2006 FORD TRANSIT air conditioning

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

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
79E742191234567

Recommended Engine Run Connection Circuit and Special Vehicle Option Auxiliary
Fuse Box
DescriptionItem
Special Vehicle Option Auxiliary Fuse Box1
Power Mini Relay2
Micro Relay3
Central Junction Box (C4-7 = Engine Run Pin) via Jumper Harness 6C1V-14A411-F_4
Ground Point/Earth Terminal(GP15)5
Connector - Customer UseC1
Connector - to Switch Harness (6C1V-14A303)C2
Connector - To Beacon Harness (6C1V-10A993)C3
Connector - Breakout to Heating, Ventilation and Air Conditioning Harness (6C1T-18B518)C4
Connector - Breakout to Instrument Panel Harness (6C1T-14K024)C5
Connector - To Engine Run Jumper Harness (6C1V-14A411-F_)C6
Connector - To Customer Connection Points via In-line Harness (6C1V-14300-C_)C7
The configuration of the Auxiliary Fuse Box is
hard wired (as shown in Figure E75088) Auxiliary
devices should be connected via the 16-way
connector C1. Most fuse / relay configurations
are available to meet particular requirements.
A maximum of 60 A is permitted per power feed,
with maximum individual fused circuits of up to
20 A.
There are 10 possible fuse locations in the fuse
box. Please refer to the following table (Fuse
Location), which shows how the fuses are
divided between the two power feeds.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
4 Electrical
123E75088

Fuse Location
Power Feed 2 (Maximum
60A)
Power Feed 1 (Maximum
60A)
Fuse Position
X*1
X*2
X*3
X4
X5
X6
X7
X8
X9
X10
The total sum of fuses marked * is not to exceed 40A
The Special Vehicle Option Auxiliary Fuse Box,
with integrated link harness, will provide the
following connections:
•– Ground
•– Battery +
•– Ignition
•– Engine run
•– Switched interior illumination
The fuse box is connected to the vehicle main
battery(s) but when the deep cycle battery is
installed it is always connected to the deep cycle
battery.
4.13.5 Additional Ignition,
Instrument Panel Illumination and
Air Conditioning On Signals
Access to these feeds can be obtained via a
jumper harness (6C1V-14A411-*) that fits into the
8-pin in-line connector between the instrument
panel (14K024) and heater (18B518) harnesses
located behind the glove-box. This jumper will
provide the following signals through three, single
6.3mm colour-coded connectors, please refer
to Fig. E75089 Heater jumper for illumination,
ignition and air conditioning on access.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
4 Electrical
124

8 Pin Connector - for Ignition, Instrument Panel Illumination and Air Conditioning
On Signals
DescriptionItem
KL15 (12V ignition feed)Pin 4
Used instead of Pin 4 on vehicles euipped with Air Conditioning)Pin 7
Instrument Panel Illumination (12V feed)Pin 6
Air Conditioning On (12V)*Pin 5
It is recommended that these signals are used
to energize relays, or any other device, as long
as the maximum current does not exceed
300mA per function, or 600mA (suitable for
powering two relays) for the ignition feed.
NOTE: *There is NO direct provision for an air
conditioning on signal. When the air-conditioning
is switched on, 12V is applied to the defrost
compressor switch and the Air conditioning low
speed blower relay (both integral to the heating
ventilation and air conditioning unit and 18B518
wiring), and the Air conditioning cycling switch
(in the engine bay as part of the 9K499 wiring
[via the 14401 and 14K024 harnesses]). Additional
load on this line is limited, so air conditioning on
is only available as a signal (300mA) for voltage
sensing or powering of a relay – powering
another device directly is Not recommended.
Where additional current is required from either
output, a standard relay should be used, please
refer to Relay Figures E75017-E75021.
The Special Vehicle Option Auxiliary Fuse Box is
recommended as the most suitable power
source for these relays. Please consult your local
National Sales Company representative for
availability.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
4 Electrical
1254E84713765

Heater Jumper for Ignition, Instrument Panel Illumination and Air Conditioning On
Signals - Early Installation
DescriptionItem
Ignition, Instrument Panel Illumination and Air Conditioning On Signals1
C4 - Connection to Heating, Ventilation and Air Conditioning Harness (18B518)2
C5 - Connection to Instrument Panel Harness (14K024)3
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
4 Electrical
126E75089123

Heater Jumper for Ignition, Instrument Panel Illumination and Air Conditioning On
Signals - Later Installation
DescriptionItem
Ignition, Instrument Panel Illumination and Air Conditioning On Signals1
C4 - Connection to Heating, Ventilation and Air Conditioning Harness (18B518)2
C5 - Connection to Instrument Panel Harness (14K024)3
4.13.6 Relays and Switches
Relays
Single pole relays must be used under the
conditions:
•Single pole, 2-way (change over) is used to
switch from one circuit to another please refer
to Relay Figures E75017-E75021 for typical
relay circuit diagrams.
•Relays can be installed inside the vehicle or
inside the Special Vehicle Option Auxiliary Fuse
Box.
•The Ford standard relays have a nominal
current of 300mA (max) at 25°C. Relays with
greater loads should not be used.
•For maximum switching currents please refer
to Relay Figures E75017-E75021.
Micro Relay
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
4 Electrical
127E88306123 E750171425312354