2006 FORD TRANSIT air condition

3.7Exhaust System..........................86
3.7.1Extensions and Optional Exhausts....
86
3.7.2Exhaust Pipes and Supports.............86
3.7.3Exhaust Heat Shields..........................86
3.8Fuel System.................................88
4 Electrical
4.1Communications Network..........90
4.1.1CAN-Bus System Description and
Interface................................................90
4.1.2Central Junction Box (CJB)................91
4.1.3Circuit Diagram....................................93
4.2Module Communications
Network—Specifications.............94
4.2.1Circit Diagram......................................94
4.3Charging System.........................95
4.3.1General Information and Specific
Warnings...............................................95
4.3.2Power Management Settings...........95
4.3.3Electrical Conversions........................95
4.3.4Fitting of Equipment Containing an
Electric Motor.......................................97
4.3.5Vehicle Electrical Capacity -
Alternator..............................................97
4.3.6Charge Balance Guidelines...............97
4.3.7Circuit Diagrams..................................97
4.4Battery and Cables.....................98
4.4.1Battery Information.............................98
4.4.2Generator and Alternator.................103
4.5Climate Control System.............106
4.6Instrument Cluster.....................107
4.7Horn...........................................108
4.8Tachograph................................109
4.8.1Legislation...........................................109
4.8.2Tachograph Mounting.......................110
4.9Information and Entertainment
System - General
Information—Specifications.......112
4.9.1Radio Connector................................112
4.9.2Possible Accessories.........................113
4.10Cellular Phone............................115
4.11Exterior Lighting.........................116
4.11.1Reversing Lamps...............................116
4.11.2Additional External Lamps................116
4.11.3Lamps – Hazard / Direction
Indication..............................................117
4.11.4Lamps – Front and Rear Fog Lights....
117
4.11.5Lamps for Wide Vehicles...................117
4.11.6Electrically operated Door Mirrors....
117
4.12Interior Lighting..........................118
4.12.1Additional Internal Lamps .................118
4.12.2Additional 'Theatre Lighting' for rear
of vehicle interior................................118
4.13Fuses and Relays.......................119
4.13.1Wiring Specification............................119
4.13.2Auxiliary Fuses, Fuse Box and Relays
(Fuses - Standard).............................119
4.13.3Customer Connection Points..........120
4.13.4Special Vehicle Option Auxiliary Fuse
Box........................................................121
4.13.5Additional Ignition, Instrument Panel
Illumination and Air Conditioning On
Signals.................................................124
4.13.6Relays and Switches.........................127
4.13.7Windscreen wipers...........................130
4.14Special Conversions..................131
4.14.1Vehicle Speed Output (Signal).........131
4.14.2Engine Run Signal (D+ Alternative)....
132
4.14.3Connectors.........................................133
4.14.4Installation and Routing Guides.......134
4.14.5Electrics for Tow bar.........................136
4.14.6Ground Points....................................140
4.14.7Special Vehicle Options (SVO) and
Aftermarket Kits.................................146
4.14.8Additional Vehicle Signals / Features..
147
4.14.9Engine RPM (Revs Per Minute) Speed
Controller.............................................157
4.14.10Adding Connectors, Terminals and
Wiring...................................................162
5 Body and Paint
5.1Body...........................................175
5.1.1Body Structures - General
Information..........................................175
5.1.2Back Panel Removal.........................177
5.1.3Integrated Bodies and Conversions...
177
5.1.4Chassis Cab........................................179
5.1.5Cab Van Floor.....................................185
5.1.6Hydraulic Lifting Equipment for Van,
Bus, Kombi and Chassis Cab..........186
5.1.7Partitions (Bulkhead) - Driver and
Front Passenger(s) Protection on Van,
Bus and Kombi..................................192
5.1.8Racking Systems...............................194
5.1.9Front End Integrity for Cooling, Crash,
Aerodynamics and Lighting.............198
5.1.10Tipper Bodies.....................................199
5.1.11Tank and Dry Bulk Carriers...............199
5.2Body System - General
Information—Specifications......200
5.2.1Van Floor - Load Compartment Tie
Downs for Van ,Bus and Kombi.....200
5.3Body Closures..........................203
5.3.1Load Compartment Interior Lining....
203
5.3.2Security, Anti Theft and Locking
System Security ...............................203
5.4Rear View Mirrors.....................208
5.4.1Mirrors for Wide Vehicles.................208
5.5Seats.........................................209
5.5.1Rear Seat Fixings Positions - Kombi...
209
5.5.2Heated Seats.....................................210
5.6Glass, Frames and Mechanisms...
211
5.6.1Rear Windows....................................211
Table of Contents
4

1.1 About This Manual
1.1.1 Introduction
This manual has been written in a format that is
designed to meet the needs of Vehicle
Converters. The objective is to use common
formats with the workshop manual which is used
by technicians worldwide.
This guide is published by Ford and provides
general descriptions and advice for converting
vehicles.
It must be emphasized that any change to the
basic vehicle which does not meet the enclosed
guideline standards may severely inhibit the ability
of the vehicle to perform its function. Mechanical
failures, structure failure, component unreliability
or vehicle instability will lead to customer
dissatisfaction. Appropriate design and application
of body, equipment and or accessories is key to
ensuring that customer satisfaction is not
adversely affected.
The information contained within this publication
takes the form of recommendations to be
followed when vehicle modifications are
undertaken. It must be remembered that certain
modifications may invalidate legal approvals and
application for re-certification may be necessary.
Ford cannot guarantee the operation of the
vehicle if non-Ford -approved electrical systems
are installed. Ford electrical systems are designed
and tested to function under operational
extremes, and have been subjected to the
equivalent of ten years of driving under such
conditions
1.1.2 Important Safety Instructions
Appropriate conversion procedures are essential
for the safe, reliable operation of all vehicles as
well as the personal safety of the individual
carrying out the work.
This manual cannot possibly anticipate all such
variations and provide advice or cautions as to
each. Anyone who departs from the instructions
provide in this manual must first establish that he
compromises neither his personal safety nor the
vehicle integrity by his choice of methods, tools
or components.
1.1.3 Warnings, Cautions and
Notes in This Manual
WARNING: Warnings are used to
indicate that failure to follow a
procedure correctly may result in
personal injury.
CAUTION: Cautions are used to
indicate that failure to follow a
procedure correctly may result in
damage to the vehicle or equipment
being used.
NOTE: Notes are used to provide additional
essential information required to carry out a
complete and satisfactory repair
As you read through this manual, you will come
across WARNINGS, CAUTIONS and NOTES.
A warning, caution or note is placed at the
beginning of a series of steps if it applies to
multiple steps. If the warning, caution or note only
applies to one step, it is placed at the beginning
of the specific step (after the step number).
1.1.4 How to Use This Manual
This manual covers vehicle conversion
procedures.
The pages at the start of this manual list the
content, by group. A group covers a specific
portion of the vehicle. The manual is divided into
five groups, General Information, Chassis,
Powertrain, Electrical and Body. The number of
the group is the first number of a section number.
Each title listed in the contents links to the relevant
section of the manual.
In some section of the book it may refer you to
see additional sections for information, links have
been provided, these links are in blue text.
This manual is also designed to be used as a
printed document, where there are links page
numbers in brackets have been added, which
will help guide you to the start of the section
which contains the relevant information.
There is also an alphabetical index at the back of
the manual. As with the contents pages you will
be able to link to sections. To do this just click on
the page number.
All left and right-handed references to the vehicle
are taken from a position sitting in the driver seat
looking forward unless otherwise stated.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
6

1.13 Package and Ergonomics
1.13.1 General Component
Package Guidelines
WARNING: Do not modify, drill, cut
or weld any suspension
components, specifically the
steering gear system, subframe or
anti-roll bars, springs or shock
absorbers including mounting
brackets.
The Vehicle Converter has to ensure that
sufficient clearance is maintained under all drive
conditions to moving components such as axles,
fans, steering, brake system etc.
The Vehicle Converter is responsible for all
installed components during the conversion. The
durability has to be confirmed by appropriate test
procedures.
1.13.2 Driver Reach Zones
Controls and/or equipment required to be used
while driving should be located within easy reach
of the driver so as not to impair driver control
1.13.3 Driver Field of View
WARNING: Make sure that the
modified vehicle complies with all
relevant legal requirements.
1.13.4 Conversion Affects on
Parking Aids
WARNING: Ensure that monitors
mounted in the cabin meet the
interior package and safety
requirements
On conversions requiring a rear camera, the
reverse signal may be taken as described in the
electrical section, described in reversing lamps.
Refer to: 4.11 Exterior Lighting (page 116).
1.13.5 Aids for Vehicle Entry and
Exit
Steps
WARNINGS:
Make sure that the modified vehicle
complies with all relevant legal
requirements.
If this modification alters the
homologated dimensions, a new
approval may be necessary.
CAUTION: Make sure that
reinforcements are installed to
maintain the integrity of the original
body structure.
Steps can be ordered as an option on the base
vehicle. Please check for availability.
Where additional steps are installed the required
ground clearance line is to be maintained.
The Vehicle Converter must make sure that a
movable step is set in the stored position when
the vehicle is running. The step surface must be
non-slip.
Grab Handles
WARNING: Make sure that the
location of the no-drill zones are
checked before drilling.
CAUTION: Make sure that
reinforcements are installed to
maintain the integrity of the original
body structure.
Grab handles can be ordered as an option on
the base vehicle. Please check for availability.
NOTE: For further information please contact
your local National Sales Company
representative, or Local Ford Dealer. If they are
unable to help you then please contact the
Vehicle Converter Advisory Service at
[email protected].
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
33

2.4 Wheels and Tires
2.4.1 Wheel Clearance
The distance from the tire to the mudguard or
wheel arch must be sufficient, even if snow or
anti-skid chains are fitted and the suspension is
fully compressed allowing for axle twist as well.
Please consult the Vehicle Converter Advisory
Service [email protected] for clearance
requirements and data.
NOTE: Make sure that only approved wheels
and /or permissible tire sizes are fitted
For standard wheelhouse dimensions.
Refer to: 5.1 Body (page 175).
(Integral Bodies and Conversions)
2.4.2 Tire Manufacturers
Replacement tires should be of the same make,
size, tread pattern and load rating as the Original
Equipment Manufacturer. Under these conditions
the original tire label should be satisfactory,
however if the specified tires and/or inflation
pressures are changed then a new label should
be affixed over the original label.
2.4.3 Spare wheel
When converting or relocating the spare wheel,
access must be ensured.
2.4.4 Painting Road Wheels
CAUTION: Do not paint wheel clamp
surfaces in contact with other
wheels, brake drum or disc, hub and
holes, or surfaces under wheel nuts.
Any further treatment in these areas
may affect the wheel clamp
performance and the vehicle safety.
•Mask the wheel when changing the color or
repairing paint.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
2 Chassis
60

2.6 Brake System
2.6.1 General
The Brake System must be fully functional when
the vehicle conversion is completed. The vehicle
brake operating modes must be checked,
including warning system and parking brakes.
Brakes are certified to 71/320EEC and ECE R13
requirements as amended.
WARNING: Do not restrict the airflow
and cooling to the brake system
CAUTION: Spoilers and wheel covers
must not affect the brake cooling
performance.
NOTE: Do not obstruct the view of the brake
fluid reservoir level
NOTE: The donor vehicle brake fluid reservoir is
translucent so that it is possible to check the level
of fluid without opening the reservoir which will
reduce the risk of contamination.
The brake fluid reservoir must remain accessible
for servicing and for adding brake fluid.
2.6.2 Kerb Mass Data
NOTE: For further information please contact
your local National Sales Company representative,
or Local Ford Dealer. If they are unable to help
you then please contact the Vehicle Converter
Advisory Service at [email protected].
2.6.3 Brake Hoses General
CAUTION: Make sure that the front
and rear brake hoses are not
twisted and are correctly located
away from body and chassis
components.
Front and rear brake hoses must not rub, chafe
or rest on body or chassis components. There
must be clearance under all operating conditions,
between full compression and extension and full
lock to lock.
Brake lines must not be used to support or
secure any other component.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
2 Chassis
62

3.2 Engine Cooling
3.2.1 Auxiliary Heater Systems
WARNINGS:
Ford coolant additives are
necessary for the complete function
of the system. Only use ford
approved or equivalent specification
component, to withstand any
detrimental effects on the materials.
Do not mount components in front
of the grille or in an area of air flow
around the engine, which could
affect the engine cooling.
CAUTIONS:
Only make connections into the
heater hose between the front cab
heater and water pump return inlet.
Do not exceed the vehicle's original
coolant volume by more than 10%
Only use the manufactures
recommended (or equivalent
specification) coolant
additives/anti-freeze. Do not mix
coolant types.
•Coolant flow to cab heater must have priority
over flow to auxiliary heater or hand wash
facility.
•Coolant tube routing must be below the base
of the degas bottle.
•Use aluminum or plastic tee junction with
swaged or beaded ends to prevent hose blow
off. Reconnect original coolant tube as shown
in view E74570 (in this section) with standard
Ford water hose clip or suitable equivalent
specification clip. Ensure interference fit
between hose and 'T' joint.
•Tube routing must be secured to the body
structure or suitable brackets avoiding
electrical components or wires, hot or moving
parts and brake or fuel system components
•Hose must be heat sleeved with appropriate
material if within 100mm of exhaust
components (for example, manifold or
exhaust gas recirculating).
•The vertical clearance between the critical
cooling components (radiator, fan shroud and
radiator brackets) and both the hood inner
and outer (assembly) panels at design position
shall not be less than 15mm.
•There shall be a minimum clearance of 7mm
between the engine assembly and flexible
components (for example, hoses or wiring
harnesses) affixed to front end sheet metal
hardware, under a maximum engine torque
roll condition.
NOTE: For further information please contact
your local National Sales Company
representative, or Local Ford Dealer. If they are
unable to help you then please contact the
Vehicle Converter Advisory service at
[email protected].
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
3 Powertrain
75

3.3 Accessory Drive
When the correct belt is used, tensioning is and
remains fully automatic for the life of the belt.
CAUTIONS:
Only use the manufacturers
recommended (or equivalent
specification) components
Make sure that the ancillary pulley
diameter is less than the crankshaft
pulley diameter.
Systems requiring a unique belt
NOTE: For further information please contact
your local National Sales Company
representative, or Local Ford Dealer. If they are
unable to help you then please contact the
Vehicle Converter Advisory Service at
[email protected].
The eigenfrequency of any bracket including the
auxiliary added should be above the maximum
excitation frequency of the main excitation order
of the individual engine at engine top speed. On
4-cylinder inline engines, this is the second
engine order.
3.3.1 Front End Accessory Drive
2.4l Diesel and 2.3l Petrol
CAUTION: Do not fit an additional
front end accessory drive to a
vehicle already equipped with and
air-conditioning compressor.
When engineering and installing a new front end
accessory drive, i.e. belt drive of the crankshaft
pulley, the longitudinal alignment must be within
+/- 0.25mm and angular within +/- 0.33°.
For most front end accessory drive applications
the longer Regular Production Option air
-conditioning belt can replace the standard belt
and pulley layout.
The maximum power that is available for front
end accessory drive applications, in lieu of the
air conditioning compressor is 26Nm torque at
any engine speed up to a maximum of 6kW.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
3 Powertrain
77

Front End accessory Drive Assembly on 2.3l Petrol Engine
Pulley and Belt Layout on 2.3l Petrol Engine
DescriptionItem
Alternator1
Idler2
Coolant Pump3
Power Steering Pump4
Compressor (may be replaced by ancillary unit)5
Crankshaft Pulley6
Auto Tensioner7
3.3.2 Front End Accessory Drive
2.2l Diesel
CAUTION: Do not fit an additional
front end accessory drive to a
vehicle already equipped with and
air-conditioning compressor.
When engineering and installing a new front end
accessory drive, i.e. belt drive of the crankshaft
pulley, the longitudinal alignment must be within
+/- 0.25mm and angular within +/- 0.33°.
The maximum power that is available for front
end accessory drive applications, in lieu of the
air conditioning compressor is 26Nm torque at
any engine speed up to a maximum of 6kW.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
3 Powertrain
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