NEW Project 2 2004 Connect T200 LX (Pic Heavy)

[paul2012]

WOW-I have just read this from start to finish I must say what a fantastic job I am new to transit connects (but not transits) and this has got to be one of the best builds ever.

Thanks

There a few more bits & pieces to work on, although the vast majority is completed

[paul2012]

Refitted dash & temporarily fitted steering column to plug in switch gear.



So far everything checks out ok & all working perfectly - including automatic wipers & headlights

Still looking for a pair of door cards, my current ones don't match the colour of dash (Dark Pewter)

Require a pair from a 2006 onwards connect in dark pewter (for elec windows)

[paul2012]

After clearing old DTC's, programming PATS(immobiliser) including erasing 2 keys & recoding them (W1 carbon chip)

Finally Fired up engine today. Unfortunately I now have a couple of electrical issues
Alternator warning light is on when engine running DTC P0622-68 Generator Field Terminal Circuit - Invalid Signal (shown below)



I'm using the same alternator which was fitted to previous engine, warning light was on even then (goes off when engine is started, then light comes on around 5-10 seconds later)
I assume alternator is faulty As brand new smart charge loom has been fitted

Glow plug feed wire overheating - Possibly down to 1 or more faulty glow plugs

Other than the above engine seems to be running perfectly & is a lot quieter than the previous engine

[gt_addict]

Good news. Well about it running anyway

[phil drew]

has the arse come down by much with those springs or do you think its a less attitude as maybe softer ride

[paul2012]

Good news. Well about it running anyway

I agree it is good news, I'm pleased engine starts & run while it's still under warranty. Other 2 faults should a relatively easy fix - I hope

has the arse come down by much with those springs or do you think its a less attitude as maybe softer ride

Rear ride height hasn't reduced by much, approx 30mm & will proberly drop further once taken on the road.
At the moment it's been standing so do not know how it handles yet.

[paul2012]

AIrbag problems B1877 - For drivers Seatbelt pretensioner

Spent all yesterday afternoon Checking & rechecking everything & still get DTC B1877
Seatbelt pretensioner itself is fine - 2.5 ohm as it should be. Wiring checks out ok, except when pluged into seatbelt no reading at all
After inspecting the internals in the plug, there's a capacitor fitted !
Plugs for seatbelt pretensioners on 2009 onwards connects have a Ferrite inductor (choke) instead

Plug at the top is from my 2007 connect body loom



Only solution to solve problem, is to change seatbelt pretensioner loom to 2009 onwards.
Luckily I managed to grab a intact wiring loom complete with plug for seatbelt clasp (seatbelt reminder light/chime) from local breakers from a 2011 connect
Ideal part no wiring involved simply plug & play



Bigger bonus finally bagged the forward section of brake pipe from ABS pump to rear - which Ford no longer lists
Also vac pipe to brake servo with T-section for Throttle shut off valve - another part Ford no longer supplies (revised version does not have T-section)

[bonny222]

first time I have see this its a shame he does not live in the north he could sort my van out good on yare Paul

[paul2012]

first time I have see this its a shame he does not live in the north he could sort my van out good on yare Paul

Thanks

Unfortunately I'm in Norfolk

[paul2012]

Now I have a few days spare, time to get on with my connect

Fitted last brake pipe from ABS pump to first union for the rear & Vac pipe to brake servo



Purchased sub wiring loom for heated washer jets - Ford part No F5191790



Old washer jets to be removed



New ones fitting along with Sub loom. All holes for plug/loom clips are already there



Subloom connects onto the wiring for wiper motor / heated screen - Plug is located under N/S scuttle panel (Blue wire with plug is 1 of 2 for the heated front screen)



Bonnet sound deadening /insulation cleaned & refitted



Thinking of a way to insulate washer bottle before refitting it May help prevent it from freezing during winter (freezes even with screenwash)

[gt_addict]

Do they do mist washer jets specifically for the connect as I've got a set for a focus and the spray angle is slightly low for optimum windscreen coverage?

[nardi]

Now I have a few days spare, time to get on with my connect

Fitted last brake pipe from ABS pump to first union for the rear & Vac pipe to brake servo



Purchased sub wiring loom for heated washer jets - Ford part No F5191790



Old washer jets to be removed



New ones fitting along with Sub loom. All holes for plug/loom clips are already there



Subloom connects onto the wiring for wiper motor / heated screen - Plug is located under N/S scuttle panel (Blue wire with plug is 1 of 2 for the heated front screen)



Bonnet sound deadening /insulation cleaned & refitted



Thinking of a way to insulate washer bottle before refitting it May help prevent it from freezing during winter (freezes even with screenwash)

Wrap it in plastic bag and fill it with expanding foam ,the best insulation.

[paul2012]

Do they do mist washer jets specifically for the connect as I've got a set for a focus and the spray angle is slightly low for optimum windscreen coverage?

Have not tried them yet, I have not refitted washer bottle

[gt_addict]

Well not being funny but the brake pipes are a tad more important

Good progress though mate.

[paul2012]

Well not being funny but the brake pipes are a tad more important

Good progress though mate.

I agree

Once I have tested washers I will post results here & yes these are specifically for connects