Download Service Bulletin 33067

Braun Interlock Removal - Intermotive Interlock Installation Instr. 33067
Service Bulletin
33067
"Providing Access to the World"
August 2006
Instructions for Removal of Braun Interlock and
Installation of Intermotive® Guardian II Interlock
Kit 32539KS: Applicable for Braun Ford Paratransit
Conversion Vans equipped with Overhead Control
Units 30987A-EM7 or 30987A-EMCM
Introduction: Pages 1-4 of Service Bulletin 33067
outline the removal of a Braun Interlock from a
Braun Ford Paratransit Conversion van. The
remainder of the bulletin details the installation of
an Intermotive® Guardian II Interlock module. The
®
®
International Corporate Hdqrs: P.O. Box 310 Winamac, IN 46996 USA
1-800-THE LIFT ®
(574) 946-6153
FAX: (574) 946-4670
installation instructions are provided as a supplement
to the instructions supplied with the Intermotive®
Guardian II Interlock kit (procedures exclusive for
Braun Ford Paratransit Conversion vans). Read and
understand all instructions before beginning.
Braun Interlock Removal
Note: Optional: Removal of drivers seat may
provide greater access to the lower dash area.
For complete seat removal instructions, refer to
the Ford Motor Company Service Manual.
1
A
Disconnect power from the vehicle by
disconnecting the ground cable from the
negative battery post.
Lower Dash Panel
Knee Bolster
2
OBD Harness
B
To access the interlock module and components, remove the drivers side lower
dash panel and the knee bolster. There
are 6 securement bolts and an OBD
harness to remove from the knee bolster.
See Photos A and B.
Knee Bolster
Securement Bolts (8mm)
3
Remove the interlock display from the
vehicle dash (shown in Photo C). Be
sure to remove any excess adhesive that
is left behind.
Service Bulletin 33067
C
Page Braun Interlock Removal - Intermotive Interlock Installation Instr. 33067
Braun Interlock Removal (continued)
For Steps 4 through 12, refer to Figure 1.
Lift Harness Connected
Here (Step 4)
Cut Black/Red Wire (Step 12)
18-pin Connector
(Main Harness)
Figure 1
Braun Interlock
Module
9-pin Connector
(Display Harness)
Disconnected in
Step 9
6-pin Jumper
Cut Light Green/Yellow Wire (Step 6)
Display Harness
9-pin Connector
4
Unplug the 9-pin lift harness connector
(yellow/light blue and gray/red wires)
from the display harness 9-pin connector. See Photo D and Figure 1. Cut
the lift harness wires at the connector
(gray/red wire used in Step 16 and yellow/light blue wire not used.) Discard the
connector.
5
Unplug the 9-pin display harness connector from the module. See Photo D
and Figure 1. Clip any cable ties securing the display harness to the vehicle
and remove the display and harness
from vehicle and discard.
6
Unplug the 6-pin jumper plug from the
module. See Figure 1. Cut the lift door
ajar light green/yellow wire close to the
plug and discard the jumper plug. The
lift door ajar wire will be reconnected in
Step 27.
7
On the main harness, unplug the Braun Tharness connecting the OEM parking brake
terminal and the OEM parking brake harness. See Photo E.
Page 9-pin Lift Harness
Connector
D
Main Harness Parking
Brake Connections
E
Service Bulletin 33067
Braun Interlock Removal - Intermotive Interlock Installation Instr. 33067
Braun Interlock Removal (continued)
White/Black Wire
8
F
Locate the Braun park microswitch and
remove the blue/white wire connected to
it. Unscrew and remove the microswitch
and the white/black wire.
Blue/White Wire
Park Microswitch
9
Disconnect the 4-pin female connector from the main harness (see Figure
1 and Photo G). Cut the tan/white wire
and the yellow/orange wire at the female
connector. Discard the connector. The
tan/white wire will be reconnected in Step
16. The yellow/orange wire will be reconnected in Step 27.
G
Braun Interlock
Module
4-pin Male
Connector
10
Unplug the main harness 3-pin connector from the OEM shift lock solenoid. See
Photo H.
11
Unplug the 4-pin male connector located
next to the shift lock solenoid.
4-pin Female
Connector
Main Harness
3-pin Connector
OEM Shift Lock
Solenoid
H
Main
Harness
Service Bulletin 33067
Page Braun Interlock Removal - Intermotive Interlock Installation Instr. 33067
Braun Interlock Removal (continued)
12
Cut the black/red wire from the 18-pin
connector. See Figure 1 on page 2.
OEM White/Blue Wire
13
Cut any cable ties securing the main harness in place. Disconnect the harness
from the interlock module and discard
the harness.
14
Unfasten the interlock module from the
vehicle and discard.
Blue/White Wire
I
Black/Red Wire from
18-pin Connector
15
16
Page Locate the Braun 4-pin female connector
that is butt connected to the OEM wiring
(disconnected in Step 11). Cut the blue/
white wire at the butt connector. Butt
connect the blue/white wire to the OEM
white/blue wire and black/red wire cut
from the 18-pin connector (Step 12).
Gray/Red Wire
from Braun Lift
9-pin Connector
Butt connect the tan/white wire (cut from
the 4-pin connector in Step 9) to the
gray/red wire (cut from the 9-pin connector in Step 4).
Tan/White Wire
from 4-pin Lift
Switch Connector
J
Service Bulletin 33067
Braun Interlock Removal - Intermotive Interlock Installation Instr. 33067
Installation of Intermotive Interlock
Lift
(Green)
Port
Display
(Blue)
Port
Vehicle 1
(Orange)
Port
Vehicle 2
(No Color)
Port
Intermotive Guardian II
Interlock Module
Figure 2
17
Install the Intermotive Guardian II Interlock module (shown above in Figure 2)
in the location where the Braun Interlock was previously installed. Fasten
with two self-tapping screws (supplied).
18
Connect the display harness to the
display port (shown in Figure 2). Route
harness under the dash to the location
where the Braun display was located
(removed in Step 5).
19
Using a 3/4˝ hole saw, drill a hole
where the center of the display will be
mounted.
Caution: Check for wires or other obstructions before drilling.
K
Display
Harness
Connector
3/4˝ Access
Hole
Display
L
20
Route the display harness connector from the backside of the dash and
through the 3/4˝ hole. Connect the
display to the harness and seat display
in place. Fasten the display using the
supplied screws.
Service Bulletin 33067
Page Braun Interlock Removal - Intermotive Interlock Installation Instr. 33067
Installation of Intermotive Interlock
Push Rivets
21
Remove the auxilary switch panel by
releasing the 6 push rivets holding the
panel in place. See Photo M.
M
Push Rivets
22
On the rear of the lift switch, disconnect
the white/pink wire (shown in Photo N).
Connect the available yellow/orange
wire to this switch terminal. Secure the
wire bunch with a cable tie as shown in
Photo O.
N
White/Pink Wire
23
Reinstall the auxiliary switch panel back
in the original location using the push
rivets removed in Step 21.
O
Cable Tie
Page Yellow/Orange Wire
Service Bulletin 33067
Braun Interlock Removal - Intermotive Interlock Installation Instr. 33067
Installation of Intermotive Interlock
24
Install the Intermotive lift harness (indicated with green tape on the end of
the harness) into the Interlock module.
Route the harness up, over and behind
the knee bolster mount support.
25
Butt connect the Intermotive lift harness
fused single red wire to the white/red/
yellow wire (ignition power) from the
Braun vehicle conversion harness. See
Photo Q.
26
27
Locate the black ground wire from the
Intermotive lift harness. See Photo R.
Cut to length, strip insulation and crimp
the eyelet terminal on the end. Fasten
to the knee bolster support arm with a
self-tapping screw.
Locate the gray 2-conductor cable
black and red wires. Cut to length,
strip insulation and crimp butt connectors on each wire. Butt connect the red
wire to the yellow/orange wire from the
auxiliary switch panel lift switch and the
black wire to the light green/yellow (lift
door ajar) wire.
Service Bulletin 33067
P
Lift Harness
Knee Bolster Mount
Support
Harness
31257A
Q
White/Red/Yellow
Wire
Lift Harness
Red Wire
R
Gray Sleeve with
Black and Red Wires
Ground Wire
Page Braun Interlock Removal - Intermotive Interlock Installation Instr. 33067
Installation of Intermotive Interlock
Vehicle 1 Harness
28
Connect harness 31257A to the OEM
wired 4-pin connector (disconnected in
Step 11) as shown in Photo S.
29
Install the Vehicle 1 harness in the
corresponding location on the Interlock
module. See Photo S. Route the harness behind the knee bolster support
arm in a similar fashion to that of the lift
harness (Step 24).
S
31257A
Harness
OEM Wired 4-pin
Connector
Female 2-Pin
Connector
30
T
From the Vehicle 1 harness, connect
the male 2-pin plug into the parking
brake input and the female 2-pin connector to the OEM connector disconnected in Step 7.
Parking Brake
Input
Page Vehicle 1
Harness
Service Bulletin 33067
Braun Interlock Removal - Intermotive Interlock Installation Instr. 33067
Installation of Intermotive Interlock
Determine Transmission Code
The next steps depend on the transmission in the vehicle. In the drivers door “B” pillar, locate
the vehicle identification tag. A sample is shown below. Under TR, if the code is B or T, follow
Steps 31 through 35. If the code is A, F or Q, proceed to Step 36 (disregard Steps 31-35).
MFD. BY FORD MOTOR CO. IN U.S.A.
DATE: XXXX
GVWR: XXXXXXXXXXXXXXX
FRONT GAWR: XXXXXXX
REAR GAWR: XXXXXXXX
XXXXXXXX
WITH
XXXXXXXX
WITH
XXXXXXXXXXXX
TIRES
XXXXXXXXXXXX
TIRES
XXXXXXXXX
RIMS
XXXXXXXXX
RIMS
AT XXXX kPalXXX PSI COLD AT XXXX kPalXXX PSI COLD
XXXX
THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR
VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF
MANUFACTURE SHOWN ABOVE.
VIN: XXXXXXXXXXXXXXXXX
XXXXX
TYPE: XXXXXXXXXXXXXXXXX
XXXXX
Ford Motor Company
ID Tag
EXT PNT: XXXXXXX XXXXXXX
RC: XX DSO: XXXX
WB BRK INT TR TPJPS R AXLE TR SPR XXXXX
XXX X
XX
XXX X
XX X XXXXX XXXXX
Figure 3
UTC
i F85B-1520472-AB
Transmission Code
Location
Transmission Code B or T:
31
Feed the orange wire from the Vehicle
1 harness into the engine compartment
through the access hole shown in Photo
U. If not equipped with access hole,
drill a 5/8˝ diameter hole, and place the
supplied grommet in place to protect
the wire.
U
Caution: Check for wires and other
vehicle components before drilling.
Access Hole
Service Bulletin 33067
Vehicle 1
Orange Wire
Page Braun Interlock Removal - Intermotive Interlock Installation Instr. 33067
Installation of Intermotive Interlock
Screws
32
V
Under the hood, unfasten the coolant reservoir but do not completely
remove it. There are three screws
holding the reservoir in place. Remove
the screws and place the reservoir on
top of the engine to gain access to the
orange wire.
Coolant Reservior
33
Feed the orange wire through the
access and up to the engine wiring
cowling.
W
Engine Wiring
Cowling
34
Locate the Ford OEM blunt cut wire
for “Park”. In gas engines, the wire is
white/orange and labeled “Park Out”.
In diesel engines, the wire is yellow/
white and labeled “TRO_P”. Place a
shrink wrap sleeve on the orange wire
but do not heat in place. Butt connect
the orange wire from the vehicle 1 harness to the applicable “park” wire.
35
Apply shrink wrap over the connection, and replace the loom over the
remainder of the Vehicle 1 orange wire.
Reinstall the coolant reservoir.
Page 10
Vehicle 1
Orange Wire
X
Ford OEM
“Park” Wire
Vehicle 1
Orange Wire
Service Bulletin 33067
Braun Interlock Removal - Intermotive Interlock Installation Instr. 33067
Installation of Intermotive Interlock
Transmission Code A, F or Q:
Transmission codes A, F or Q require
an additional harness (harness
A-GRDP1 - supplied with kit).
36
On the Vehicle 1 harness, cut the orange wire near the 6-pin connector (at
the Interlock module). See Photo BB.
Save the rubber grommet but discard
the orange wire and loom.
37
Remove the center console. Caution:
The auxilary panel harness will need to
be disconnected before the console can
be fully removed.
Y
Ford Black 16-pin
Connector
Harness A-GRDP1
38
Locate the Ford black 16-pin connector located above the transmission bell
housing. See Photo Y. Seperate the
connectors.
39
Connect the 16-pin connector of harness A-GRDP1 between the separated
Ford 16-pin connector. See Photo Z.
40
Drill a 5/8˝ diameter hole in the engine
cover bulkhead flange. See Photo AA.
Z
AA
Caution: Check for wires, hoses and
other vehicle components before
drilling.
41
Route the two green wires through the
hole. Place the grommet removed in
Step 36 over the green wires and insert
it into the drilled hole to protect the
wires.
Service Bulletin 33067
5/8˝ Hole
Engine Cover
Bulkhead Flange
Page 11
Braun Interlock Removal - Intermotive Interlock Installation Instr. 33067
Installation of Intermotive Interlock
42
Install the two green wires into the two
empty cavities of the Vehicle 1 harness
connector (shown in Photo BB). Either
green wire can be installed in either
slot. Ensure that the wire pins fully lock
into the 6-pin connector.
Vehicle 1
Harness
BB
Harness
A-GRDP1
Green Wires
Orange Wire Cut in Step 36
Cable Tie
43
Cable tie the harness as shown in
Photo CC. Replace the center console
and refasten the auxilary panel harness
removed in Step 37.
44
Connect the Vehicle 2 harness into
the corresponding port on the interlock
module.
CC
DD
Vehicle 2
Harness
Vehicle 2
Port
Page 12
Service Bulletin 33067
Braun Interlock Removal - Intermotive Interlock Installation Instr. 33067
Installation of Intermotive Interlock
Harness
31527A
45
46
47
Cable Tie
Vehicle 2
Harness
Connect the Vehicle 2 harness male 3pin plug to the connector from harness
31527A (installed in Step 28). See
Photo EE. Lock the connectors together using a cable tie. Place a cable
tie around all four harnesses to secure
in place.
EE
Shift Lock
Solenoid
Connect the Vehicle 2 harness female
3-pin connector to the shift lock solenoid as shown in Photo FF.
In the electrical access panel, install
a 7.5 Amp fuse in F3 (optional circuit).
This will ensure there is power to the
Guardian II module only when the ignition is on.
FF
Vehicle 2 Harness
3-pin Connector
GG
F3
(7.5 Amp)
Fuse
Block
Service Bulletin 33067
Page 13
Braun Interlock Removal - Intermotive Interlock Installation Instr. 33067
Installation of Intermotive Interlock
48
Locate the diode in the electrical access
panel (with green/yellow wire, brown wire
and black/white wire). Cut the brown wire
3˝ from the diode. Cut the green/yellow wire next to
the diode. Butt connect the green/yellow wire into
the brown wire as shown in Photo II.
HH
II
Diode
49
Reinstall vehicle knee bolster and lower
dash panel (removed in Step 2).
50
Reinstall the drivers seat, if removed.
Ensure that both securment nuts and
bolts are tightened to torque specifications.
Brown and Green/
Yellow Wire Butt
Connection
Diode
Torque Specification: 41 foot lbs.
51
52
Page 14
Resupply vehicle power (disconnected
in Step 1).
Cycle through operations according to
the Intermotive Post Installation
Checklist.
Service Bulletin 33067