Abacus Car Alarms

General Interest

Classic Japanese Motorcycles

Ford Transit CDL Installation Kit

Preparation:

1. Remove the door trim panels and inner plastic skins.

2. Remove the kick panels etc. to allow cables to be run to the doors.

3. In each front door locate the operating cable that connects the inner door handle with the latch. This will now be referred to as 'the cable'

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 it is pulled firmly towards you.

Front Doors:

The example described is for the right hand door ( UK driver's door ). The installation in the other front door is almost the mirror image of the door shown. The same template can be used but must be reversed.

4. Cut out the template and carefully align it on the vehicle. Drill a 3mm hole at position 'C' as shown in Pic 1. The position is not critical but ensure that the mounting will not be seen when the door trim is refitted.

5. Mount the motor locking assembly to the door at position  "C" as shown in Pic 1 and position the large metal bracket  so that it is parallel to the edge aperture. Drill through holes "A" and "B" and then secure these with two self tapping screws.

6. Clip "the cable" in position as shown in Pic 2. The outer covering of the cable must be removed between the clips. Mark the area to be removed ( about 40mm ) and cut it away carefully with a sharp knife. It may  be easier to unclip the cable again for this.

7. Fit the connecting rod and clamp as shown in Pics 1 and 2. A small "U" shaped channel fits inside the mounting clamp and onto the cable. Lock the door. Trigger the latch as explained in section 3. Loosen both the allen screws in the rod clamp. Hook the connecting rod onto the motor and then push the clamp onto the inner cable. ( see Pic 2 ) Slide the clamp to the right until it touches the clip and tighten the top allen screw. Do not yet tighten the lower screw.

8. Repeat the installation in the opposite door

9. Cut out the sliding door contact templates and carefully tape them to the door frame and sliding door as shown in Pics 3 & 4.

10. Drill the 3.5mm and 14mm holes shown on the template on the sliding door and check the template on the door frame is aligned correctly. It may help to push a pencil through the two 14mm holes to make a mark on the door frame template.

11. When you are sure that the door frame template is in the correct position drill its 3.5mm and 14mm holes.
12. Drill a 6mm diameter hole at position "D" as shown in Pics 5.

13. Bend down the metal flap shown in Pic 6.
14. Refer to Pic 6 and fit the plastic clip into hole "D". Now fit the connecting rod to the motor and bolt the motor in place in position "E" ( the flap ) and "F". Position "F" is a factory made hole and you should use the bolt that was removed when removing the trim panel. Attach the connecting rod into the clip and manually test the operation.  Note remove the bolt at position "F" before refitting the trim panel back on and then refit the bolt through the panel.

Electrical Wiring

15. Mount the control relay and run the harness. This is best installed behind the fusebox. Plug on the 5 core harness. Plug the connector with the black wires onto the pin marked with an earth symbol. A 2 way connector will be found on the harness near the control box, plug the 2 core harness onto this sliding door and the rear door.
16. Fit the electrical terminals. On the drivers door fit all five cables with connectors but plug in only the black, brown and purple wires to the actuator. The red and blue will be connected later. The front passenger door uses only the red and blue wires and these are connected to the matching colours on the actuator. At the door frame . by sliding the door, connect the twin to the smaller half of the door contact set and then fit this in place. Then connect a short piece of twin cable to the larger half of the door contact set and install this on the sliding door. Connect the remaining end of the cable to the motor. Run the cable to the rear door and connect to the motor as before.
17. Connect power and earth wires. The remaining red wire near the control box is to be connected to a permanent 12 volt power supply. This must be protected by a 25 Amp fuse. The single black wire connects to earth.

FRONT DOOR CLAMP ALIGNMENT

18. Passenger's door clamp alignment:   Ensure that the latch is triggered  ( see section 3 ) or that the doors are closed. Lock the door. Now push the passenger's door 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.
19. Drivers Door Clamp Alignment: Ensure that r=the latch is triggered or that the door is closed. Do not connect the red and blue wires 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. Test that operating the door lock from outside with the key causes the other doors to lock/unlock. Setting up the correct clam 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 and then connect the red and blue wires to the drivers door motor.
20. Test that all doors lock and unlock as they should. If any door is locking when it should unlock then reverse the red and blue wire to that motor. Refit all the panels and test again.
21. Ensure all wires are carefully insulated and secured by cable ties. Particularly check that they will not catch the cars pedals or the widow mechanism when they are used. 

HIGH TOP REAR DOORS

The motor fits into the right hand of the two doors.

1. Cut out the paper template for the rear door and tape it into place so that you can drill two 5mm holes at positions "N" & "P" as shown in Pic 7.
2. Unbolt the door latch mechanism to gain access to the operating lever. Fit the rod retaining clip into the factory hole and fit the rod into the clip. Now refit the mechanism.
3. Hook the motor onto the rod and then mount the actuator with two self tapping screws.

TWIN REAR DOORS

The motor fits into the right hand of the two doors.

1. Cut out the paper template for the rear door and tape it into place so that you can drill two 5mm holes at position "N" & "P" as shown in Pic 1.

2. Unbolt the doors latch mechanism to gain access to the operating lever Pic 2. Fit the rod retaining clip into the factory hole marked "R" in Pic 2 and fit the rod into the clip. Now refit the mechanism.
3. Hook the motor onto the rod and then mount the actuator with two self taping screws. Do not dislodge the two spacers on the actuator which are glue in place to help you with the installation.