networktransmission speed 125 kbps, including theoff-board tester, is 32.The two wires forming each pair of CAN H and CANL connections shall be routed via physicallyadjacent pins as shown in the figure E212567.


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E212567

ABC

DescriptionItemNon Adjacent PinsAAdjacent PinsBCAN H or CAN LC

Each Bus pair may be routed via separateconnectors.Details of the pin allocation for each node shallbe defined in the relevant module specificationThe voltage supply used by the network interfacemust not be directly connected to any externalpart. That means that the regulated power usedby the CAN-circuitry on the printed circuit boardshall be used only inside the cover of the ECU.Note: this does not apply to the Vbat connectionrequired for full-sleep functionality in transceiverspowered by Vbat.The CAN network shall be fully functional, as aminimum, over the operating range 9V to 16V, asmeasured at the modules battery pin. Outside thisoperating range, it is recommended that modulescontinue to communicate. However, it is notacceptable for modules to send corruptmessages/error frames/illegal symbols, or disruptthe transmissions of other modules.NOTE: Module feature requirements may requirea larger operating rangeModules shall not drive the CAN bus dominantduring module reset.Common mode EMC chokes shall not be used interminating nodes. Additionally chokes may onlybe used in non-terminating ECU's with theagreement of the relevant FMC design authority,for each vehicle program to which the ECU shallbe fitted.Suppliers may Electrostatic Component Dischargecomponents as long as pass tests:• Conducted Immunity

– CI 280 Electrostatic Discharge– CI 270-C Immunity to Voltage Overstress

(24V), applied to CAN H and CAN L

Additionally, the capacitance of the component,measured at 2.5V reverse bias, shall be <30pFThe zener stacks may be removed for moduleson CAN links that do not connect to the diagnosticconnector as long as it is shown that theunpowered ESD test can be passed without theseparts (Powered ESD testing on the CAN pins isnot required for modules that do not connect tothe diagnostic connector). The circuit board padsfor these parts must be present for all designs.All grounding of the CAN transceiver andcapacitors shall be made to ECU signal ground.All transceiver voltage reference pins shall be leftopen circuit.Capacitors shall be monolithic ceramic capacitorsor equivalent.A ground plane is required under the transceiverchip on the component layer of the PCB.Transceiver shall be located as close to edgeconnector as possible. Other IC’s are notpermitted between edge connector and thetransceiverCAN H / CAN L circuits between edge connectorand transceiver shall be as short as possible androuted side-by-side. Guard tracks are required forall CAN H / CAN L, TXD and RXD circuits on thesame PCB layer. Guard tracks should not beplaced between CAN H and CAN LAll guard tracks shall be at least 0.5mm wide andgrounded at least every 10mm.The decoupling capacitor shall be placed as closeas possible to the transceiver.Transceivers that are battery powered arerequired to have a Flexisafe capacitor.


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4.17.10 Adding Connectors

Additional ‘Theater Lighting’ for rear ofvehicle interior

1

4

3

6

E146835

DescriptionItemSupply through Battery SaverPin 1Ground - DimmingPin 5

Marker Lamps

11927

324042

29

1814

2628

394159

31

E147188

DescriptionItemSide Marker Supply - Yellow /VioletPin 14

WARNING: The Position and MarkerLamps of the vehicle are collectivelypowered via F15 in the Body ControlModule at a rating of 25A. A nominalcurrent rating of 20A (full load includingall potentially fitted additional lamps)must not be exceeded.

Additional Rear Speakers

NOTE: The connectors on the Instrument Panelharness (14K024) and the main harness (14401)are reversed between Left Hand Drive (LHD) andRight Hand Drive (RHD) vehicles, hence differentsets of terminals/wires are required to cover allthe markets.For information on rear speakers:Refer to: 4.9 (page 121).

Unused Connectors

The harnesses may have a number of unusedconnectors – these are dedicated to other featuresand options, e.g. heated seats, but are not alwayspresent depending on level of harness fitted. Forddo not recommend the use of these connectorsfor any other purpose than that intended by design.

Power Outlet / Cigar Lighter

Both features adopt a 20A fusing strategy. With asingle battery system, continued loading of thesefeatures will lead to battery drain, and risk vehiclestarting. If continuous power is required, a secondbattery option should be installed and thecustomer connection points, where fitted, utilized.At engine OFF, all three power outlets areconnected to the battery saver system, where thesupply will switch off at 30 minutes. Battery savercan be ordered or reconfigured to a longer durationof 180 minutes.


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4.18 Grounding

4.18.1 Ground Points

WARNING: It is recommended to only useone eyelet per stud for high currentapplications. If more than one eyelet perstud is unavoidable, the highest currenteyelet feed should be connected closestto the supply terminal. Do not exceed twoeyelets or crimp terminals per studconnection. See figure E145379 and thefollowing table for recommended groundpoints that can be used.

CAUTIONS:Only use the ground points indicated.Using alternative points may affect thevehicle integrity.Make sure that all ground points aretightened to the correct torque.

NOTE: The Ground Point (GP) numbers are onlyfor reference to show the location of the GP.Ground wires should be brought back to the Fordground points provided, please refer to thefollowing figures. For very high current users, it isrecommended that the ground connection ismade directly to the ground point close to thebattery ground point. For High Current Supply andGround ConnectionsRefer to: 4.4 Battery and Cables (page 93).If a new grounding point is required, avoid weatherzones, especially for high current grounds. Groundconnections should be routed back close to thelocation of the +12V supply. This helps to reducethe electromagnetic field particularly generatedby inrush current and improve electromagneticcompatibility.

Van, Bus, Kombi Ground Points

2019 21 2728261712 189102 634 5

7 8 1314 1516 24 22

32

23 25 29 30

1 11

E145379


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12

4

65

3E168170

7 8

E145382

HarnessTypeLocationGroundPoint

14401Misc Power ElectricEngine Bay LHSGP114401Misc Power ElectricEngine Bay LHSGP2

9K499EXH EMS ControlEngine Bay LHS FrontGP39K499EXH EMS ControlEngine Bay LHS FrontGP49K499EXH EMS ControlEngine Bay LHS FrontGP514406Fuel Tank SenderEngine Bay LHSGP614401Misc Power ElectricEngine Bay RHS FrontGP714401Misc Power ElectricEngine Bay RHS FrontGP814405Rear LampA Pillar LHS UpperGP914401Misc Power ElectricA Pillar LHS LowerGP1014401Misc Power ElectricA Pillar LHS LowerGP1114401General Power GroundA Pillar LHS LowerGP12

14A005Rear LampA Pillar RHS UpperGP13*14401Misc Power ElectricA Pillar RHS LowerGP1414401Misc Power ElectricA Pillar RHS LowerGP1514401General Power GroundA Pillar RHS LowerGP16

14K024Misc Power ElectricCross Car Beam LHSGP1714K024Misc Power ElectricCross Car Beam LHSGP1814K024Misc Power ElectricCross Car Beam LHSGP1914K024Misc Power ElectricCross Car Beam LHSGP20*

-Misc Power ElectricCross Car Beam LHSGP21*14K024Misc Power ElectricCross Car Beam LHSGP22*14K024Misc Power ElectricCross Car Beam RHSGP23*14K024Misc Power ElectricCross Car Beam RHSGP24*14401Misc Power ElectricFloor PanGP25*14405Misc Power ElectricD Pillar LHS LowerGP26*14405Misc Power ElectricD Pillar LHS LowerGP2714405Misc Power ElectricD Pillar LHS LowerGP28

14A005Misc Power ElectricD Pillar RHS LowerGP2914A005Misc Power ElectricD Pillar RHS LowerGP3014D502Diesel Vaporizer PumpTransmission FWDGP32

* Recommended Ground Points that can be used.Ford Part Number W505255-S450M, M6 Screw type fixing - Torque 12Nm +/- 1.8


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Abbreviations used in table:• LHS - Left Hand Side• RHS - Right Hand Side

• Misc - Miscellaneous• EXH EMS - Exhaust Emissions• FWD - Front Wheel Drive

E145385

9

10

19 24

17

18

20

21

11

12

13

1415

16

23

22

E145383

25

E145384

28

26

27

E145386

3029

E222648

32


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5.1 Body

5.1.1 Body Structures - GeneralInformation

When carrying out vehicleconversions/modifications the following pointsshould be considered:• Make sure that the vehicle structural integrity

is maintained.• Do not drill into closed frame body members.• Make sure that the design for the body

alterations or additional structure disperse theload evenly.

CAUTION: Uneven load distribution couldresult in unacceptable handling andbraking characteristics.

• Re-paint metal edges after cutting or drilling.All metal edges must comply with exterior andinterior protection legislation.

• All fixings through the floor, sides or roof mustbe sealed.

Ensure proper sealing against ingress of water,salt, dust, after cutting or drilling the body. UseFord approved sealing and finishing material, andunderbody corrosion protection.Refer to: 5.13 Corrosion Prevention (page 206).• Make sure that fixings in the 'B'-pillar area do

not encroach on the seat belts or seat belt reels.For unique floor fixings, see (Frame Drilling andTube Reinforcing).Refer to: 5.14 Frame and Body Mounting (page 207).For Load Compartment Tie Downs (Load LashingPoints)Refer to: 5.4 (page 186).

WARNINGS:Do not drill Boron steel parts, see figureE146882 in this section.Before drilling the floor, check the No DrillZones, see Figure E145378 in this section.

For additional No Drill ZonesRefer to: 4.1 Wiring Installation and Routing Guides

(page 61).Refer to: 5.6 Body Closures (page 190).

5.1.2 Welding

WARNING: Do not weld Boron steel parts,see figure E146882 in this section.

Before welding work is performed on a vehiclebody, all safety measures for the protection ofpeople, modules and electrical components mustbe observed.

Electronic Components

Increased use of comfort and safety electronicsin modern motor vehicles also requires the greatestattention to be paid during body work. Overvoltages produced during welding and in alignmentwork during body shell rectification may causeelectronic systems to be damaged. In particular,the safety instructions for performing welding workon vehicles with airbag systems must be adheredto.NOTE: After disconnecting the power supply andbefore performing further work, a wait time of upto 15 minutes must be maintained, depending onthe vehicle. Work on airbag systems may only beperformed by personnel who have a relevantcertificate of competence.Pay attention to the following points:• Disconnect the battery negative clamp and

cover the battery terminal.• Disconnect the electrical connector at the

airbag control module.• If welding is to be performed directly near a

control module, it must be removedbeforehand.

• Never connect the negative cable of the weldernear an airbag or a control module.

• Connect the negative cable of the welder closeto the location of the weld.

Before Welding

Interior surfaces of new bodywork componentswhich will no longer be accessible after installationmust be painted beforehand. The welding flangesare treated with a special welding primer. The jointareas are not always accessible from inside later.Therefore, prepare these areas so that no soot isproduced by burning paint during welding.NOTE: In order to ensure that the corrosionprotection produced in production is not destroyed,the working area must be kept as small aspossible.NOTE: Do not touch cleaned bare metal any morewith the bare hands. The dampness of your handswill corrode the metal.Procedure:• Remove the primer or paint/zinc layer in the

welding area using a tress wire brush to preventthe formation of soot from the paint.

• Thoroughly clean the welding area with a metalcleaning agent and rub dry.

• Coat the welding flange with welding primer onall sides and allow to dry.

NOTE: The welding primer must only be appliedthinly to the spot welding area, to minimizespattering when welding.


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The following points must be noted whenwelding:• Zinc starts to melt at about 420°C.• The zinc vaporizes at a temperature of about

900°C.• The amount of heating determines the damage

to the zinc coating, and therefore to thecorrosion protection.

• Resistance spot welding is particularly suitablefor welding zinc-coated panels, because nowidespread warming occurs.

• With electrolytically zinc-plated panels thereis no need for any special preparation becausethe zinc coating does not need to be removed.

After Welding

During work, body panels are often heated at veryhigh temperatures, which results in the destructionof the corrosion protection.

Working of the affected areas is therefore vital:• Grind the welded seams flat and clean

thoroughly with silicone remover. Dry with alint-free cloth.

• If the join area is accessible from the inside, thetransition area to the paint must be abradedfor all types of join so that good adhesion ofthe primer is achieved later.

• If the join area is not accessible from the inside,the cleaning and sanding work is not done. Forthis reason, ensure that there is as littlecontamination as possible in the area of therepair. This allows the cavity wax applied laterto penetrate the join area without hindrance.

NOTE: Only apply a small amount of panelcleaner to the cleaning cloth when cleaning thearea. Make sure that no cleaner reaches theconnecting flange, so that the welding primer isnot washed away again.Priming after weldingPrimer is applied to the welded flanges aftercleaning. A check must also be made that theproduction corrosion protection is present in thearea of the flanges. Any damage must also bere-primed.


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5.1.3 Boron Steel Parts

Boron Steel Parts - No Drill or Weld Zones

E146882


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5.1.4 Floor 'No Drill Zones' under the Floor Fuel Tank

E145378

1 2

1 2

A

B

H

C

E

J

K

F

G

D

3

Floor 'No Drill Zones' Dimensions (mm)350K394DCenter line Front Wheel Axle1

Note: Vehicles with fuel cooler usedimension 'J', vehicles without fuelcooler use dimensions C + E + K

1282ECenter of 'B'-Pillar2680FCenter line of vehicle3164G1207A

1074H1182B2464J250C


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5.1.5 Front End Integrity for Cooling,Crash, Aerodynamics and Lighting

Cooling Continuous air flow through the front endand engine compartment is not to be hindered byadding any additional equipment. If uncertainplease consult the Vehicle Converter AdvisoryService [email protected] Do not alter the lighting system.Crash Do not cut, drill or weld any parts that areload path relevant in case of crash. Do not addmaterial in the crash zone. This could affect thecrash sensor calibration.The side airbag system is not permitted if:• A swivelling device is fitted on the front seats.• Any additional material or structure is attached

to the B-pillar inner and/or outer area.


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5.2 Hydraulic Lifting Equipment

5.2.1 Hydraulic Lifting Equipment forVan, Bus and Kombi

General Information

WARNINGS:Do not cut away any structural member.

Equipped vehicles must be designed tobe stable under “worst case” operatingconditions with support legs extended,if fitted.Do not lift vehicle off the ground.

CAUTIONS:Safety devices must ensure the legs aredeployed when operating the liftingequipment.Safety devices must ensure the legs arestowed and locked away prior toengaging vehicle drive.

NOTE: There are no tie down locations in thefloor. It is the converters responsibility to fix withadequete reinforcements from below.For additional information:Refer to: 5.14 Frame and Body Mounting (page

207).The vehicle converter is responsible for:• Fitting decals, advising on the safe use of the

equipment.• Route electrical and hydraulics separately and

away from original Ford equipment.

• Use suitable clip to fix on vehicle body and subframe.

• Offer master switch in the cab to isolate thewhole system.

It is recommended to design sub-frames in waythat there is no adverse strain on the vehiclestructure. Use compliant and fixed mounts toattach to the vehicle body. For design principlerefer to E145387.For Van, Bus and Kombi:• It is recommended to fix every mount with M8

bolt grade 8.8 minimum.• Any other floor contact should be padded to

prevent local stress and to allow function ofcompliant mounts.

• Very stiff sub-frames should not be rigidlymounted to the floor, please refer to FigureE145387 for an example of a compliant mount.Compliant bushes should allow up to +/-12mmmovement at a rate of 100kg per 1.0mmdeflection with only the rear pair of loadcompartment tie down mounting bracketsbeing fixed.

• Support legs, if required, must be fitted directlyto the sub-frame.

• Support legs must be designed to prevent anyadverse strain on the vehicle structure whenoperating the equipment.

• It is recommended to lift the subframe fromthe floor as shown in figure E145387.


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Rigid or Torsion Stiff Sub-frame for Van, Bus and Kombi

E145387

4

2

3

5

1A B

4

2

3

1

21

DescriptionItemCompliant MountAFixed MountBSub-frame longitudinal1Sub-frame outriggers2Floor of vehicle3Fix to floor using adequate reinforcements4Captive compliant bush5


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Hydraulic tail lift

E145388

A

DescriptionItem1000mmA

It is recommended to fix lift framework on bottomand on top side by using reinforcing plates andthrough bolts. It is also recommended to designand/or locate the reinforcing plates in a way thatload can be routed into adjacent reinforced bodystructure. If mounted at rear door symmetrical tothe vehicle center line load capacity is up to 700kgat 1000mm from floor edge to center of load.If mounted asymmetrical to the vehicle centerline or if mounted at side load door load capacityis up to 500kg at 1000mm from floor edge tocenter of load. For pillar lifts with adjustable reachswing jib fixed only to one rear door pillar loadcapacity is reduced to 100kg at maximum1000mm reach.For load conditions as described above additionalstabilizing equipment is not necessary. Hydraulicunder-slung tail lifts are not recommended forTransit Van, bus and Kombi.Greater off-sets and/or loads require additionalstabilizing equipment such as outriggers or groundjacks. It is recommended not to increase vehiclebody stress over limit as given by load factorsabove. If uncertain please consult your localnational sales representative or the VehicleConverter Advisory Service [email protected]

It is the Vehicle converters responsibility to fit adecal to the converted vehicle stating that theequipment must not be used withoutoutriggers/ground jacks in operating position. It isalso the vehicle converters responsibility toguarantee safe functioning of the equipment.


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5.3 Racking Systems

5.3.1 Racking Systems

For attaching a racking system it is recommendedto use the marked areas shown in figure E146883.• Frames should be rigid, self-supporting and

bolted through the floor, use reinforcements onthe underfloor.

• It is not recommended to drill through the floorin combination with plastic load floor liners.

• For alternatively fixing through the floor to theside members please refer also to FigureE148689 Frame Drilling and Tube Reinforcing.

• Ensure proper sealing against ingress of water,salt, dust, after cutting or drilling the body. UseFord approved sealing and finishing material,and underbody corrosion protection.

• To minimize stress in body side upper areaadditional cross brace roof bows are to be used.

• If linings are planned for the inside of the loadarea. All racking through bolts must be designedto be accessible through the lining to the bodystructure with spreader plate.

• No load bearing fixing to the lining only.• For increased crash performance the racking

system should be designed with diagonalreinforcements.

• Vehicle should be equipped with Ford standardoption bulkhead to give best protection to driverand front passengers.

• Preferably, there should be a rack each side tobalance the vehicle load.

For additional informationRefer to: 5.13 Corrosion Prevention (page 206).For additional information on Precautionary/NoDrill ZonesRefer to: Wiring Installation and Routing Guides

(page ?).Refer to: Body (page ?).Refer to: 5.6 Body Closures (page 190).


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Recommended Fixing Locations

E146883


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Design Proposal for non Ford Production Option Racking System (Left Hand SideShown)

1

E146885

2

1

Racking - Floor Fixings to Load Compartment Tie DownsDescriptionItem

Rigid Self-Supporting Racking Frame Work1Fixing to floor2


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Glass Racking on Outside of Van

E146884

3

1

2

3

Glass Racking on Outside of Van - Through Fixed to Internal Racking (Recommended Minimum)DescriptionItem

Top Load Bearing Attachments (2x)1Lower Load Bearing Attachments, through body side to internal racking (2x)2New Through Bolts (2 bolts per top attachment and 1 bolt per lower attachment)3

For designing glass carrying rack on body sideouter, construct internal rack and bolt through thebody side to the internal rack, see figure E146885.


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5.4 Body System - General Information—Specifications

5.4.1 Load Compartment Tie Downs for Van, Bus and Kombi

All vehicles are fitted with load compartment tiedowns, these are all 'D' rings as shown in E145395.Not all vehicles will have all locations shown, itwill depend on the base vehicle. For additionalfixing locations.Refer to: 5.3 Racking Systems (page 182).

E145395

1


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Dimensions for Load Tie Downs

L2L1Dimension (mm)Dimension from B-Pillar (1)

78A1177B

20831716C26112374D28822515E

Vertical from floor137A161B1395C175D12E1

From center line of vehicle733A2817B2882C2791D2450E2

L1 = 2933mm Wheel Base, L2 = 3300mm Wheel Base


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5.5 Front End Body Panels

5.5.1 Partitions (Bulkhead) - Driver andFront Passenger(s) Protection on Van,Bus and Kombi

CAUTION: Bulkheads serve an importantfunction and are legally required in someterritories.

It is the vehicle converter’s responsibility to ensurelocal current legislation, governing bulkheads andprotective window grilles, is met. It is also theconverter’s responsibility to ensure legal loadconstraint requirements if using a non Fordstandard bulkhead.

Standard Ford bulkheads do have a clearancebetween bulkhead and body structure to allownatural body flexing and an air circulation from thecab to the rear load space for ventilation control.Air circulation and body flexing must be also givenconsideration when engineering an alternativebulkhead. It is not recommended to restrict driver’sor passengers’s seat adjustment travel.The following figures E145399 and E166841 showthe standard bulkhead fixing locations on B-pillar.These are hexagonal holes for M6 thin sheet rivettype nuts. The standard range of Ford bulkheadscan be retro-fitted at these points. Standard FordBulkheads are fitted with tamper-proof bolts.

H1 Roof Height - Bulkhead Fixing Locations

E145399


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H2 Roof Height - Bulkhead and Parcel Shelf Fixing locations

E166841

H2 Roof Height - Kombi Close Out Panel

E172272


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5.6 Body Closures

5.6.1 Security, Anti Theft and LockingSystem

NOTE: It is not recommended to alter the lockingsystem or damage the security shielding aroundthe lock and latch.However, in case a modification is required for theconversions, please consult the Vehicle ConverterAdvisory Service [email protected] avoid locking system security complications, itis recommended to discuss with the local Forddealer prior to modifications taking place.

When removing and reapplying door seals takecare to fit correctly, using the same seals as thisis critical to door closing efforts. Any modificationto the sealing flanges or surfaces will requireconsultation with your local Ford dealer or VehicleConverter Advisory Service ([email protected]).This may also include air extraction/ventingadjustments to assist door close efforts ifsignificant changes to closures are required.The Body Control Module is designed to workspecifically with the Ford Transit lock and latchmechanisms and therefore drives latches to lockand unlock for specific time periods. Additionalpower locking functionality should be basedaround the use of additional Ford Transit latchmechanisms. Additional latches can be driven viarelays connected in parallel with existing latches.The following figures outline the areas in which itis not advisable to drill.

No Drill Zone - Driver and Passenger Doors

E145401

A

BD C

No Drill Zone - Driver and Passenger DoorsDescriptionItem

300mmA55mmB150mmC190mmD


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No Drill Zone - Lift-Gate

E145402

CB

A

No Drill Zone - Lift-GateDescriptionItem

480mmA430mmB305mmC


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No Drill Zone - Side Sliding Doors

E145403

A

B

C

F

G H

E

D

J

No Drill Zone - Sliding DoorsDescriptionItem

620mmA165mmB360mmC740mmD290mmE250mmF215mmG500mmH300mmJ


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No Drill Zone - Rear Cargo Doors

E145404

F

C

B

E

D

A

G

No Drill Zone - Rear Cargo DoorsDescriptionItem

250mmA115mmB385mmC250mmD480mmE260mmF175mmG


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5.7 Interior Trim

5.7.1 Load Compartment Interior Lining

Do not damage the lock, hinge, latch or check armsystem (electrical cables, release system) whenapplying interior lining.Be careful not to damage the weather shield(water shield covering inner door access hole)when removing or applying interior door trim.

WARNINGS:Plan fixing points for other fitments suchas racking to ensure through bolting canbe achieved. Fixing to the lining materialmay be inadequate for normal safeoperation of the vehicle.Varnish or paint wooden interior cargoarea panels if exposed to high humidityconditions.

The additional weight of the linings on doors mayrequire additional reinforcements to the door andpillar at the hinge and check mechanism.

5.7.2 Plywood Lining/Cladding

E145400

CAUTION: Do not drill into the vehiclebefore checking the Precautionary/NoDrill Zones and electrical wire routing.

Refer to: 4.1 Wiring Installation and Routing Guides(page 61).

Refer to: 5.6 Body Closures (page 190).Refer to: 5.1 Body (page 174).• Panels should be precision cut by machine, not

by hand jigsaw, to reduce rough edges andsplinters.

• Panels should be pre drilled.• Do not drill through floor panels, use existing

load lashing points when securing the panels.• It is recommended that when fitting a plywood

floor that it is joint free.• Use aluminum floor trims.• Plywood should be water resistant (WBP, water

and boil proof).• It is recommended to use 9mm thickness for

floors and 6mm thickness for side and doorlining.

For any further details and advice please consultyour local National Sales Company representativeor Local Ford Dealer. If they are unable to help youthen please contact the Vehicle ConvertersAdvisory Service at [email protected]


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5.8 SeatsNOTE: When reassembling the seat and the seatbelt use specified bolts and ensure to apply thespecified torque. For torque specifications contactyour local Ford dealer or the Vehicle ConverterAdvisory Service at [email protected]

5.8.1 Van

CAUTION: Do not install seats in the rearcargo area of a van.

5.8.2 Windowed Van

The body and floor of a windowed van are notequipped with the appropriate reinforcementsrequired for Original Equipment Manufacturers(OEM) rear seats and seat belt systems. Do notinstall original rear seats or rear seat belts.

For installation of non OEM rear seats, the rearseats and seat belt systems need to comply withthe relevant legal requirements and ECE directivesor ADR 3,4,5 or applicable local legislation.Refer to: 3.6 Exhaust System (page 56).Vehicle Exhaust Systems - Vans with Bulkheads.

5.8.3 Heated Seats

WARNING: The electrical feed for theoriginal heated Ford seat must not beused for other purposes, e.g. otherelectrical consumers.

It is not advisable to retrofit heated seats due topotential airbag operation or malfunction(incorrect configuration).

5.8.4 Rear Seat Fixing Positions

The following figure shows the second and thirdrow seat fixing positions in the floor. Thesepositions are independent of the wheelbase.


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Kombi Van - Rear Seat Fixing Positions (Left Hand Drive Shown)

FG

H

2

D

C

E

1

B

A

J

K

L

ME145405


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Kombi Van - Rear Seat Seat Fixing Positions

Third RowSecond RowItemFront Axle1Center line of vehicle2

-937A-758B-538C-433D13021302E378378F9090G12321232H1291J1395-K1658-L1794-M

Right Hand Drive symmetrically opposite about center line of vehicle.

Double Cab in Van (DCIV) - Rear Seat Fixing Locations (Left Hand Side Shown)

E

2

B

D

C

1 A

E151752

DCIV - Rear Seat Fixing Locations

Triple Seat - Second RowItemFront Axle1Center line of vehicle2937A280B1302C520.5D377.5E

Righ Hand Side symmetrically opposite


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5.9 Glass, Frames and Mechanisms

5.9.1 Heated Windshield and HeatedRear Window

WARNING: The base system should notbe tampered with (controlled by bodycontrol module and multiplexarchitecture) and no feeds taken from theassociated wiring or controller.

These options are not suitable for aftermarket orVehicle Converter fit.NOTE: For further information please contact yourlocal National Sales Company representative, orLocal Ford Dealer. If they are unable to help youthen please contact the Vehicle Converter AdvisoryService at [email protected]

5.9.2 Rear Windows

For windows, it is recommended to specify thebase vehicle as a Kombi or Bus body - however,when converting a van, the following should beadhered to:• Cut the outer panel of the body side and door

to within 1mm of the inner panel flange.• Do not cut across panel joints or pillars.• Use approved glass for installation according

to legal requirements.WARNING: For rear seat installation

Refer to: 5.8 Seats (page 195).

A B

E145406

C D

For wheel base and overall vehicle height keydimensionsRefer to: 1.1 About This Manual (page 6).


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Section Through Typical Van Body Side for Window Engineering

E146620

B

A

4

4

1

1

2

2

14

1

3

22

4

DescriptionItemHorizontal Section Through 'C' PillarAVertical Section Through Side Window (Non Side Load Door)BGlass1Adhesive2Cut within 0 and 1.5mm of inner body panel flange edge all around3Window trim strip4


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5.10 Airbag Supplemental Restraint System (SRS)

5.10.1 Airbags

Front Airbag Deployment Zones

WARNING: Do not place accessories inthe deployment zone of the driver andpassenger airbags as they may impairairbag deployment.

NOTE: Front passenger airbag includes beltminder function.

E145410

Side and Curtain Airbag DeploymentZones

WARNING: Do not place accessories inthe deployment zone of the side andcurtain airbags as they may impair airbagdeployment.

NOTE: It is recommended to specify a base vehiclewithout airbags if planning modifications in thisarea.NOTE: All M1 Buses are specified with side andcurtain airbags as standard fitment.

Side Airbags (Seat Mounted):The side airbagson this vehicle have not been validated for use withswivelling front seats. Do not specify a base vehiclewith side airbags if planning to retrofit a swivellingdevice on the front seats and/or an armrest on theouter side of the front seats; this may affect thefunction and/or deployment of the side airbags.Ensure any seat covers installed are designed tobe used with side airbag equipped seats.Curtain Airbags:Extensive modifications to theroof and headlining may impair deployment of thecurtain airbags. If roof or headlining is to bemodified or replaced, do not specify curtain airbagson the base vehicle.If access to the roof is required, to install roofmounted exterior accessories for example, ensurethe unmodified headlining is refitted using theexisting mounting points.


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E146251

Restraints Control Module (RCM)

The RCM is located between the front seats ,underneath the parking brake console, see figureE145413.

WARNINGS:Modifications or reinforcements in thearea of the RCM may affect the sideairbag deployment timing and result inuncontrolled side airbag deployment.The RCM device is protected by theparking brake and console to preventdamage from occupants when steppingpast the seat to access the rear of thevehicle. The parking brake and consoleshould be maintained in their fittedposition to ensure protection for theRCM.

Restraints Control Module (RCM)

E145413

Front and Side Sensors

The airbag sensor for the front airbags is locatedbehind the front grille, see figure E145411.The sensors for the side airbags are located at thebottom of the B-pillars, see figure E145412.

WARNINGS:Modifications or reinforcements in thearea of the sensors may affect the sideairbags deployment timing and result inuncontrolled side airbag deployment.Drilling or grinding operations in thesearea are only permitted when batterycables are disconnected.

If the battery is disconnectedRefer to: 4.4 Battery and Cables (page 93).Battery and Monitoring Sensor section forreconnecting battery.


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Front Sensor

E145411

Side Sensor

E145412


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5.11 Seatbelt Systems

5.11.1 Seat Belts

WARNING: Follow removal andinstallation procedures for the seat beltsystem to ensure correct function of therestraints system.

The removal and reinstallation of the seat belt,buckle or any component of the seat belt systemshould be avoided. However if removal andre-installation of the system is required during theconversion, follow the removal and installationguidelines of the seat belt system as described inthe workshop manual. Please consult your localNational Sales Company representative for furtherinformation.When removing the seat belt system, a seat beltwebbing forked retainer should be applied to thewebbing 200mm below the webbing button stop.This prevents a situation where all the webbingruns back into the retractor and the retractorbecomes locked.When reinstalling, fit the retractor to the body firstand gently pull the webbing out of the retractorto allow fitment of the D loop. Then remove theforked retainer. If the retractor is locked, allow asmall amount of webbing to reel back into theretractor to allow the webbing lock to release. Donot attempt to release the retractor by pulling onthe webbing with significant force or by manuallyinterfering with the locking mechanism.

5.11.2 Driver Belt Minder

Driver belt minder is a legal requirement for an M1vehicle. A switch is provided in the driver's buckleto sense the seat belt wearing status of the driver.If an M1 vehicle is modified, this function must beretained.Belt minder is included with the front passengerairbag.


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5.12 Roof

5.12.1 Roof Ventilation

Sun Roof Retrofit Option

1

E145407

DescriptionItemLocal form in Roof Panel (Low Roof Only)1

General - It is not recommended for apertures tocut through roof bows, see figure E145407.Ventilators must prevent direct entry of water anddust. A shut-off system should be available toprevent fume ingress. Interior and exteriorprojection legal requirements must be maintained.In case a roof bow is cut or removed, it must bereplaced by an appropriate structure providing theequivalent structural integrity and functionality asthe original structure. Any legal requirements mustbe maintained.Ventilation Units -The roof panel can supportup to 1kg on an unsupported area of roof. Loads,up to a maximum of 25kg must be distributed over2 - roof bows.Air Conditioning Units - Units weighing morethan 25kg must be internally supported on crossbrace members distributing the load out to theroof rails.

5.12.2 Roof Racks

H1 Roof Height

E145408

1

DescriptionItemRoof Rack Supports, 3 attachments each side. Positions depend on wheel base.1

WARNING: When installing a roof rack orany other accessory the fixing points needto be sealed for preventing water ingressinto the interior of the vehicle.

NOTE: Refer to the Owner's Manual for maximumroof load, including roof rack.NOTE: Read and follow the manufacturer'sinstructions when fitting a roof rack.


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NOTE: Maximum roof rack length for H1 roofheight vehicles should consider liftgate in fullyopened position.NOTE: Vehicles with H2 roof height do not havereinforcement bolts in the roof. It is recommendedto use Roof Rack Mounting KitAMBK21-V46002-AC, which contains the fittinginstructions.Roof racks may be fitted to all van, bus and kombivariants as illustrated in figure E145408, providingthe following is satisfied:• The carried load does not exceed the

recommended weight stated in the Owner'sManual.

• The load is evenly distributed (converter toensure Owner’s information book identifies thislimitation).

• The load of a single attachment under worstcase loading, must not exceed 75kg.

• The roof rack should be fixed to the roof usingone or two M8 bolt/s per attachment as shownin figure E145408.

• It is recommended that the rack leading edgeshould not be located forward of the rear edgeof the driver’s door, or “B” pillar.


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5.13 Corrosion Prevention

5.13.1 General

Avoid drilling into closed frame body members toavoid the risk of corrosion from swarf.If drilling is required, however:• Re-paint metal edges and protect against

corrosion after cutting or drilling operations.• Endeavor to remove all swarf from inside the

side member and treat to prevent corrosion.• Apply corrosion protection inside and outside

of the chassis frame.For Welding:Refer to: 5.1 Body (page 174).

5.13.2 Repairing Damaged Paint

After cutting or reworking any sheet metal on thevehicle the damaged paint must be repaired.Ensure all materials are compatible with therelevant Ford specifications and maintain theoriginal performance where possible. Forspecifications consult the Vehicle ConverterAdvisory Service [email protected]

5.13.3 Under Body Protection andMaterial

WARNING: Do not over-coat orcontaminate surfaces of componentssuch as brakes or catalytic converters.

Ensure all materials are compatible with therelevant Ford specifications and maintain theoriginal performance where possible.Some proprietary products affect the originalcoatings. For specifications of corrosion protectionmaterials, please consult your local National SalesCompany representative or the Vehicle ConverterAdvisory Service [email protected]

5.13.4 Painting Road Wheels

WARNING: Do not paint wheel clampsurfaces in contact with other wheels,brake drum or disc, hub and holes orsurface under wheel nuts. Any furthertreatment in these areas may affect thewheel clamp performance and the vehiclesafety. Mask the wheel when changingthe color or repairing paint.

5.13.5 Contact Corrosion

When using different materials with a differentelectrochemical potential, ensure that materialsare isolated from each other to prevent contactcorrosion caused by a potential difference.Use appropriate isolation materials. Wherepossible, choose materials with low level ofelectrochemical potential difference.


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5.14 Frame and Body Mounting

5.14.1 Mounting Points and Tubing

Holes on frame are a result of the productionprocess. They are not designed for fixingadditional equipment. If additional fixings to thechassis frame are required please follow therecommendation given in figure E148689. Thisdoes not apply to areas of load applications suchas spring fixings or damper fixings.

NOTE: After drilling, deburr and countersink allholes and remove chips from the frame. Followcorrosion prevention.Refer to: 5.13 Corrosion Prevention (page 206).

Frame Drilling and Tube Reinforcing

E148689

E

3

2

3

2 11

A

B

C

D

X

X

DescriptionItemDescriptionItemDiameter 16.5mm maximumBFull Penetration, Full diameter weld

each side1

Diameter 11mmCCenter line of holes/tubing230mm to 35mmDCenter line of holes/tubing350mm minimumE30mm to 35mmA

5.14.2 Frame Drilling and TubeReinforcing

The chassis frame may be drilled and reinforcingspacer tubes may be welded in place, providingthe following is applied:• Adhere to all details shown in figure E148689.• Drill and weld only side walls of the chassis

frame.• Locate and drill holes accurately, using a drill

guide to ensure holes are square to framevertical center line (allow for side memberdraft angle).

• Drill undersize and ream out to size.• Endeavor to remove all swarf from inside side

member, and treat to prevent corrosion.• Fully weld each end of the tube and grind flat

and square, in groups if applicable. Be awareof side member draft angle.

• Apply corrosion protection inside and outsideof the chassis frame.Refer to: 5.13 Corrosion Prevention (page 206).

• Holes should be in groups of two, eithervertically spaced at 30 to 35mm from chassisframe top and/or bottom surface, orhorizontally at 50mm minimum pitch, 30 to35mm from top and/or bottom chassis framesurface, please refer to figure E148689.

• Always use M10 bolts with grade 8.8 minimum.• Do not position tubes at the medium chassis

frame height, this may create “oil canning” ofthe deep section side walls.

• A diameter of 16.5mm is the maximumallowable hole size in the chassis frame sidewall, irrespective of the usage.

Avoid drilling into closed frame body members toavoid the risk of corrosion from swarf.Refer to: 5.13 Corrosion Prevention (page 206).


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Drilling and welding of frames and body structurehave to be conducted following the guidelines.Please consult the Vehicle Converter AdvisoryService [email protected] for details.Refer to: 5.1 Body (page 174).Welding.

5.14.3 Area for Fitting Additional BodyAttachments to the Rear of theBumper

NOTE: With the vehicle on level ground and withall measurements taken rear ward of the bumperbar edge. The area designated for the fitting ofattachment is defined as 220mm horizontally by95mm vertical downward to the road surface, witha max width of 1390mm about vehicle center line.It is not the manufactures recommendation to fitadditional body attachments (tow bars, steps,bicycle racks and carriers) outside of thedesignated area.

5.14.4 Water Tank on Camper Vehicles

NOTE: It is recommended that a decal or label isfitted adjacent to the filler aperture identifying thecorrect fluid to be used, for example: 'Water only'for water tanks.


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AAbout This Manual.........................................................6Accessory Drive.............................................................52Adaptive Cruise Control...........................................130Adding Connectors.....................................................170Additional External Lamps.....................................128Additional Internal Lamps......................................129Additional Loads and Charging Systems...........101Additional Rear Speakers........................................125Additional 'Theater Lighting' for rear of vehicle

interior...........................................................................129Additional Vehicle Signals/Features...................137Aids for Vehicle Entry and Exit.................................27Airbags..........................................................................200Airbag Supplemental Restraint System

(SRS)..........................................................................200Air Flow Restrictions.....................................................51Alternative Type Approval...........................................9Anti-Lock Control — Stability Assist.....................45Area for Fitting Additional Body Attachments

to the Rear of the Bumper...................................208Audio Head Unit (AHU) - Multimedia In Car

Entertainment (ICE) Pack Summary.................121Auto Wipe and Auto Lamp for vehicles with large

overhangs.....................................................................141Auxiliary Fuse Panel (A526)...................................147Auxiliary Heater Installation......................................51Auxiliary Heater Systems..........................................50Auxiliary Switches.......................................................157

BBattery and Cables......................................................93Battery Configuration, Additional Loads,

Start-Stop and Smart Regenerative Charging(SRC)..............................................................................97

Battery Configurations...............................................97Battery Information.....................................................93Battery Monitoring Sensor (BMS).......................103Battery Rules..................................................................97Beacon Preparation Pack (A606).......................153Body.................................................................................174Body Closures..............................................................190Body Control Module (BCM)....................................77Body Structures - General Information..............174Body System - General

Information—Specifications................................186Boron Steel Parts........................................................176Brake Hoses General..................................................45Brake System.................................................................45

CCamper Central Connectors...................................143CAN-Bus System Description and Interface......75Cellular Phone..............................................................127Center of Gravity Height Calculation....................36Center of Gravity Height Test Procedure.............34Center of Gravity Position.........................................34Central Locking.............................................................131Changing Vehicle Speed Maximum Setting.....120Charge Balance Guidelines......................................92Charging System...........................................................81Circuit Diagrams...........................................................92Climate Control System.............................................111Clutch...............................................................................54Commercial and Legal Aspects................................8Communications Network........................................75

Connector Pin Out Practices....................................61Connectors....................................................................142Contact Corrosion.....................................................206Contact Information......................................................11Conversion Affect on Fuel Economy and

Performance................................................................22Conversion Affects on Parking Aids.......................27Conversion Homologation.........................................19Conversion Type............................................................15Conversion Type - Reference Tables......................15Corrosion Prevention...............................................206Cruise Control..............................................................130Customer Connection Points (CCP)...................142

DDiesel Particulate Filter (DPF).................................57Door Removal or Modification................................131DPF and RPM Speed Control................................120Drilling and Welding.....................................................10Driver Belt Minder......................................................203Driver Field of View.......................................................27Driver Reach Zones......................................................27

EElectrical Connectors and Connections.............142Electrical Conversions................................................90Electrically Operated Door Mirrors.......................128Electrics for Tow Bar.....................................................71Electromagnetic Compatibility (EMC)

Awareness....................................................................64Electromagnetic Compatibility (EMC)................20Electronic Engine Controls.......................................114Engine Cooling..............................................................50Engine...............................................................................46Engine Power Curves..................................................46Engine RPM (Revs Per Minute) Speed Controller

(A003)..........................................................................116Engine Selection for Conversions..........................46Exhaust Heat Shields.................................................56Exhaust Pipes and Supports...................................56Exhaust System............................................................56Extensions and Optional Exhausts.......................56Exterior Lighting..........................................................128

FFitting Equipment Containing Electric

Motors............................................................................92Floor 'No Drill Zones' under the Floor Fuel

Tank................................................................................177Formulas..........................................................................36Frame and Body Mounting.....................................207Frame Drilling and Tube Reinforcing..................207Front, Rear and Side Under-run Protection........27Front End Accessory Drives — General

Information...................................................................52Front End Body Panels.............................................188Front End Integrity for Cooling, Crash,

Aerodynamics and Lighting..................................178Front Suspension.........................................................42Fuel System...................................................................58Fuses and Relays........................................................134Fuses...............................................................................134

GGeneral..................................................................45, 206

Index

209

General Component Package Guidelines............27General Information and Specific Warnings........81General....................................................................45, 206General Product Safety Requirement......................9General Wiring and Routing.......................................61Generator and Alternator..........................................107Glass, Frames and Mechanisms............................198Grounding.................................................................62, 171Ground Points.................................................................171

HHandles, Locks, Latches and Entry Systems......131Hardware—Specifications.........................................33Heated Seats.................................................................195Heated Windshield and Heated Rear

Window.........................................................................198High Current Supply and Ground

Connections..................................................................93High Specification Vehicle Interface Connector

(A608)..........................................................................160Horn....................................................................................113How to Use This Manual...............................................6Hydraulic Brake—Front and Rear Brakes.............45Hydraulic Lifting Equipment....................................179Hydraulic Lifting Equipment for Van, Bus and

Kombi.............................................................................179

IImportant Safety Instructions.....................................6Information and Entertainment System - General

Information—Specifications...................................121Instrument Panel Cluster (IPC)...............................112Interior Lighting.............................................................129Interior Trim....................................................................194Introduction.......................................................................6

JJacking...............................................................................23

KKerb Mass Data..............................................................45

LLamps – Front and Rear Fog...................................128Lamps – Hazard / Direction Indication...............128Legal and Vehicle Type Approval..............................8Legal Obligations and Liabilities................................9Lifting.................................................................................24Load Compartment Interior Lining.......................194Load Compartment Tie Downs for Van, Bus and

Kombi............................................................................186Load Distribution...........................................................34

MManual Transmission...................................................55Mid-Radio and Mid-Radio with DAB....................123Minimum Requirements for Brake System..........10Mounting Points and Tubing...................................207MyConnection Radio and MyConnection Radio

with DAB........................................................................122

NNew for this Body and Equipment Mounting

Manual (BEMM) Publication 04/2017..................6No Drill Zones — Rear Cargo Area..........................66Noise, Vibration and Harshness (NVH)................25

PPackage and Ergonomics...........................................27Painting Road Wheels.......................................44, 206Parking Brake..................................................................45Partitions (Bulkhead) - Driver and Front

Passenger(s) Protection on Van, Bus andKombi............................................................................188

Permitted Antenna Location......................................21Plywood Lining/Cladding.........................................194Power and Connectivity Usage

Recommendations...................................................106Power Management Settings..................................89Prevention of Squeaks and Rattles........................62Product Liability...............................................................9

RRacking Systems..........................................................182Rear Seat Fixing Positions........................................195Rear Suspension............................................................43Rear Windows...............................................................198Recommended Main Load Area Dimensions.....29Relays...............................................................................135Remote Keyless Entry/Tire Pressure Monitoring

System Receiver (RKE/TPMS Receiver)..........132Repairing Damaged Paint.......................................206Restraints System............................................................9Reversing Lamps..........................................................128Road Safety......................................................................10Roof Racks....................................................................204Roof.................................................................................204Roof Ventilation..........................................................204

SSeat Belts......................................................................203Seatbelt Systems.......................................................203Seats.................................................................................195Security, Anti Theft and Locking System...........190Single and Twin Battery Systems.........................104Spare Wheel...................................................................44Special Conversions....................................................137Special Vehicle Options (SVO) Harnesses and

Aftermarket Kits.........................................................137Special Vehicle Option (SVO) Order Codes.........15Springs and Spring Mounting............................42, 43Start-Stop.......................................................................114Start-Stop Override and Configurable

Charging.........................................................................84Supplemental Information...........................................7Suspension System.......................................................41System Operation and Component

Description....................................................................82

TTemporary Mobility Kit................................................44Terminology.......................................................................8Tire Manufacturers.......................................................44Tire Pressure Monitoring System (TPMS)...........44Tow Bar Requirements................................................38

Inde

x

210

Tow Bar Types...............................................................38Towing..............................................................................38Trailer Tow Connectivity.............................................74

UUnder Body Protection and Material.................206Unused Connectors.....................................................62Utility Vehicle Switch Pack (A607)......................155

VVan...................................................................................195Vehicle Dimensions Key.............................................28Vehicle Duty Cycle Guidelines..................................22Vehicle Electrical Capacity — Alternator.............92Vehicle Exhaust Systems — Vans with

Bulkheads......................................................................57Vehicle Interface Connector...................................146Vehicle Ride and Handling Attributes...................22Vehicle Transportation Aids and Vehicle

Storage..........................................................................26

WWarnings, Cautions and Notes in This

Manual..............................................................................6Warranty on Ford Vehicles..........................................8Water Leakage Prevention........................................62Water Tank on Camper Vehicles.........................208Welding...........................................................................174Wheel Clearance..........................................................44Wheels and Tires.........................................................44Whole Vehicle Type Approval....................................8Windowed Van............................................................195Windscreen Wipers....................................................136Wiring Harness Information......................................61Wiring Installation and Routing Guides................61Wiring Specification....................................................63Wiring Splicing Procedures.......................................62Wiring Through Sheet Metal....................................65

Index

211

Body and Equipment Mounting Manual - Ford México€¦ · 1.1 About This Manual 1.1.1 New for this...

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Transcript of Body and Equipment Mounting Manual - Ford México€¦ · 1.1 About This Manual 1.1.1 New for this...