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Ford Ka Central Locking Installation Guide
PREPARATION
1
) Remove the door trim panels and inner
skin and speaker.
These are held on by a
combination of screws and clips. Two screws
are behind a removable panel on
the grab handle. This pulls straight off.
On our test car this was impossible to
do without breaking at least one of the
securing clips! This panel will push back
into place even if all the clips break.
2
) Remove the kick panels etc. to allow cables to be run to the doors.
3)
In each door locate the operating cable that connects the inner door handle
to the door latch. With the door open trigger each latch so that it is
in the closed position. Note that to lock the door the inner handle is
pressed in, to unlock it is pulled slightly towards you, and to open the
door fully it is pulled firmly towards you.
The
operating cable will be referred to as 'THE CABLE'
in these instructions.
INSTALLATION
The
example described is for the UK drivers door. The installation in the
other front floor is the mirror image of the door shown. The same templates
can be used but they must be, reversed.
The
5 wire motor assembly fits in the drivers door and
the two wire in the passenger door.
4)
Cut out the templates and carefully align them on
the vehicle as shown
in Photograph
1.
Drill 3mm
holes at positions A. B
& C, and
a 5MM hole at position D
5)
Attach the metal mounting plate to
the door with two short,
screws. (Photograph
2.)
6)
Clip "the cable" in position as shown in Photograph 2.
The
outer covering of the cable must be removed between the clips. Mark the
area to be removed ( about 40mm ) and carefully cut with a sharp knife
(stanley knife).
7)
Fit the motor and mounting plate as shown in Photograph 3.
The
motor mounting plate fits inside the door and is attached with No 8 self
tapping screws through the holes drilled at positions "C" and
"D". A
spacer (provided in the kit) must be fitted to the screw between the door
skin and the actuator mounting plate at position D.
8)
Fit the Connecting Rod and clamp as shown in Photograph 2 and 3.
A
small "U" shaped channel fits inside the mounting clamp and
onto the cable. Lock
the door. The latch must be triggered as explained in section 3.
Loosen
both the alien screws in the rod clamp. Hook
the connecting rod onto the actuator, then push the clamp onto the inner
cable (see Photograph 2) . Slide
the clamp to the right until it touches the clip and tighten the top alien
screw. Do not yet tighten the bottom allen screw.
9)
Repeat the installation in the opposite front door.
ELECTRICAL WIRING
10)
Mount the control relay and run the harness.
This
is best installed behind the fuse box. Plug on the 5 core harness, it
will only fit one way. Plug the connector with three black wires onto
the remaining pin. Run
the shortest 5 core cable to the nearest front door and the longest to
the furthest front door.
11)
Fit the electrical terminals. On
the drivers door fit all five cables with connectors but for the time
being plug on only the black, brown and purple wires to the motor.
On
the passenger door only the red and blue wires are used and these should
be connected to the matching colours on the motor.
12)
Connect Power and Earth wires. The
remaining red wire near the control box is to be connected to a permanent
power supply. On our test car position 1 of the fuse box (bottom left
hand corner) is a 12 volt permanent power supply. Remove the fuse and
then refit it with the power take off plugged on.
The
remaining black wire must be earthed. A suitable bolt was found behind
the drivers side kick panel near the floor.
13)
Alignment of the clamp on the passenger door.
Ensure
that the latch is triggered (see section 3) or that the door is closed.
Lock
the door Now push the motor piston fully "in" (retracted) and
whilst holding this position tighten the lower allen screw on the clamp.
Check
that the door can be opened and locked using the inner handle.
14)
Drivers door clamp alignment. (5 wire actuator)
Ensure
that the latch is triggered (see section 3) or that the door is closed.
Do
not connect the red and blue wires to this motor yet.
Note
that when the motor piston is pushed fully In" the other doors should
lock and that when the piston is pulled fully "out" they unlock.
Lock
the door. Push the motor piston fully "in" and then pull it
"out" very slightly until it is just before the point
where
it unlocks the other doors. Whilst holding this position tighten the lower
allen screw on the clamp.
Test
that operating the door lock from outside with the key and inside with
the handle causes the other doors to lock/unlock. Setting up the correct
clamp position may require a little trial and error but it is important
to get this part correct.
Check
that the door can be opened using the inner handle.
Now
connect the red and blue wires to the drivers door actuator.
COMPLETION
15)
Ensure all wires are carefully insulated and secured by cable ties. Particularly
check that they will not catch on the cars pedals or the window mechanism
when they are used. (5 wire motor)
Ensure
that the latch is triggered (see section 3) or that the door is closed.
16)
On some vehicles the trim panel may foul on the central locking clamp
when it is refitted. To ensure that this does not happen:
a)
Test the system is working correctly
b)
Check that the allen screws are tight.
c)
File the allen screws down until they are flush with the clamp.
d)
Remove the foam trim on the back of the trim panel at this point.
Refit
all panels and test again.
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