NEW Project 2 2004 Connect T200 LX (Pic Heavy)

[BIG E]

Are the clips that hold the headlining in oncers Paul? I want to take the lining down to insulate it this week and if i'm going need clips i'd rather order them before hand
Toffee wheels a cracking bit of kit for your tool box. I used one on a rear window i fitted for a member on here to get rid of some nasty smeg someone had used to try and seal the window

[Vacuumsealed]

Toffee wheels a cracking bit of kit for your tool box. I used one on a rear window i fitted for a member on here to get rid of some nasty smeg someone had used to try and seal the window

I'll second that! It was my van he used it on

No, it wasn't me who put the nasty smeg on there!

[Vacuumsealed]

[quote="paul2012"]


So when are you going to sell me the cab ceiling shelf? !!!

[paul2012]

So when are you going to sell me the cab ceiling shelf? !!!

Sorry that one is not for sale, I did have a couple a while ago & they sold very quickly.
I will keep a look out for one.

As for other Tourneo bits, there one here being broken up for spares

http://www.ebay.co.uk/itm/Breaking-FORD ... 51b1e27652

[Vacuumsealed]

As for other Tourneo bits, there one here being broken up for spares

http://www.ebay.co.uk/itm/Breaking-FORD ... 51b1e27652

Seen it mate. Tez sent me the link. The guy doesn't reply to questions for some reason.

[paul2012]

Here are the Full wiring diagrams for the AUTOWIPE/LIGHTS for Connects 2009 onwards

Autowipe (Automatic wipers)



Autolights (automatic headlights)

[paul2012]

Refitted bulkhead & clean out the rear.



Also refitted overhead shelf & liner - Wiring hanging in the middle of screen is for rain/light senor



Old bracket for original centre floor console has be removed & replaced with a new one for the 2009 onwards console.



Finally got the brackets for the front ABS sensor wirings & Headlight switch for Autolights.

[paul2012]

Are the clips that hold the headlining in oncers Paul? I want to take the lining down to insulate it this week and if i'm going need clips i'd rather order them before hand
Toffee wheels a cracking bit of kit for your tool box. I used one on a rear window i fitted for a member on here to get rid of some nasty smeg someone had used to try and seal the window

If removed carefully they can be re-used

[paul2012]

Just looking underneath, to see what needs to be done to remove rest of old loom that runs from engine bay to rear lights.

For a start all exhaust heat shields have to be removed including fuel tank. you can see the forward section of loom hanging down below

[paul2012]

It seems that the last brake pipe for ABS/ESP which runs from pump to the first union just above steering rack for brake pipe to rear, Ford doesn't list it. Although I obtained the rest from them.
So it looks like I will have to make one up.

Anyway cracking on with installation of ABS/ESP

Time to get pump fitted - removed from a 2012 connect complete with mounting bracket



Fits perfectly with new brake pipes - you can see I'm missing the pipe for rear wheel



Fuse/relay box refitted & loads of room left around pump etc





Now the wiring bit.

I need to change this plug - which fits the MK70 (6S43-2M110-AA) ABS pump fitted to connects from 2006 to present (NON ESP)



To this plug which fits 9T16-2C405-AE ABS/ESP pump fitted to connects from 2009 to present



That's an easy job

[paul2012]

Time to sort out the dash loom

Now before It can be fitted, I have to patch in all this 2009 onwards equipment.



Into this 2007 dash loom.



It's fairly straight forward, most of wiring is already there, just going to the wrong place.
For example wiring for wipers- On connects from 2003-2009 they are controlled by instrument cluster (intermittent wipe) where on connects from 2009 onwards they are controlled by the GEM module located behind fuse panel on N/S.
So Wiring has to be disconnected from instrument cluster plugs & chased back to Fuse panel & bulkhead Plugs that's connects to engine bay loom.

This will take a few days to complete.

Time consuming part is finding the relevant wiring that needs to be changed then label it. Then pulling the whole loom apart to change its route or added before taping loom up.
This way I will end up with just 1 loom to fit, instead of adding a subloom like I did when I first retrofitted all equipment to the old 2004 loom.

[Vacuumsealed]

Time to sort out the dash loom

Now before It can be fitted, I have to patch in all this 2009 onwards equipment.



Into this 2007 dash loom.



It's fairly straight forward, most of wiring is already there, just going to the wrong place.
For example wiring for wipers- On connects from 2003-2009 they are controlled by instrument cluster (intermittent wipe) where on connects from 2009 onwards they are controlled by the GEM module located behind fuse panel on N/S.
So Wiring has to be disconnected from instrument cluster plugs & chased back to Fuse panel & bulkhead Plugs that's connects to engine bay loom.

This will take a few days to complete.

Time consuming part is finding the relevant wiring that needs to be changed then label it. Then pulling the whole loom apart to change its route or added before taping loom up.
This way I will end up with just 1 loom to fit, instead of adding a subloom like I did when I first retrofitted all equipment to the old 2004 loom.

I've got a similar loom project to do, but on a motorbike.

I've said before, I take my hat off to you for the extensive work carried out on this van. Serious dedication.

[paul2012]

More work done, removed complete axle & springs.
Started to remove the rest of old loom from engine bay to rear lights (that's the wiring hanging)



The old original axle with springs

[paul2012]

whats elc st br cnt

Electronic Stability and Braking Control

As Ford specs are:-

Electronic Stability Programme (ESP)
Anti-lock brakes (ABS) with electronic brake-force distribution (EBD)
AYC (Active Yaw Control) – assists with under steer and over steer
Traction Control System (TCS)
Hill Launch Assist (HLA)
Electronic Brake Light (EBL) - hazards flash upon hard braking
Drag torque control – used in snowy conditions and raises the torque of the engine to assist acceleration

Hopefully I can get to work.
That's once all 4 ABS sensors & pump connected up along with steering angle, Yaw rate/ESP sensor & engine ECU configured for ESP

[Skippy]

Nice work mate, thoroughly enjoyed your work so far. Story tarnished somewhat by several members comments though. Attention to detail is brilliant and well documented. You've got some talent !