NEW Project 2 2004 Connect T200 LX (Pic Heavy)

[paul2012]

Decided to fit the crome bonnet trim today

[tipp3r]

I've cut the plugs of 2010 loom for clocks the couler of the wires don't match old loom

[paul2012]

I've cut the plugs of 2010 loom for clocks the couler of the wires don't match old loom

No not all the wire colours on your original dash loom will match to the ones on the 2010 loom. This is due to wiring differences for interior lights, wipers etc.

your original instrument cluster has CTM (Timer) built into it which controlled the interior lights & intermittent wipers, heated screen & mirrors * if fitted.
Hence why they dont't work when instrument cluster is unplugged.

The 2010 instrument cluster has no CTM therefore it does not control the above systems. They are controlled by the GEM module which has CTM built into it.
If you wish to use the 2010 instrument cluster, the GEM module has too be installed as well. You will need to make up a new loom & patch it into your existing dash loom.
so that the following are operated via the GEM module

Central Locking
Intermittent wipers
Interior lights (doors)
Indicators & hazards
Headlamps
Side/parking lights
Battery saver (interior dome lights)
AIr recirculation
Heated Front screen (if fitted)
Heated wing mirrors (if fitted)
Rear Wipers (if fitted)
Auto headlamps & wipers (if fitted)

It is complex & unfortunately not simply plug & play

[paul2012]

To fit ABS with ESP to my connect. I am using the ABS wiring loom from a 2005 connect.

In order to salvage the wiring for the ASB Pump etc.

I started with this, part engine bay loom, front ABS sensor wiring & pump wiring with fuse/ relay panel



Stripped it down, now I have the full ABS wiring loom.



Already have fitted the section that runs from front bulkhead to rear N/S light & sensor loom from N/S light to rear ABS sensors
I just need to fit the ASB pump & sensor loom having retained the original terminals on 12V+ feeds from fuse/relay box for ABS pump. This is very simple to fit as it is
But as I am fitting ABS with ESP, I need to add a few more pins to the ABS pump plug for Yaw sensor etc.

[PeterBuzzacott]

Nice work mate and thanks for posting in such detail. Your van has come up a treat.

[paul2012]

When fitting the 2010 forward section of centre floor console.



You will require this mounting bracket, which is the base for the gearshift assembly
Available from Ford at £10 (Trade)
Ford Part No F5050131



This is what the forwards section of centre floor console is mounted to

The rear section of centre floor console is mounted using this bracket (fitted to floor behind Handbrake lever assembly)

[paul2012]

As my connect originally had front fog lights, the headlight switch that came with the 2010 dash was not equipped for them.

So I obtained replacement from a C-Max, which works perfectly



After receiving a few PM's on "how to stop the front bumper sagging in the middle & distorting bottom of top grille ?"

I advise to replace the lower bumper reinforcement bar (The thin bar that is mounted to the bottom of slam panel between headlights shown in pic below)


Part required Ford Part no F4992893 - This is the part where top of bumper clips onto just below the grille

When fitted, bumper & bottom of top grille should look like this

[millertime_1985]

As my connect originally had front fog lights, the headlight switch that came with the 2010 dash was not equipped for them.

So I obtained replacement from a C-Max, which works perfectly



After receiving a few PM's on "how to stop the front bumper sagging in the middle & distorting bottom of top grille ?"

I advise to replace the lower bumper reinforcement bar (The thin bar that is mounted to the bottom of slam panel between headlights shown in pic below)


Part required Ford Part no F4992893 - This is the part where top of bumper clips onto just below the grille

When fitted, bumper & bottom of top grille should look like this

That's one hell of a facelift you have done there... almost as impressive as the guy that facelifted a mk3/4 to look like a mk 6/7 (I forget which ones , off the top of my head)

[millertime_1985]

looking over more of this thread I have to wonder, just how handy do you have to be to be able to do this sort of thing...
not that I have any grand designs like this for my own TC... but I can't imagine its physically/practically easy doing such a drastic facelift to your TC

especially since I doubt they sell an instruction manual.

[paul2012]

looking over more of this thread I have to wonder, just how handy do you have to be to be able to do this sort of thing...
not that I have any grand designs like this for my own TC... but I can't imagine its physically/practically easy doing such a drastic facelift to your TC

especially since I doubt they sell an instruction manual.

On changing the front bumper it's straight forward to fit. Simply bolts into place.
Which can be easily done by anyone with the right info

Fitting the main dash is also straight forward, except for the floor centre console.
Although the main body shell looks the same on all models from 2003 to present, I have found there are differences in mounting points & brackets etc.
As for wiring the later instrument cluster & all modules etc, newer vehicles are getting far more complex with onboard diagnotic & computer systems.
theoretically experience / knowledge in vehicle electrical systems is preferred especially when fitting them to vehicle that were not originally equipped with them.

I wouldn't even bother getting a Haynes manual, they only supply a service manual that mostly covers connects from 2006-2009 with partial information on 2009 onwards.
The electrical system it covers are only 2006-2009 even then it's incomplete

In the process of adding these systems/modules to my connect.
I cross referenced 2003-2006 wiring diagrams with 2009 onwards ones obtained from Ford & worked it out from there.
& ended up putting together a 30 page electrical manual detailing on wiring the 2009 systems/modules etc into a 2003-2006 connect.
Which lists all wiring diagrams, connection points, diagrams of connection plugs & pin arrangements etc.

Then used it as my instruction manual on installation, otherwise it would have been a nightmare to remember everything.

[paul2012]

Nice work mate and thanks for posting in such detail. Your van has come up a treat.

Thanks

Still have several more things to do yet

[paul2012]

Bagged this for a fiver - chap didn't know what it was
Removed from a 2012 connect, I was supprised to see it was virtually stripped. it had only been in for a couple of days



Yaw rate sensor complete with mounting bracket - The final part for the ESP & hill start assist
These cost over £400 new from Ford

Although still waiting for the ABS pump to arrive

[millertime_1985]

Bagged this for a fiver - chap didn't know what it was
Removed from a 2012 connect, I was supprised to see it was virtually stripped. it had only been in for a couple of days



Yaw rate sensor complete with mounting bracket - The final part for the ESP & hill start assist
These cost over £400 new from Ford

Although still waiting for the ABS pump to arrive

by the end of your project, how much of your van will remain the same as when it was shipped out of turkey...
and.. how much do you reckon you will have Saved, over just buying an "09" model TC?

[paul2012]

by the end of your project, how much of your van will remain the same as when it was shipped out of turkey...
and.. how much do you reckon you will have Saved, over just buying an "09" model TC?

Not alot is original for a 9 year old connect apart from the shell everthing else has been replaced at some point.

With the cost of van & parts for conversion, estimated cost to date is around £2000

Alot cheaper than a good used low mileage 2009 onwards basic model

[g-man]

Alot cheaper than a good used low mileage 2009 onwards basic model

and worth a lot less