Table of Contents
Advertisement
4.1 Wiring Installation and Routing Guides
4.1.1 Wiring Harness Information
NOTE: Ford Motor Company has no control over
the modification or installation process of the
electrical content of auxiliary systems and
therefore can take no responsibility for such
installations.
The following provides an installation guide for
any electrical modifications or additional systems
being added to the vehicle. The aim is to maintain
robust integration of auxiliary systems without
compromising existing systems, in areas such as
splicing techniques into existing wiring, module
package location and EMC issues. It is also
expected that the vehicle converter will test their
installation and comply to all legal and
homologation requirements.
4.1.2 General Wiring and Routing
Temperature requirements: Wiring systems in the
vehicle interior are expected to function over the
temperature ranges of – 40°C to 85 °C for
exposure and – 40°C to 75°C for function. For
engine compartment and underbody, the
minimum temperature is - 40°C, while the
maximum exposure and operational temperatures
are +125°C for exposure and 105°C for
operational.
Make sure that the insulation is compatible with
any fluids it may encounter , for example: gasoline,
oil, antifreeze, brake fluid, transmission fluid and
power steering fluid.
If a connector will be located in a hostile
environment or wet area use a sealed connector.
'Hostile environment' areas include the engine
compartment, wheel wells, underbody and doors.
Do not route wires near weld points or weld
flashes. A minimum of 15mm clearance to any
sheet metal welds under static and dynamic
conditions is required. However, it is best to avoid
routing near weld points or weld flashes at all
times.
In general, the distance between retention points
for wiring not contained in a rigid shield should be
less than 300mm.
A minimum 25mm clearance is recommended
from all sharp edges and a minimum 35mm
clearance of all moving parts of the parking brake
assembly. If these clearances cannot be met,
protect the wires with a convolute.
For conversions with walkthroughs, it is
recommended to provide appropriate protection
on the floor in the walkway.
EU
FORD TRANSIT 2016.75
4.1.3 Connector Pin Out Practices
When designing a harness to component
connection, it is best practice to put the female
terminals in the harness side connection and the
male terminals in the component side. When
determining connector pin outs, make sure that
power and ground circuits are not in close
proximity, adjacent, to one another. A minimum
separation of 5 mm between power and ground
circuits is required.
WARNING: Do not use connectors which
cut through the outer covering and into
the core wire.
CAUTION: Only use Ford approved
connectors
Cutting into vehicle wiring is not permitted
because:
• The base vehicle specification is unsuitable for
incremental loads except in conjunction with
Special Vehicle Option Auxiliary Fuse Panel.
• Long term risk of a faulty connection
developing.
• Potential fire risk from over-loading.
All connections into existing wiring must be
permanently insulated. Exterior connections must
be water-proof.
When designing electrical circuits, or making
alterations, 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 to
below 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 added
to the Owner's information or a separate
manual supplied with the vehicle for each
unique component.
NOTE: For further information please contact
your local National Sales Company representative,
or local Ford Dealer.
Where wires are required to be extended, break
in points and only Ford approved connectors
should be used.
Ford approved jumper harnesses should be used.
Date of Publication: 03/2018
85
Advertisement
Table of Contents
