NEW Project 2 2004 Connect T200 LX (Pic Heavy)

[paul2012]

On a 2011 connect limited there are 10 separate modules in total some are on HS-CAN (high speed)& the rest are on MS-CAN (medium speed) & they all communicate with each other via the instrument cluster as a gateway

module list

Instrument Cluster (IC) - HS-CAN & MS-CAN (GATEWAY)
Generic Electronic Module (GEM) - MS-CAN
ECU module - HS-CAN
ABS module - HS-CAN
Steering Angle Sensor Module (SASM) - HS-CAN
Airbag Module (RCM)- MS-CAN
Occupant Classification System Module (OCSM) - MS-CAN
Stereo head unit (ACM) MS-CAN
BT/VC Module (SRM) BT/VC - MS-CAN
Tire Pressure Monitoring System (TPMS) - MS-CAN

Yes both networks are resistance rated & by splicing/joining or reducing network cable length can effect it's resistance which results in breakdown in communications

HS-CAN network independence 60 ohm with 2 termination modules
MS-CAN network independence 40 ohm with 3 termination modules

with every module connected to the neworks is why you can view all DTC codes from every module including ecu via the instrument cluster on all later models

Ford first introduced CAN (Controller Area Network) in 2004 on the Focus
Mondeo Mk3's has SCP & CAN from 2004-2006 & connect has SCP from 2003-2006

[tipp3r]

im just thinking put dash in then try and get a price on a spaky to wire all clocks and swithces up how many hours labour do you think it will take them,,,

[paul2012]

Once I worked out the details it took me nearly a day to connect all modules & switches up.
check to see if you have pins 6 & 14 on the DLC (DLC socket found on left hand side of centre console below cig lighter)

[paul2012]

Connects 2009 onwards - Wiring Diagrams for GEM module & Level 2 Instrument Clusters

GEM Module


Level 2 Instrument cluster

[paul2012]

Started to work on engine today

Inlet manifold removed



Old EGR cooler, gave it a couple of taps & nothing but carbon fell out of it.



Old Inlet manifold



EGR is completely blocked with carbon deposits, no point of fitting a blanking plate



Clear view of AUX Elec Heater



Replacement inlet manifold fitted no problem

[paul2012]

Paul, let work backwards:

you said:

"When fitting new modules, like GEM, ECU, Instrument cluster etc.There's is no need to modify wiring etc on newer vehicle, simply unplug old one & plug new one in. Then use IDS for module installation"

Yes it's easy on model that has HS-CAN & MS-CAN already fitted from factory !! but when you have a 2003-2006 connect that has not got them fitted, then it'S a lot harder to do & NOT PLUG & PLAY

Just done that on this (sorry yo keep going on about it) Focus TDDI, it needed a replacement pump, got a s\hand one, bolted it on plugged in VCM ran IDS coded pump to PATS, nothing new there

Yes when using IDS connected at DLC the coms is SCP !,
Or simply fit a pump that has it's rim cleared, switch ignition on to position 2.
Then switch ignition off, Lock & unlock vehicle it will then be coded to your vehicle. simples

You do a very good job of photographing the progress your making on your van. So here's the million dollar question:

Where are the photo's of this special wiring loom that you have made, by cutting and splicing to add this wonderful HS-CAN \ MS-CAN system ????

I have stated before,I have not fitted a 2010 dash loom into a 2004 connect. If I wanted to do that, I would have to replace main body loom, Engine bay loom complete Fuse /Relay box & Engine loom.
Then I would need to fit the R3PA or KKDA engine, as they have Siemens Fuel system (Injectors & Pump) were My current F9DA engine uses Delphi.

You want proof that I have wired /patched the Later modules & HS-CAN & MS-CAN networks then here you go.

2010 connect dash loom as removed from dash


2010 dash loom stripped down this the GEM module with wiring


This is the original 2004 connect Fuse panel with dash loom (also seen several time in previous pics)


2010 connect GEM module fitted behind fuse panel


Here you can still see the 2 plugs for the original central locking interface, which had been removed & it's wiring connected to GEM module. Also at bottom of pic is the rear door unlock relay


Vid here shows all the extra functions I have available under the onboard vehicle settings.
http://www.youtube.com/watch?v=c--cRAGk10g

[tipp3r]

Can i just cut the plugs of my old clocks and wire new plugs on to old loom
one

[paul2012]

Now it doesn't look at mess







LITEACE I did say, that I never fitted the 2010 dash loom

[paul2012]

Can i just cut the plugs of my old clocks and wire new plugs on to old loom
one

The ONLY wiring connections from the original instrument cluster that are required for the New instrument cluster/clocks, as follows

Handbrake/ low brake fluid warning indicator. BK/YE
VBat 12v+ (Constant live) RD
Accessory 12v+ YE/BU
Ignition 12v+ GN/RD
Illumination OG
Fuel Gauge BN/RD & WH/RD
GND BK/OG

Wipers, indicators, interior lights, air recirculation, & if fitted heaters in wings mirrors & heated screen which were controlled by the old instrument cluster/clocks.
They are NOT controlled by the later new one, as they are controlled by the GEM module instead.

This is where is gets very complicated
You have to make up a new wiring loom for these systems & patch it into you original dash loom. 2 relays are also required, one for rear door unlock & the other for Headlamp low beam interrupt. Also the High beam relay in engine bay fuse/relay box will require a slight adjustment, the GND side of relay coil needs to be changed to 12v+ ! This is due to high beam relay feed from new instrument cluster is GND !


Also the polarity on the original column switch gear is Positive this was changed to GND on connects from 2009 onwards

[tipp3r]

Cheers Paul is that the only wires I have to connect to get clocks working

[paul2012]

Cheers Paul is that the only wires I have to connect to get clocks working

This will power up the clocks /instrument cluster & fuel guage will work. As for the rest it requires the GEM module to be connected to runs indicators, wipers, Main/low beam headlights, interior lights etc

[paul2012]

Since I have fitted the later inlet manifold with elec EGR.

The EGR cooler also had to be replaced.


Why is it called an EGR cooler ? When the main coolant supply is from the cylinder head to EGR cooler which is then fed to heater matrix (cab heater) from EGR cooler before being returned back to engine!
This EGR cooler get hot very quickly by exhaust gases when EGR valve is open which preheats the coolant before going to the cab heater especially when starting engine from cold.
BUT when engine is up to running temp the EGR cooler isn't being cooled

Along with main coolant supply pipe to heater matrix (cab heater) from EGR cooler.




To fit later intercooler pipe to manifold, the power steering reservoir has to be replaced. There no room for it in its current location.


So I have just bought a new one (New from Ford & cheaper than a second hand one on ebay)


Unfortunately it looks like I may have to make a mounting bracket for it, As this connect doesn't have it. Which is no surprise I have found several minor differences in body work on models between 2003-2006 & 2006 onwards


Removed the AUX elec heater from my connect, as it is no longer required, as I have heat inside the cab within a couple of minutes with the new setup
Now I know why these AUX elec heaters were not fitted to later connects.

[paul2012]

Obtained a good second hand air intake pipe from filter box to turbo



& finally the Ext ambient air temp sensor has arrived.

[paul2012]

Wiring diagrams for connects 2009 onwards

Full Airbag system (Single stage airbag)


Full ABS system MK70 with ELC ST BR CNT


Full ABS system without ELC ST BR CNT

[paul2012]

What I find best when adding modules to vehicles that were not quipped for them, is to retrieve as much as the loom with the modules at the same time. Then strip that loom down to the basics & work it out from there.
& if possible get complete wiring looms. Like this ABS rear sensor wiring.



When connecting to the original loom, some case it is not possible to fit new module plugs. Sometimes they are not available or the original vehicke wiring is too short to connect up to to the new modules.
Hence why I used heatshrink butt connectors (waterproof) to connect the GEM module to the original Central locking circuit. All the 12v+ supplys to GEM module for interior light, wipers indicators, headlamps etc & relays. New pins were fitted to relvant GEM module wiring & then replaced the associated pins in the plugs on main fuse panel.

I order new pins & plugs (if available) from Simtek
http://www.simtekuk.co.uk/index.php/aut ... ?k=:12:486:

GEM module with loom stripped down. Note Ford's way of Splicing wiring (Non Insulated bare crimp & wrapped in duct tape )


Ford also did the same on the Main 2010 fuse panel
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