Ford TRANSIT CUSTOM 2012.75 Mounting Manual
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Ford TRANSIT CUSTOM 2012.75 Mounting Manual

Body and equipment mounting manual
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Body and Equipment Mounting Manual
FORD TRANSIT CUSTOM 2012.75
Date of Publication: 04/2012

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Summary of Contents for Ford TRANSIT CUSTOM 2012.75

  • Page 1 Body and Equipment Mounting Manual FORD TRANSIT CUSTOM 2012.75 Date of Publication: 04/2012...
  • Page 2 This publication, or part thereof, may not be reproduced nor translated without our approval. Errors and omissions excepted. © Ford Motor Company 2012 All rights reserved.

  • Page 3: Table Of Contents

    Codes..............7 Wheels and Tires.......40 Commercial and Legal Aspects..8 2.4.1 Wheel Clearance........40 1.2.1 Terminology............8 2.4.2 Tire Manufacturers........40 1.2.2 Warranty on Ford Vehicles.......8 2.4.3 Spare Wheel..........40 1.2.3 Legal and Vehicle Type Approval...8 2.4.4 Tire Repair Kit..........40 1.2.4 Alternative Type Approval......8 2.4.5 Painting Road Wheels......40 1.2.5...
  • Page 4 4.1.6 Prevention of Squeaks and 4.12.3 Lamps – Hazard / Direction Rattles.............57 Indication............112 4.1.7 Water Leakage Prevention.......57 4.12.4 Lamps – Front and Rear Fog 4.1.8 Wiring Splicing Procedures......57 Lights...............112 4.1.9 Wiring Specification........58 4.12.5 Lamps for Wide Vehicles......112 4.1.10 Electromagnetic Compatibility (EMC) 4.12.6 Electrically Operated Door Mirrors..113 Awareness.............59 4.13 Interior Lighting.........114...
  • Page 5 Body Closures........161 5.6.1 Load Compartment Interior Lining.............161 5.6.2 Plywood Lining/Cladding......161 5.6.3 Security, Anti Theft and Locking System ............161 Seats..........166 5.7.1 Van..............166 5.7.2 Windowed Van.........166 5.7.3 Heated Seats..........166 5.7.4 Rear Seat Fixing Positions....166 Glass, Frames and Mechanisms..169 5.8.1 Heated Windshield and Heated Rear Window............169 5.8.2 Rear Windows...........169...

  • Page 6: About This Manual

    This BEMM is the first publication for the new FORD TRANSIT CUSTOM 2012.75 vehicle. It is vehicle integrity by his choice of methods, tools or components.

  • Page 7: Special Vehicle Option (Svo) Order Codes

    L1 = 3.0m wheel base, L2 = 3.3m wheel base H1 = Low roof height *Not to be ordered with tachograph, as uses the same 1 DIN console. **Not available with A607 Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 8: Commercial And Legal Aspects

    The Vehicle Converter should warrant its design, Vehicle Converter shall also ensure that any materials and construction for a period at least alteration it makes to a Ford vehicle or component equal to any applicable Ford warranty. does not reduce its compliance with the European The Vehicle Converter must ensure that any General Product Safety Directive.

  • Page 9: Product Liability

    For additional information: your local National Sales Company representative, Refer to: 5.10 Airbag Supplemental Restraint or Local Ford Dealer. If they are unable to help you System (SRS) (page 173). then please contact the Vehicle Converter Advisory Service at VCAS@ford.com 1.2.9 Drilling and Welding...

  • Page 10: Contact Information

    Dealer in your Market. E-Mail: mmontalt@ford.com If your Local National Sales Company Postal Via Andrea Argoli 54 Representative or Local Ford Dealer are unable to Address: help you, please contact the Vehicle Converter Advisory Service at VCAS@ford.com. ROME 00143 Ford of Britain...
  • Page 11 1140 Postal Lienga 2 Address: P.O.BOX 514 Ford of Switzerland KOLBOTN Contact: Dominik Baechi - Transit Brand Manager N-1411 Phone: +41-43-2332253 Fax: +41-43-2332005 E-Mail: dbaechi@ford.com Postal Wallisellen Address: Geerenstrasse 10 Wallisellen 8304 Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 12 Building 5 E-Mail: gmitropo@ford.com MOSCOW Postal 4 Konstantinoupoleos and Ganata Address: Street 141400 Peristeri Athens Ford Central & Eastern Europe 121 33 Contact: Balázs Págyi - CV Product Specialist Phone: +36-26-802538 Fax: +36-26-802-590 E-Mail: bpagyi@ford.com Postal 3 Galamb Jozef Utca...
  • Page 13 3D CAD data in iges format is available on CD-ROM, you can request specific information by contacting the Vehicle Converter Advisory Service, vcas@ford.com Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 14: Conversion Type

    Refer to: 4.12 Exterior Lighting (page 112). Refuse Collection Refer to: 4.4 Battery and Cables (page 80). Generator and Alternator. Refer to: 4.9 Tachograph (page 104). Refer to: 4.12 Exterior Lighting (page 112). Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 15 Refer to: 4.9 Tachograph (page 104). Recovery Vehicles Refer to: 5.13 Frame and Body Mounting (page 178). Refer to: 4.16 Special Conversions (page 120). Auto Wipe and Auto Light for Vehicles with large over-hangs Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 16 Refer to: 5.7 Seats (page 166). Refer to: 5.8 Glass, Frames and Mechanisms (page 169). Refer to: 5.9 Roof Opening Panel (page 171). Roof Ventilation. Refer to: 5.10 Airbag Supplemental Restraint System (SRS) (page 173). Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 17: Conversion Homologation

    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 VCAS@ford.com Date of Publication: 04/2012...

  • Page 18: Electromagnetic Compatibility (Emc)

    30-54 1, 2, 3 68-87.5 1, 2, 3 142-176 1, 2, 3 380-512 1, 2, 3 806-940 1, 2, 3 1200-1400 1, 2, 3 1710-1885 1, 2, 3 1885-2025 1, 2, 3 Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 19: Suggested Antenna Location

    • With the engine running. • During a road test at various speeds. Check that electromagnetic fields generated inside the vehicle cabin by the transmitter installed do not exceed applicable human exposure requirements. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 20: Vehicle Duty Cycle Guidelines

    NOTE: For further information 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 VCAS@ford.com...

  • Page 21: End Of Life Vehicle (Elv) Directive

    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 VCAS@ford.com Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 22: Jacking

    NOTE: Any modifications to the vehicle must be noted in the owner's handbook or new descriptive literature included with the owner's documentation. Front Jacking Points Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 23: Lifting

    It is important that only the correct lifting and support locations are used at all times. Lifting Points Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 24: Noise, Vibration And Harshness (Nvh)

    The interior noise levels should not be deteriorated by the conversion. Reinforce panels and structures as appropriate to avoid vibrations. Consider the usage of sound deadening material on panels. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 25: Vehicle Transportation Aids And Vehicle Storage

    Months Claims arising from deterioration caused by Check Vehicle is incorrect storage, maintenance or handling are clean not the responsibility of Ford. Remove external Vehicle Converters must determine their own contamination procedures and precautions, particularly where vehicles are stored in the open as they are...

  • Page 26: Package And Ergonomics

    NOTE: For further information please contact your requirements. local National Sales Company representative, or Local Ford Dealer. If they are unable to help you then please contact the Vehicle Converter Advisory 1.13.4 Conversion Affects on Parking Service at VCAS@ford.com...

  • Page 27: Recommended Main Load Area Dimensions

    A (mm) B (mm) C (mm) L1 - H1 2412 1400 1400 L2 - H1 2818 1400 1400 L1 = 3.0m Wheel Base, L2 = 3.3m Wheel Base H1 = Low Roof Height Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 28 L1 - H1 3061 L2 - H1 3437 L1 = 3.0m Wheel Base, L2 = 3.3m Wheel Base H1 = Low Roof Height Load Through Hatch only available with Dual Front Passenger Seat Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 29 A (mm) B (mm) C (mm) L1 - H1 1468 1400 1400 L2 - H1 1853 1400 1400 L1 = 3.0m Wheel Base, L2 = 3.3m Wheel Base H1 = Low Roof Height Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 30: Hardware Specifications

    20.0 28.0 25.0 35.0 41.0 55.0 50.0 70.0 68.0 92.0 95.0 125.0 170.0 230.0 230.0 310.0 252.0 317.0 317.5 399.4 345.0 430.0 434.7 541.8 470.0 590.0 592.2 743.4 600.0 750.0 756.0 945.0 Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 31: Load Distribution

    For further information please contact your local Measurement National Sales Company representative, or Local Ford Dealer. If they are unable to help you then In order to check the center of gravity height the please contact the Vehicle Converter Advisory following described method is proposed.

  • Page 32: Center Of Gravity Height Calculation

    Inclination Angle* Center of Gravity Height Z** **Center of Gravity Height Z: *Inclination Angle: 1.15.4 Center of Gravity Height Calculation Given or measured parameter Wheelbase Front axle weight Rear axle weight Front height Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 33: Formulas

    E145328 can be used to derive the auxiliary values below: In inclined system the main variable is the inclination angle which is the quotient of the lifting height and the wheelbase: Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 34 Using the rule of proportion leads to the Center of Gravity height formula: Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 35: Towing

    National Sales Company representative, • For attachment of the tow bar, under run bar or Local Ford Dealer. If they are unable to help you and step see diagram E145327 - Tow Bar Van, then please contact the Vehicle Advisory Service Bus and Kombi 2.5 - 3.3 tonne.
  • Page 36 Attachment details for Tow Bar Van, Bus and Kombi, 2.8 - 3.3 tonne ITEM DESCRIPTION M16 x 55 Screw M16 Washer M16 Nut M12 x 75 x 90 Hexagonal Flange Bolt M12 Hexagonal Flange Nut 177mm 53mm 75mm 35mm 20mm Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 37: Suspension System

    CAUTION: Modifications to the suspension system can cause a deterioration of the vehicle handling characteristics and durability. NOTE: For detailed information please contact the Vehicle Converter Advisory Service at VCAS@ford.com Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 38: Front Suspension

    Electronic Stability Program, ESP). NOTE: Do not damage the surface or corrosion protection of the spring during disassembly and installation. NOTE: For detailed information please contact the Vehicle Converter Advisory Service at VCAS@ford.com Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 39: Rear Suspension

    Adding or removing leaves may result in failure or reduced function of the spring as well as other vehicle related issues for which Ford Motor Company can not be held responsible. CAUTIONS:...

  • Page 40: Wheels And Tires

    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. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 41: Brake System

    National Sales Company representative, The brake fluid reservoir must remain accessible or Local Ford Dealer. If they are unable to help you for servicing and for adding brake fluid. then please contact the Vehicle Converter Advisory Service at VCAS@ford.com...

  • Page 42: Engine

    For electrical supply to auxiliary equipment. Engine. Refer to: 4.3 Charging System (page 74). • Common Rail 2.2L TDCi 92kW (125PS) Diesel Engine. • Common Rail 2.2L TDCi 114kW (155PS) Diesel Engine. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 43 FWD Common Rail 2.2L TDCi 74kW (100PS) Diesel Engine Item Description Torque Curve Nm Max Torque = 310Nm at 1300-2100 1/min Power Curve kW Max Power = 74kW (100PS) at 3500 1/min 1/min Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 44 FWD Common Rail 2.2L TDCi 92kW (125PS) Diesel Engine Item Description Torque Curve Nm Max Torque = 330Nm at 1350-2400 1/min Power Curve kW Max Power = 92kW (125PS) at 3500 1/min 1/min Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 45 FWD Common Rail 2.2L TDCi 114kW (155PS) Diesel Engine Item Description Torque Curve Nm Max Torque = 385Nm at 1700-2200 1/min Power Curve kW Max Power = 114kW (155PS) at 3500 1/min 1/min Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 46: Engine Cooling

    NOTE: For further information please contact your local National Sales Company representative, or • Coolant tube routing must be below the Local Ford Dealer. If they are unable to help you minimum line of the degas bottle. then please contact the Vehicle Converter Advisory service at VCAS@ford.com...

  • Page 47: Auxiliary Heater Installation

    The location of the heating system your local National Sales Company representative, should not be in close proximity to movable or Local Ford Dealer. If they are unable to help you components. Any body reworks which damage then please contact the Vehicle Converter the paint must be fully protected against Advisory Service at VCAS@ford.com...

  • Page 48: Accessory Drive

    NOTE: For further information on systems requiring a unique belt 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 VCAS@ford.com Date of Publication: 04/2012...
  • Page 49 Idler Alternator Idler Power Steering Pump Crankshaft Pulley Compressor Auto Tensioner Front End Accessory Drive Shield - only Start-Stop Engine Top Cover Front End Accessory Drive Shield Front End Accessory Drive Shield Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 50: Clutch

    It is necessary to select the appropriate drive, engine, gear ratio, gross vehicle mass, gross train mass, axle plates and payloads of the base vehicle to match the customers order. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 51: Manual Transmission

    1.864 7.804 7.338 8.786 1.121 4.695 4.415 5.286 0.780 3.268 3.073 3.679 0.844 2.570 2.416 2.784 0.683 2.080 1.956 2.254 Reverse 1.423 16.154 15.189 17.504 VMT6 - 6 Speed Manual FWD Transmission Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 52: Exhaust System

    • Ensure existing shields are maintained. converter, the diesel particulate filter and • Add further shields over exhaust system as any part of the exhaust system. necessary to avoid fire risk. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 53: Diesel Particulate Filter (Dpf)

    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 VCAS@ford.com 3.6.4 Diesel Particulate Filter (DPF) The DPF forms part of the emissions reduction systems fitted to your vehicle.

  • Page 54: Fuel System

    E145335 and table for recommended clearances. Fuel Cooler Clearance Zone for Air Flow 1 = Center Line Front Wheel Axle A = 1074mm, B = 995mm, C = 1207mm 2= Center Line B - Pillar Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 55 Auxillary fuel line has a female connector TI LOCC QC 7.89 fitted as standard. It is recommended to use a 7.89 male adapter mating part (manufacturer TI Automotive GmbH). For further information please contact VCAS@ford.com Drive Direction Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 56: Wiring Installation And Routing Guides

    4.1 Wiring Installation and Routing Guides 4.1.1 Wiring Harness Information 4.1.3 Connector Pin Out Practices NOTE: Ford Motor Company has no control over the modification or installation process of the When designing a harness to component electrical content of auxiliary systems and...

  • Page 57: Unused Connectors

    Ford do not recommend the use of these The drip loop is a section of wiring that is connectors for any other purpose than that deliberately formed and routed BELOW the point intended by design.

  • Page 58: Wiring Specification

    'Current Rating of Wire Sizes' table. temperatures are the continuous usage where as the maximum fuse also needs to protect for high current short term loadings such as electric motors. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 59: Electromagnetic Compatibility (Emc) Awareness

    Wiring must be suitably fixed without any Awareness detrimental effect on other wiring. Single or bunched looms must maintain the The installation and routing of Ford wiring, following clearances: (example of wiring shown in figure E145359), have been fully-validated and have passed the requisite •...

  • Page 60: Wiring Through Sheet Metal

    There are three locations in the dash panel which have been identified for additional holes to route Ford released hardware is available to support wires through. See figure E145360 (view from further installations to the vehicle. Only this engine bay) for locations.

  • Page 61: No Drill Zones Rear Cargo Area

    Rear Cargo Area No Drill Zones L1/H1 with Lift Gate (Right Hand Side) L1 = 3.0m Wheel Base, L2 = 3.3m Wheel Base H1 = Low Roof No Drill Zones L1/H1 Lift Gate Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 62 No Drill Zones L1/H1 with Lift Gate (Left Hand Side) L1 = 3.0m Wheel Base, L2 = 3.3m Wheel Base H1 = Low Roof No Drill Zones L2/H1 Rear Cargo Doors (Right Hand Side) Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 63 No Drill Zones L2/H1 Rear Cargo Doors L1 = 3.0m Wheel Base, L2 = 3.3m Wheel Base H1 = Low Roof No Drill Zones L2/H1 Rear Cargo Doors (Left Hand Side) Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 64: Electrics For Tow Bar

    Trailer Tow Jumper (with Trailer Tow Module connector 'A' BK2T-13B576-A_ see figure E151247) Trailer Tow Socket Jumper BK2T-13B576-D_ Fuel Tank Harness BK2T-14406-** Main Harness (with Trailer Tow Module connectors 'B' and BK2T-14401-** 'C' see figure E151247) Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 65 Tow bar electrical system may be ordered as a NOTE: The trailer detect circuit is part of the Ford 13-pin DIN connector, as part of the original vehicle Trailer Tow module, it can only be implemented build. on vehicles with power locking and perimeter or CAT 1 alarms.
  • Page 66 – 9V < TTM power supply voltage < 16V switched on to detect that the trailer has been • Short circuit detection: 30A connected. If a trailer light is already switched on the related current will be checked. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 67: Trailer Tow Connectivity

    Trailer Tow 14406 Interface Connector The Body Control Module does not support the incremental load of powering side marker lamps on a trailer, if these are required they should also be driven using separate relays. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 68: Communications Network

    Local Interconnect interface wiring or connectors. The Network (LIN) and ISO 9141 K-line serial links. addition of unapproved CAN-Based modules could impact the safe operation of the vehicle. CAN-Bus System Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 69 Global Positioning System Sensor Anti-Lock Brake System Control Module Fuel Fire Heater Module 2.2L I4 Diesel Trailer Tow Module Engine Control Module Rear View Camera Controller Alternator Rear View Camera *Either low, medium or navigation Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 70: Body Control Module (Bcm)

    Description Label Position WARNINGS: Vehicle BCM configuration must NOT be modified once the vehicle has left a Ford Unapproved and/or incorrect connection production plant, except for any changes to any of the mating wiring can cause that may be carried out using dealership...
  • Page 71 Configurable Locking (set at time of order) Heated Mirrors High Series - BK2T-14B467_C (incremental over Mid) Category 1 Alarm (CAT1) includes: Interior Motion Sensor (IMS) Battery Backed Sounder with Inclination Sensor (BBS) Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 72 Unfold fitted, relay and/or Printed Circuit Board damage Power Fold Mirrors High Side Driver Mirror Motor Blown Fuse if bigger fuse Fold fitted, relay and/or Printed Circuit Board damage Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 73 Light Switch Module, Steering Wheel Module Supply, Stop Light Switch Supply Low/Mid/High F8011 Instrument Control Panel, Multi Function Display Supply Low/Mid/High F6061 Ignition Passive Anti-Theft Supply Low/Mid/High F6022 Radio, Hybrid Electronic Cluster, Navigation K175 Supply Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 74: Charging System

    4.3 Charging System 4.3.1 General Information and Specific The Transit utilizes multiplexed vehicle electronics, Warnings it is recommended that the appropriate Ford proprietary accessory systems are used. Inappropriate or incorrect connection of additional The Transit electrical system is a 12-Volt supply equipment could cause mis operation, or damage with a negative ground return.

  • Page 75: System Operation And Component Description

    Description Power Control Module (PCM) or Engine Control Module (ECM) Body Control Module (BCM) Battery Monitoring Sensor (BMS) Where fitted Battery For Start-Stop application there will be two batteries Electrical consumers Alternator Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 76 15.2V. These refresh phases are required as the battery charge status is 80% over long periods of time. Refer to: 4.4 Battery and Cables (page 80). Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 77: Power Management Settings

    Ford diagnostic service tool with the correct level of security clearance. The any combination) within 10 seconds. Ford dealer has the correct tools and If a vehicle is received from the dealer where level of security to do this if required.

  • Page 78: Electrical Conversions

    Also see section concerning installation of equipment containing an electric motor. Electrical Circuits Associated with Management System Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 79: Fitting Equipment Containing Electric Motors

    • Disconnect the alternator multi-plug prior to your local National Sales Company representative, using welding or cutting equipment. or Local Ford Dealer. If they are unable to help you • If welding or cutting is to be performed directly then please contact the Vehicle Converter near a control module, it must be removed Advisory Service at VCAS@ford.com...

  • Page 80: Battery And Cables

    (CCV) is applied, the voltage must not be less than to reprogram the vehicle. It retains its ‘normal’ 12.4 volts. This applies to any of the Ford battery power management settings and configurations. technologies used and applies to both batteries if However, the central locking latches may cycle if a twin system.
  • Page 81 Owners manual. There is a dedicated charge point under the hood. Failure to comply may lead to high current paths that may damage peripherals and ECU's especially in a jump start condition. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 82: Battery Configurations

    Relay) Circuit, later in this section. Extra batteries and capacity when using the SureStart ® added to the power supply should be connected system and listed in the Ford battery table. as shown at the end of this section. • Third party batteries are isolated from the standard Ford system at key off.

  • Page 83: Battery Configuration, Additional Loads, Start-Stop And Smart Regenerative Charging (Src)

    Ford battery. supply architecture. Start-Stop and SRC system functionality cannot The Charge can also be applied to the Ford fit be guaranteed with these configurations. If such batteries, all relays/switches connected, but only a battery configuration is required, it is for an emergency charge.
  • Page 84 Ford Fit Vehicle Start Battery Ford Fit SureStart® Battery Relay Ford Fit Loads (from Auxiliary Battery) Switched Ground Engine Run Signal (200mA) Converter Fit +12V Fused KL30 Supply Converter Fit Power Supply Fuse Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 85: Battery Monitoring Sensor (Bms)

    Connecting to the negative battery terminal will Specification Interface Connector. Contact your bypass the BMS and affect the correct local Ford Dealer or National Sales Company assessment of the battery state of charge. Refer representative for advice on which system for your to BMS section in this manual.
  • Page 86 BMS will not be able to accurately correlate the battery state of charge. Note there is approximately 20mA of key off load from existing Ford fit systems so the additional maximum is 80mA of converter fit system. Any third party installations should ideally be activated via Ignition or engine RUN.

  • Page 87: Battery Disconnect Relay (Split Charge Relay)

    Reconfiguration of the system can be updated to a twin system. This the BCM software by the Ford dealership is requires updating to a split charge relay, instead required to support this feature. It will also be of the shorting bar.
  • Page 88 BMS for Auxiliary Battery (also used for Single Battery System) AV1T-10C652-A_ BMS for Vehicle Start Battery W520102 -S442 M8 Nut for fixing BMS to 14301 (1 each BMS) *only one battery pending on drive. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 89: Power And Connectivity Usage Recommendations

    Note: includes SVO Auxiliary Fuse Panel (A526). handbrake on. For example: Police Vehicles and Ambulances. *Utility Vehicle Switch Pack (A607) and High Specification Interface Connector (A608) can not be ordered together. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 90: Generator And Alternator

    2.66 for 2.2L (B) shows the alternators revolutions per minute diesel. (1/min). NOTE: These alternator curves do not show spare output capacity as this would be dependant on original vehicle features and options. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 91 Voltage 12.9V Diagram E75873 shows the alternator output performance at five different temperatures In accordance to Ford specification at five different temperatures. The vertical axis (A) shows output current (Amps) and the horizontal axis (B) shows Alternator speed in revolutions per minute (1/min).
  • Page 92 Diagram E146659 shows the torque in Nm which is required to drive the alternator. The vertical axis (A) shows the torque (Nm) and the horizontal axis (B) shows the alternators revolutions per minute (1/min). Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 93 This can be done by turning on the hazard switch in conditions where it is convenient and legal to do so. Contact your local Ford Dealer or National Sales Company representative. Date of Publication: 04/2012...

  • Page 94: Climate Control System

    If routing is required in these areas, shield against stone pecking as appropriate. • Do not route hoses near sharp edges. Utilize guards to protect against cutting or chafing. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 95: Instrument Panel Cluster (Ipc)

    MS CAN + Grey/Orange Power MS CAN Low Violet/Grey Twisted MS CAN High Blue/Grey Cluster Signal Ground White/Brown Cluster Signal Yellow Cluster Set Green/Violet Automatic Transmission Ground Black/Violet Tachograph Grey/Blue Crank Detect White/Green Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 96: Horn

    A dual horn may be fitted to the vehicle in place of the single horn. Any other aftermarket horn (for example an air horn) will need to be driven by a separate relay energised by the horn circuit. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 97: Electronic Engine Controls

    A drain exceeds 50 Ampere. ignition off. • Ford Engine RPM (Revs Per Minute) Speed It is very important not to make any modifications Controller System is active. to the shielding around exposed moving parts on •...
  • Page 98 100mA for 7 days or more pedal will stall the engine. If an RPM controller is will cause Start-Stop to inhibit. required – it is recommended to use the Ford For additional information engineered system as this is developed with the Refer to: 4.4 Battery and Cables (page 80).

  • Page 99: Engine Rpm (Revs Per Minute) Speed Controller (A003)

    RPM speed ramp up and down should design the switch box to withstand with buttons. The end user is free to select RPM these conditions. values between 1300-3000rpm in 25rpm Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 100 Stop Engine RPM 1 on/off or Variable Control 'Idle' RPM 2 on/off or Variable Control 'Negative (-)' RPM 3 on/off or Variable Control 'Positive (+)' RPM Control Armed or Increased Idle on/off Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 101 1. Via the IDS diagnostics system at a Ford dealer out of RPM speed control mode. If a foot pedal (there may be a charge for this).
  • Page 102 3 speed mode). apply to idle up speed). 6. Press and release the same RPM button to reset the stored RPM speed to the current engines RPM. 7. Release the accelerator pedal. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 103: Changing Vehicle Speed Maximum Setting

    The Vehicle Speed Maximum Setting can be changed via the Integrated Diagnostic System (IDS) menu under the following tabs: Toolbox, Powertrain, Service, Functions, PCM. The IDS on screen menus will guide the dealer through the options and setup. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 104: Tachograph

    • Tachograph Harness, see figure E145371 for mounting and harness routing. 4.9.2 Tachograph Harness Mounting Standard Ford installation in the overhead console using DIN radio bracket, see figure E145372. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 105 Tachograph Mounting Item Description In-line connector to main harness Tachograph Harness Bracket Roof Console Bracket Console Mounting Tachograph Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 106: Fitting A Tachograph To Vehicles Built With Out Digital Tachograph Option

    (headliner) to support fitting a Tachograph. NOTE: The Tachograph units are not supplied by NOTE: Only vehicles fitted with mid to high feature Ford service and are only available by the level harness's will support Tachographs. It is Continental/VDO Calibration Center. Formerly recommended for your local Ford Dealer to assess known as Siemens/VDO.

  • Page 107: Vehicle Configuration Change

    DTCO Tachograph must be calibrated. The Digital Tachograph activation must be completed by an authorized VDO workshop. The Ford Dealer will organize the Tachograph Calibration. When the Tachograph is in an un-calibrated state...

  • Page 108: Information And Entertainment System - General Information Specifications

    Output Left Front Speaker + Output Right Front Speaker - Output Right Front Speaker + Output Right Rear Speaker - Output Right Rear Speaker + Output 26 Pin Connector (8476-1 / 544128-1) Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 109: Additional Rear Speakers

    14K024, but not the rear of the Audio Head Unit, see next table for necessarily in the harnesses 14401 and details. 14405/14A005 that then take the signals to the rear speaker locations. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 110 Left Rear - Brown/Yellow Rear Speakers - In-line connector 14401/14K024 Item Description Rear Speaker Left + (White/Green) Pin 41 Rear Speaker Left - (Brown/Yellow) Rear Speaker Right - (Brown/Blue) Rear Speaker Right + (Brown/White) Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 111: Cellular Phone

    Ford dealership. These use the Ford MS CAN multimedia bus to operate in conjunction with the Ford audio and navigation systems. Date of Publication: 04/2012...

  • Page 112: Exterior Lighting

    NOTE: For various vehicles CAT 6 repeater lamps checked before designing the wiring circuit. The must be fitted. See legislation for full details. maximum permissible load with the standard Check with your local Ford dealer or National Sales system is: Company representative. Date of Publication: 04/2012...

  • Page 113: Electrically Operated Door Mirrors

    WARNING: Do not tamper with the base system (controlled by Body Control Module and multiplex architecture) and any feeds taken from the associated wiring or controller. NOTE: These options are not suitable for aftermarket or converter fit. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 114: Interior Lighting

    Special Vehicle Option (SVO) Auxiliary Fuse Panel. If enhanced bright lights are required for the cargo area of a van, it is recommended to fit the Ford Enhanced Load Space Lighting. Option A080 and LED lamp part numbers 2x front BK2V-13776-A_ and 2x rear BK2V-13773-A_ , jumper wires may also be required for updates.

  • Page 115: Handles, Locks, Latches And Entry Systems

    (i.e. one relay for lock all, one relay for driver door unlock etc). Locking is controlled by the BCM. There is current The use of Ford Transit lock mechanisms is sensing on certain locking circuit pins as part of strongly recommended as the BCM is designed the security system –...
  • Page 116 Left Lock Supply Right Lock Supply Driver Door Unlock Supply Dead Lock Left Door Supply Pin 41 Lift Gate Latch Release Dead Lock Right Door Supply Rear Cargo Door Passenger Door Unlock Supply Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 117: Fuses And Relays

    4.15 Fuses and Relays 4.15.1 Fuses NOTE: Only use Ford fuses as shown in below table. Other fuses may interfere with the validated WARNING: No increase in existing vehicle fusing strategy. standard fuse capacity is allowed under any circumstances. There are no spare...

  • Page 118: Relays

    5M5T-14B192-A_ Black 6X4T-14B192-A_* Grey *Silent/Low Noise Relay NOTE: Only use Ford Relays shown in table. Micro Relay Ford standard relays have a nominal coil current of 300mA (max) at 25°C. Relays with higher loads should not be used. For maximum switching currents please refer to Relay Figures E75017 E75021.

  • Page 119: Windscreen Wipers

    NOTE: Power to wiper motors is limited by the size of the wiring and associated relays. If any alternative wiper installation is made, it must have a specification equivalent to Ford components. Refer to: 5.8 Glass, Frames and Mechanisms (page 169).

  • Page 120: Special Conversions

    WARNING: Only Ford release wiring should be used to support added vehicle functionality. If the implementation of wiring other than this is required, Ford guidelines must be followed. Please also Refer to: 4.15 Fuses and Relays (page 117). Refer to: 4.18 Grounding (page 144).
  • Page 121 Pin 13 can be accessed from either male or female Refer to: 4.1 Wiring Installation and Routing Guides connector between harnesses 14401 to 14A005 (page 56). or 14401 to 14405 (Green/Brown wire). Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 122 This circuit can only have a relay added (maximum 300mA) to control additional lighting. Check with your local Ford dealer or National Company Sales representative for conversion compatibility. The use of the trailer tow connector is not recommended.
  • Page 123 CAT 6 lights, the feeds for these should not be used as the BCM would need reconfiguring, which could have safety as well as functional implications. Item Description 12V Feed Ground Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 124: Auto Wipe And Auto Light For Vehicles With Large Overhangs

    Conversion or Installation forward (zone 2) where Auto Light and Wipe feature will NOT function correctly The feature is not to be specified with the donor or configured OFF by the Ford dealer. Auto sensor location. NOTE: The Auto Wipe, Auto Light feature should...

  • Page 125: Electrical Connectors And Connections

    If splicing into existing wiring is unavoidable, see wiring splicing procedures in this manual. Refer to: 4.1 Wiring Installation and Routing Guides (page 56). NOTE: Ford approved jumper harnesses should be used. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 126: Customer Connection Points

    The connection point kit, contact your local Ford dealer fixing torque (M5) is 3.5–4.5 Nm. or National Sales Company representative for details of the kit.

  • Page 127: Standard Interface Connector

    4S7T-14489-VD_. signals. See figure E152877 for location and A service kit (KTBK2V-14A411-C_ ) can be ordered signals. from your local Ford Dealer, the kit contains the mating connector to access these signals, and 3 WARNINGS: meters of wiring.

  • Page 128: Svo Auxiliary Fuse Panel (A526)

    (driving two or more relays in error). provides an advanced customer access point (C1) connector as well as a (C2) interface connector to further switch installations and a power and ground supply. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 129 SVO Auxiliary Fuse Panel (A526) - Left Hand Drive Item Description C1 Connector C2 Switch Connector Standard Interface Connector Ground 2 Way Radio Connector SVO Auxiliary Fuse Panel within the Pre-Fuse Box (lid not shown) Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 130 SVO Auxiliary Fuse Panel (A526)- Right Hand Drive Item Description C1 Connector C2 Switch Connector Standard Interface Connector Ground 2 Way Radio Connector SVO Auxiliary Fuse Panel within the Pre-Fuse Box (lid not shown) Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 131 E152950 and table. A service kit Item Description (KTBK2V-14A411-A_) can be ordered from your KL30 20A local Ford dealer, this kit contains the mating connector, and 3 meters of wiring. Ground C3 Mating Connector - 6S6T-14A459-HK_ Date of Publication: 04/2012...
  • Page 132 SVO Auxiliary Fuse Panel Circuit Diagram Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 133 20A Relay (LHS Indicator/Aux 1*) C2-9 KL30 20A Relay (RHS Indicator*) C2-10 R5 Solenoid IN B 20A relay C3-1 KL30 C1- A R2 Output 1 C3-2 Ground *When specified on Ford options Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 134: Beacon Preparation Pack (A606)

    Item Description Contact your National Sales Company Ground representative or Local Ford Dealer for availability and options. Beacon Supply Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 135: Utility Vehicle Switch Pack (A607) - Right Hand Drive Shown

    BK2V-14A303_, see E152948 and E152949 for C1 into the C2 connector of the SVO switch harness connector location and also figures E152953 and BK2V-14A303_. E152954 in SVO Switches. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 136: Svo Switches

    4.17.7 SVO Switches Item Description Left Hand Drive location Right Hand Drive location C2 Connector In-line Connector 10A933 BK2V-14A303_ Harness (see E152954 and switch table) Front Beacon Connector Over Head Console - Containing Switches Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 137 BK2V-13768-A BK2V-13D734-A_ BK2V-13D734-B_ * Limited availability check with your Local Ford Dealer or National Sales Company representative. There are a combination of switch packs available If heavy loads are required, controlled via these to order for specific conversions. The 'Beacon...

  • Page 138: High Specification Interface Connector (A608)

    These signals include those for customer to use. See also Fuse Rating table. required for Police /Emergency Service conversions. The part numbers of the dedicated harnesses are BK2V-14401-A_/D_and BK2V-14K024-A_/D_. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 139 36 and 39, is provide (no other wires). A mating 43 way connector with three meters of wiring (with all wires) is available as a kit (KTBK2V-14A411-D_) from your local Ford dealer. WARNING: This link wire provides a 'no start function'.
  • Page 140 Control Units only 0.75 Reverse Signal Pulse Width Modulation 300mA Signal from BCM 0.75 High Beam Output from BCM 300mA 0.75 Low Beam Output from BCM 300mA 0.75 Fog Lamps Output from BCM 300mA Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 141 B+ (Always +12V) KL31 Chassis or Body Ground KL50 Crank/Start Position 3 KL58 Side Marker and Licence Plate Lighting KL75 Accessory - Position 1 Supplementary Fuse Box - for High Specification Interface Connector Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 142: Adding Connectors

    43 way connector should be used. The connector to add wiring for switches and beacons is still available. Item Description Pin 1 Supply through Battery Saver Pin 5 Ground - Dimming Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 143 – these are dedicated to other features and options, e.g. heated seats, but are not always present depending on level of harness fitted. Ford do not recommend the use of these connectors for any other purpose than that intended by design.

  • Page 144: Grounding

    Make sure that all ground points are tightened to the correct torque. CAUTIONS: Ground wires should be brought back to the Ford Only use the ground points indicated. ground points provided, please refer to the Using alternative points may affect the following figures.
  • Page 145 M6 Screw type fixing - Torque 12Nm +/- 1.8 Abbreviations used in table: • LHS - Left Hand Side • RHS - Right Hand Side • Misc - Miscellaneous • EXH EMS - Exhaust Emissions • SDR - Sender Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 146 Engine Bay Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 147: Body

    • Disconnect the electrical connector at the salt, dust, after cutting or drilling the body. Use airbag control module. Ford approved sealing and finishing material, and • If welding is to be performed directly near a underbody corrosion protection. control module, it must be removed Refer to: 5.12 Corrosion Prevention (page 177).
  • Page 148 Primer is applied to the welded flanges after cleaning. A check must also be made that the production corrosion protection is present in the area of the flanges. Any damage must also be re-primed. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 149: Boron Steel Parts

    5.1.3 Boron Steel Parts Boron Steel Parts - No Drill or Weld Zones Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 150: Floor 'No Drill Zones' Under The Floor Fuel Tank

    • A swiveling device is fitted on the front seats. please consult the Vehicle Converter Advisory • Any additional material or structure is attached Service VCAS@ford.com to the B-pillar inner and/or outer area. Lighting Do not alter the lighting system. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 151: Hydraulic Lifting Equipment

    Do not lift vehicle off the ground. • Route electrical and hydraulics separately and away from original Ford equipment. • Use suitable clip to fix on vehicle body and sub CAUTIONS: frame. Safety devices must ensure the legs are •...
  • Page 152 8.8 minimum. attach to the vehicle body. For design principle • Any other floor contact should be padded to refer to E145387. prevent local stress and to allow function of compliant mounts. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 153 100kg at maximum 1000mm reach. For load conditions as described above additional stabilizing equipment is not necessary. Hydraulic under-slung tail lifts are not recommended for Transit Van, bus and Kombi. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 154: Racking Systems

    • It is not recommended to drill through the floor reinforcements. in combination with plastic load floor liners. • Vehicle should be equipped with Ford standard • For alternatively fixing through the floor to the option bulkhead to give best protection to driver side members please refer also to Figure and front passengers.
  • Page 155 Recommended Fixing Locations Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 156 Design Proposal for non Ford Production Option Racking System (Left Hand Side Shown) Racking - Floor Fixings to Load Compartment Tie Downs Item Description Rigid Self-Supporting Racking Frame Work Fixing to floor Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 157 New Through Bolts (2 bolts per top attachment and 1 bolt per lower attachment) For designing glass carrying rack on body side outer, construct internal rack and bolt through the body side to the internal rack, see figure E146885. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 158: Body System - General Information Specifications

    'D' rings as shown in E145395. Not all vehicles will have all locations shown, it will depend on the base vehicle. For additional fixing locations. Refer to: 5.3 Racking Systems (page 154). Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 159 Dimensions for Load Tie Downs Dimension (mm) Dimension from B-Pillar (1) 1177 1716 2083 2374 2611 2515 2882 Vertical from floor From center line of vehicle L1 = 3.0m Wheel Base L2 = 3.3m Wheel Base Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 160: Front End Body Panels

    M6 thin sheet rivet type nuts. The protective window grilles, is met. It is also the standard range of Ford bulkheads can be converter’s responsibility to ensure legal load retro-fitted at these points.

  • Page 161: Body Closures

    WARNING: Plan fixing points for other your local National Sales Company representative fitments such as racking to ensure or Local Ford Dealer. If they are unable to help you through bolting can be achieved. Fixing then please contact the Vehicle Converters to the lining material may be inadequate Advisory Service at VCAS@ford.com...
  • Page 162 No Drill Zone - Driver and Passenger Doors No Drill Zone - Driver and Passenger Doors Item Description 300mm 55mm 150mm 190mm Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 163 No Drill Zone - Lift-Gate No Drill Zone - Lift-Gate Item Description 480mm 430mm 305mm Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 164 No Drill Zone - Side Sliding Doors No Drill Zone - Sliding Doors Item Description 620mm 165mm 360mm 740mm 290mm 250mm 215mm 500mm 300mm Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 165 No Drill Zone - Rear Cargo Doors No Drill Zone - Rear Cargo Doors Item Description 250mm 115mm 385mm 250mm 480mm 260mm 175mm Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 166: Seats

    For torque specifications contact the relevant legal requirements and ECE directives. your local Ford dealer or the Vehicle Converter Refer to: 3.6 Exhaust System (page 52). Advisory Service at VCAS@ford.com Vehicle Exhaust Systems - Vans with Bulkheads.
  • Page 167 Kombi Van - Rear Seat Fixing Positions (Left Hand Drive Shown) Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 168 Double Cab in Van (DCIV) - Rear Seat Fixing Locations (Left Hand Side Shown) DCIV - Rear Seat Fixing Locations Item Triple Seat - Second Row Front Axle Center line of vehicle 1302 520.5 377.5 Righ Hand Side symmetrically opposite Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 169: Glass, Frames And Mechanisms

    • Use approved glass for installation according your local National Sales Company representative, to legal requirements. or Local Ford Dealer. If they are unable to help you WARNING: For rear seat installation then please contact the Vehicle Converter Advisory Service at VCAS@ford.com Refer to: 5.7 Seats (page 166).
  • Page 170 Horizontal Section Through 'C' Pillar Vertical Section Through Side Window (Non Side Load Door) Glass Adhesive Cut within 0 and 1.5mm of inner body panel flange edge all around Window trim strip Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 171: Roof Opening Panel

    150kg Maximum Maximum roof rack length: L1 = 2096mm, L2 = 2462mm Roof Rack Supports, 3 attachments each side, positions depending on wheel base. L1 and L2 = Length pending on wheel base Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 172 E145408, with two M8 bolts per attachment. • It is recommended that the rack leading edge should not be located forward of the rear edge of the driver’s door, or “B” pillar as shown in E145408. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 173: Airbag Supplemental Restraint System (Srs)

    Ensure any seat covers installed are designed to be used with side airbag equipped seats. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 174 RCM. If the battery is disconnected Refer to: 4.4 Battery and Cables (page 80). Restraints Control Module (RCM) Battery and Monitoring Sensor section for reconnecting battery. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 175 Front Sensor Side Sensor Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 176: Safety Belt System

    Driver belt-minder is a legal requirement for an M1 vehicle. A switch is provided in the driver's buckle to sense the seat belt wearing status of the driver. If an M1 vehicle is modified, this function must be retained. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 177: Corrosion Prevention

    After cutting or reworking any sheet metal on the vehicle the damaged paint must be repaired. Ensure all materials are compatible with the relevant Ford specifications and maintain the original performance where possible. For specifications consult the Vehicle Converter Advisory Service VCAS@ford.com 5.12.3 Under Body Protection and...

  • Page 178: Frame And Body Mounting

    Avoid drilling into closed frame body members to and square, in groups if applicable. Be aware avoid the risk of corrosion from swarf. of side member draft angle. Refer to: 5.12 Corrosion Prevention (page 177). Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...

  • Page 179: Area For Fitting Additional Body Attachments To The Rear Of The Bumper

    5.13.4 Water Tank on Camper Vehicles NOTE: It is recommended that a decal or label is fitted adjacent to the filler aperture identifying the correct fluid to be used, for example: 'Water only' for water tanks. Date of Publication: 04/2012 FORD TRANSIT CUSTOM 2012.75...
  • Page 180 Conversion Affect on Fuel Economy and Performance..............20 About This Manual............6 Conversion Affects on Parking Aids.......26 Accessory Drive..............48 Conversion Homologation...........17 Adding Connectors............142 Conversion Type.............14 Additional 'Theater Lighting' for rear of vehicle Corrosion Prevention...........177 interior................114 Customer Connection Points........126 Additional External Lamps........112 Additional Internal Lamps.........114 Additional Rear Speakers.........109...
  • Page 181 Generator and Alternator.........90 Partitions (Bulkhead) - Driver and Front Glass, Frames and Mechanisms......169 Passenger(s) Protection on Van, Bus and Grounding...............57, 144 Kombi................160 Ground Points..............144 Plywood Lining/Cladding.........161 Power and Connectivity Usage Recommendations...........89 Power Management Settings........77 Handles, Locks, Latches and Entry Systems..115 Prevention of Squeaks and Rattles.......57 Hardware...
  • Page 182 Vehicle Exhaust Systems Vans with Bulkheads..............53 Vehicle Ride and Handling Attributes....20 Vehicle Transportation Aids and Vehicle Storage................25 Warnings, Cautions and Notes in This Manual..6 Warranty on Ford Vehicles...........8 Water Leakage Prevention.........57 Water Tank on Camper Vehicles......179 Welding................147 Wheel Clearance............40 Wheels and Tires............40...

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