ford transit 2006 service traning

New Product Introduction

Transit 2006.5 (04/2006-)

Service Information

Technical Service TrainingCG 8171/S en 12/2005

TN7002156H

To the best of our knowledge, the illustrations, technical information, data and descriptions in this issue were correct at the time

of going to print. The right to change prices, specifications, equipment and maintenance instructions at any time without notice

is reserved as part of FORD policy of continuous development and improvement for the benefit of our customers.

No part of this publication may be reproduced, stored in a data processing system or transmitted in any form, electronic,

mechanical, photocopy, recording, translation or by any other means without prior permission of Ford-Werke GmbH. No liability

can be accepted for any inaccuracies in this publication, although every possible care has been taken to make it as complete and

accurate as possible.

Copyright ©2006

Ford-Werke GmbH

Service training programs D-F/GT1 (GB)

Model year 2006.5 will see the introduction of a modified front end as well as a range of new functions and equipment

options for the Transit. Also available will be two new body versions; one with a higher payload as well as a van

with medium wheelbase and flat roof (front wheel drive).

As well as the modification of the outer appearance, the interior of the driver cab has also been completely redesigned.

In addition to a multitude of storage compartments, the new interior offers the latest generation of audio units, a

navigation system, a hands-free kit, a Bluetooth interface and voice control for the phone and audio functions ex

works.

The 1,850 kg front axle load version has been added to the range. Disc brakes are installed on the rear axle.

Furthermore, stability assist is available as an option.

The previous 2.0L Duratorq TDCi engines have been replaced by a modified generation upgraded to a cubic capacity

of 2.2 liters. The 2.4L Duratorq TDCi engine versions have also been modified, while consumption has been

reduced. All engines meet emission standard IV.

The vehicle electrical system has undergone significant modification; in addition to providing an instrument cluster

with message center it now also permits some custom setting options for the locking system. A second battery

(standard on all rear wheel drive versions) as well as a function for charging the radio remote control represent a

marked improvement in terms of the power supply.

Protection against theft and ease of repair with regard to the control modules have been notably improved by an

innovative Controller Area Network.

The body has again been modified with regard to its crash characteristics. In addition, side air bags and ISOfix

mounting points are now available on the Transit for the first time.

You should get to know the new systems, their operation and their function in good time. Only then will you be

able to interpret customer complaints correctly and carry out fast and effective diagnoses and/or repairs.

The following product introduction, TN7002156H, CG 8171/S, should provide you with an overview of the vehicle's

new systems and components.

Please remember that our training literature has been prepared for FORD TRAINING PURPOSES only. Repairs

and adjustments MUST always be carried out according to the instructions and specifications in the workshop

literature. Please make full use of the training offered by Ford Technical Training Courses to gain extensive

knowledge of both theory and practice.

1Service Training (G542739)

Preface

Preface..............................................................................................................................

5At a glance.......................................................................................................................

7Position of electrical components...................................................................................................................................

Lesson 1 – General Information

Lesson 2 – Chassis

9Suspension System......................................................................................................................................

9Front axle........................................................................................................................................................................

10Brake System - General Information........................................................................................................

10General............................................................................................................................................................................

11ABS system overview.....................................................................................................................................................

12Bosch 8.0 ABS system....................................................................................................................................................

13Active rollover protection...............................................................................................................................................

Lesson 3 – Powertrain

14Engine System - General Information......................................................................................................

162.2L Duratorq-TDCi (Puma) diesel................................................................................................................................

16General...................................................................................................................................................................................................

17Engine data.............................................................................................................................................................................................

19Injection system..............................................................................................................................................................

20High-pressure pump...............................................................................................................................................................................

22Fuel injectors..........................................................................................................................................................................................

23Valve train..............................................................................................................................................................................................

24Accessory drive......................................................................................................................................................................................

Service Training2

Table of Contents

26Cylinder head.........................................................................................................................................................................................

28Cylinder block........................................................................................................................................................................................

282.4L Duratorq-TDCi (Puma) diesel................................................................................................................................

28General...................................................................................................................................................................................................

29Engine data.............................................................................................................................................................................................

31Centrifugal oil filter (140 PS version only)............................................................................................................................................

32Oil level/temperature sensor (103 kW version only).............................................................................................................................

332.3L Duratec-HE (MI4)..................................................................................................................................................

34Engine data.............................................................................................................................................................................................

37Transmission...................................................................................................................................................................

37Shift mechanism.....................................................................................................................................................................................

37Clutch assembly..............................................................................................................................................................

Lesson 4 – Electrical

38Instrument Cluster.....................................................................................................................................

38Overview.........................................................................................................................................................................

40Operation.........................................................................................................................................................................

41Configuration of the message center (high equipment level).................................................................................................................

41Diagnostics.............................................................................................................................................................................................

42Tachograph..................................................................................................................................................

42General............................................................................................................................................................................

43Audio System...............................................................................................................................................

43Overview.........................................................................................................................................................................

44General............................................................................................................................................................................

49Navigation System......................................................................................................................................

49Travel Pilot EX................................................................................................................................................................

3Service Training

Table of Contents

51Cellular Phone............................................................................................................................................

51General............................................................................................................................................................................

53Exterior Lighting........................................................................................................................................

53General............................................................................................................................................................................

54Communications Network.........................................................................................................................

54Overview.........................................................................................................................................................................

57Module Configuration................................................................................................................................

57Central module configuration.........................................................................................................................................

59Module Controlled Functions....................................................................................................................

59General............................................................................................................................................................................

63Service instructions................................................................................................................................................................................

64Power supply...................................................................................................................................................................

65PATS................................................................................................................................................................................

66Multifunction Electronic Modules............................................................................................................

66Overview.........................................................................................................................................................................

Lesson 5 – Body and Paint

69Body.............................................................................................................................................................

69General............................................................................................................................................................................

71Interior....................................................................................................................................................................................................

71Anti-corrosion protection.......................................................................................................................................................................

71End of Life Vehicles Directive...............................................................................................................................................................

73Central door locking........................................................................................................................................................

77SRS..................................................................................................................................................................................

79List of Abbreviations.......................................................................................................

Service Training4

Table of Contents

Transit 2006.5 (03/2006-)

Internal designation:

• V347 = Front wheel drive

• V348 = Rear wheel drive

Chassis

• Improved drivability through fine-tuning of springs,

shock absorbers and steering

• Modified brake system (disc brakes on the rear axle)

• Stability assist with active rollover protection

• Reinforced front axle (for vehicle versions with high

payload)


At a glanceIntroduction

Powertrain

• Modified diesel engines with increased power and

lower consumption, emission standard IV,

second-generation common-rail technology

• Modified 2.3L Duratec-HE (MI4) engine with

emission standard IV, LPG (Liquefied Petroleum

Gas) (optional)

• 2.4L Duratorq TDCi with 85 kW (115 PS) and 105

kW (143 PS) in conjunction with 6-gear manual

transmission (rear wheel drive)

• Gearshift lever in the instrument panel

Electrical system

• Central module configuration

• New GEM (Generic Electronic Module) with

integrated PATS (Passive Anti-theft System)

function

• Completely newly developed vehicle electrical

system with MS-CAN (Controller Area Network)

and HS-CAN bus

• New instrument cluster with dot matrix display

• Speed control system

• Power management

• Recharging function for the radio remote control

• Modified locking system with configurable locking

functions

• Anti-theft alarm system in accordance with Thatcham

CAT 1

• Latest generation of audio units and Travel Pilot EX

navigation system

• Hands-free kit with Bluetooth interface and voice

control

Body

• Improved crash characteristics

• side air bag modules

• New front end design

• New instrument panel with numerous storage options

• Improved corrosion protection

• Two new vehicle versions

• New exterior colors

• New fabric and leather seats

(G542739) Service Training6

IntroductionAt a glance

Position of electrical components

Shown: LHD (Left-hand Drive)

GEM behind glove compartment, passenger side1

IFS (Inertia Fuel Shutoff) (vehicles with petrol

engine)2

Right-hand crash sensor (with side air bag only)3

Receiver for radio remote control (in center of

headliner)4

Booster heater (vehicle underbody, driver side)5

Trailer module (under driver seat)6

Left-hand crash sensor (with side air bag only)7

Instrument cluster8

Hands-free kit/voice control module (beside

instrument panel)9

PCM (Powertrain Control Module) in left-hand

side of engine compartment10

ABS (Anti-lock Brake System) module, engine

compartment, underneath brake master cylinder11

GPS (Global Positioning System) antenna (in

center of instrument panel)12

RCM (Restraints Control Module) (next to the

GEM)13


At a glanceIntroduction

IFS switch

The IFS switch is installed in the instrument panel

(passenger side).


IntroductionAt a glance

Front axle

Strut and spring assembly (reinforced front axle)A

Strut and spring assembly (standard front axle)B

In addition to the front axle installed as standard, a

reinforced version with a permissible axle load of 1,850

kg is available as an option.

Press-fit ball joint (standard front axle)1

Bolted ball joint (reinforced front axle)2

Here the ball joints are bolted between the transverse

control arm and strut and spring assembly (standard:

press-fit) and larger wheel bearings installed.

This requires a new procedure for installation and

removal. Instructions for this can be found in the

relevant Service literature.

Rear axle

In addition to modified suspension points at the rear

axle and a reinforced differential, modified final drive

ratios are also available.

Vehicles with front wheel drive feature a VXT75 manual

transaxle as standard with a final drive ratio of 4,23:1

or 4,54:1 depending on the payload.

Vehicles with rear wheel drive feature final drive ratios

of 3,73:1 or 5,88:1 in conjunction with MT75 or MT82

manual transmissions.


Suspension SystemLesson 2 – Chassis

General

Front brakeA

Rear brakeB

Brake pad wear indicator1

Larger brake discs as well as modified brake calipers

are installed on the front axle depending on the engine.

Disc brakes are installed as standard on the rear axle

(except optional version).

The rear brake calipers are similar to those in the

Mondeo 2001. The special tool 206-085 is needed to

reset the brake caliper piston.

NOTE: To reset the left-hand brake caliper piston,

apply pressure to the brake caliper piston while

simultaneously turning it counter-clockwise. To reset

the right-hand brake caliper piston, apply pressure to

the brake caliper piston while simultaneously turning it

clockwise.

All vehicles feature a brake pad wear indicator at the

disc brakes. The sensors for the brake pad wear indicator

are installed at the inner brake pads and connected in

series.

If one of the sensors is interrupted, the instrument cluster

registers a missing ground and activates a warning

indicator in the instrument cluster.


Lesson 2 – ChassisBrake System - General Information

ABS system overview

HS-CAN data bus input/output signals1

Gateway (GEM)2

ABS module3

ABS motor4

ABS/HCU (Hydraulic Control Unit).5

Stoplamp switch6

Pressure sensor (in the ABS/HCU)7

Yaw rate sensor and lateral acceleration sensor

(at the right-hand or left-hand foot controls)8

Steering wheel rotation sensor (behind the

steering wheel)9

Wheel speed sensors10

Stability assist switch11


Brake System - General InformationLesson 2 – Chassis

HS-CAN input signals:

1. CKP (Crankshaft Position) sensor > GEM Gateway

> ABS module

2. Engine idle speed (from PCM) > ABS module

3. Engine status (OFF, idling, stalling) (from PCM) >

ABS module

4. Duration of driving cycle (from GEM) > Gateway

> ABS module

5. Tire circumference > GEM Gateway > ABS module

6. Ignition lock position > GEM Gateway > ABS

module

7. Torque (from PCM) > ABS module

8. APP (Accelerator Pedal Position) position > GEM

Gateway > ABS module

9. BPP (Brake Pedal Position) switch > PCM > ABS

module

10. Parking brake switch > GEM Gateway > ABS

module

11. Outside air temperature sensor > GEM Gateway >

ABS module

12. Total mileage > GEM Gateway > ABS module

13. GEM Gateway > Instrument cluster > Data for

central vehicle configuration

HS-CAN output signals:

1. Vehicle speed signal > ABS module > GEM

Gateway

2. Intervention BTCS (Brake Traction Control System)

> ABS module > PCM

3. Torque adaptation request > ABS module > PCM

4. ABS module > GEM Gateway > Instrument cluster

> ABS warning indicator


> Brake system warning indicator




> Stability assist warning indicator ESP

8. Signals of all four wheel speed sensors > ABS

module > PCM

The following brake systems are available, depending

on the vehicle version:

– ABS (Bosch 8.0)

– ABS/BTCS

– ABS/BTCS, stability assist, electronic EBA

(Emergency Brake Assist), active rollover protection

Bosch 8.0 ABS system

The Bosch 8.0 ABS system is an enhancement of the

previously installed Bosch 5.3 system.

The hydraulic ABS unit and the rear brake calipers are

service pre-filled. The front brake calipers and the

cylinders of the rear drum brake are not pre-filled.

The steering wheel rotation sensor is integrated together

with the clockspring in a housing and is located behind

the steering wheel.

The steering wheel rotation sensor works according to

the principle of magnetoresistance and permits absolute

sensing of the steering wheel position.

NOTE: When replacing the sensor, make sure that the

new sensor is installed centrally and is calibrated using

WDS (Worldwide Diagnostic System). Instructions for

this can be found in the relevant Service literature.

The yaw rate/lateral acceleration sensor is

accommodated in a housing and is located on a separate

bracket to the left of the foot controls (LHD and RHD

(Right-hand Drive)).

Stability assist can be deactivated via a switch in the

instrument panel.


Lesson 2 – ChassisBrake System - General Information

Active rollover protection

The active rollover protection (ARM = Active Roll-over

Mitigation) is a function of the stability assist program

and is integrated as software in the – ABS/stability assist

module as standard. This function does not require any

further components.

Operation

If a sudden evasive maneuver by the driver is registered

during driving, the outside front wheel is braked for a

brief period.

Evasive maneuvers are detected by the steering wheel

rotation sensor. For this purpose, a rotational angle speed

of more than 512 ° per second must be detected.

The vehicle is stabilized through the braking of the

outside front wheel. The active rollover protection is

active and effects braking in a vehicle speed range

between approx. 30 and 130 km/h.

As soon as the rollover protection is activated, this is

indicated by the stability assist warning indicator in the

instrument cluster.

If the stability assist is deactivated, the rollover

protection nevertheless remains on standby.


Brake System - General InformationLesson 2 – Chassis

Engine/transmission combinations

2.2L Duratorq-TDCi (Puma) diesel1

2.4L Duratorq-TDCi (Puma) diesel2

2.3L Duratec-HE (MI4)3

VXT-75 5-speed manual transaxle4

MT82 6-speed manual transmission5

MT-75 5-speed manual transmission6


Lesson 3 – PowertrainEngine System - General Information

The Transit 2006.5 (03/2006-) is available with the

following engine/transmission combinations:

• 2.2L Duratorq-TDCi (Puma) diesel with VXT-75

5-speed manual transaxle (front wheel drive)

• 2.4L Duratorq-TDCi (Puma) diesel with MT-75

(5-speed) and MT82 (6-speed) manual transmission

(rear wheel drive)

• 2.3L Duratec-HE (MI4) with MT-75 5-speed manual

transmission (rear wheel drive)

The engine range consists of the following power

versions:

Torque (Nm)Power output PS (kW)Cubic capacity (drive)

25085 (63)2.2L (front wheel drive)

(previously 2.0L)

285110 (81)

310130 (96)

285100 (74)2.4L (rear wheel drive)

320115 (85)

375140 (103)

200145 (107)2.3L (rear wheel drive) petrol


Engine System - General InformationLesson 3 – Powertrain

2.2L Duratorq-TDCi (Puma) diesel

General

• The previously installed 2.0L TDCi engine will be

replaced by a modified 2.2-liter version.

• The 2.2L Duratorq-TDCi (Puma) diesel is essentially

based on the previously installed 2.0-liter engine. It

is available in three different power output versions

of 63 kW, 81 kW and 96 kW.

• The engine features a modified valve train as well

as a modified accessory drive.

• The oil change interval is 25,000 km or one year.

• The 63 kW version is the entry-level version for the

front wheel drive vehicles. A turbocharger with a

wastegate is used.



• The 81 kW version additionally has oil spray nozzles

for cooling the piston crown.

• The 96 kW version has a turbocharger with

electrically adjustable guide vane geometry as well

as fuel injector nozzles with an increased flow rate.

Injection system

Denso

• Fuel injectors

• High-pressure pump

• Fuel injection supply manifold

Engine management

• Visteon

• EOBD (European On-board Diagnostic) for the

monitoring of emissions-related components.

Engine emission control

• Meets emission standard IV

• Electrical EGR (Exhaust Gas Recirculation) valve

with water cooling

Diagnosis

• Diagnosis using WDS via the DLC (Data Link

Connector).

Engine data

2.2L Duratorq-TDCi

(Puma) diesel

P8FA (85 PS)

QVFA (110 PS)

QWFA (130 PS)

Engine code

1,998 ccmCubic capacity

86 mmStroke

86 mmBore

19 : 1Compression ratio

1-3-4-2Firing order

900 rpmIdle speed

63 kW (85 PS) at 3,500

rpm, 250 Nm at 1,500 rpm

81 kW (110 PS) at 3,500


96 kW (130 PS) at 3,500


Max. power output, torque

DieselFuel



Power and torque curves

Torque (Nm)A

Engine speed (rpm)B

Power output (kW)C

Torque curve for 96 kW engine1

Power curve for 96 kW engine2







Injection system

High-pressure pipe1

Leak-off pipe2

Fuel injection line3

Injector4

Pressure relief valve5

Fuel injection supply manifold6

Fuel metering valve7

Fuel pressure sensor8

Fuel temperature sensor9

High-pressure pump10

Fuel return11



The introduction of the Transit 2006.5 (03/2006-) will

see the previously used Delphi common-rail system

replaced by the Denso common-rail system.

This has achieved an increase in engine power while at

the same time reducing fuel consumption.

Fuel injection supply manifold

Fuel pressure sensor1

Pressure relief valve2

Fuel injection supply manifold3

NOTE: The pressure relief valve operates as a

disposable valve. This means that it must be replaced

after it has been triggered once, as the fuel-tightness of

the valve can no longer be guaranteed.

The pressure relief valve opens at a fuel pressure of

approx. 2000 bar. It serves as a safeguard in the event

of a malfunction in the high-pressure system. This

prevents damage caused by excessive fuel pressure in

the high-pressure system.

Any triggering of the pressure relief valve is detected

by the PCM, which then sets an appropriate DTC

(Diagnostic Trouble Code- WDS) and the MIL

(Malfunction Indicator Lamp) is activated.

For installation and removal, refer to the instructions in

the current Service Literature.

High-pressure pump

The high-pressure pump is flanged onto the left of the

cylinder head in the direction of travel and is driven by

the intake camshaft.



High-pressure pump coupling1

Intake camshaft coupling2

Flange for high-pressure pump3

An appropriate coupling is attached to both the intake

camshaft and the high-pressure pump for this purpose.

The instructions in the service literature must be

followed when installing the high-pressure pump.



Fuel injectors

The fuel injectors are mounted by means of a bracket

with a central screw that fastens two nozzles at once.

It should be noted that if one of the two fuel injector

nozzles is removed, the second nozzle attached using

the common bracket must be resealed.

The associated high-pressure lines must also be replaced.

Instructions for this can be found in the relevant Service

literature.

Further information on the Denso common-rail injection

system can be found in the Student Information "Diesel

Fuel Injection and Engine Management Systems –

Common-Rail Systems", CG 8180/S.

Identification number (injector correctionfactor)

Illustration shows the fuel injector from above

Electrical connection, solenoid valve1

16-digit identification number2

Connection, leak-off pipe3



To ensure optimum fuel metering, the PCM must be

informed when a new injector is installed.

Furthermore, after new PCM software has been loaded

via WDS, the injectors must also be configured.

This is achieved by entering the 16-digit identification

number into the PCM using WDS, taking into account

the relevant cylinder.

Note: If the identification numbers are not entered

properly with WDS, the following faults can occur:

• Increased black smoke formation,

• Irregular idling,

• Increased combustion noise.

Valve train

The valve train has been adapted to the new position of

the high-pressure pump. The timing chain now only

drives the two camshafts. Consequently, the housing as

well as the routing of the timing chain have been

modified.



Accessory drive

Accessory drive without A/C (Air Conditioning)

compressorA

Accessory drive with A/C compressorB

Tensioner1

Tensioning rollers2

If air conditioning is installed, the accessory drive belt

of the A/C compressor is tensioned via a timing belt

tensioner. If there is no air conditioning installed, the

accessories are driven by two self-tensioning

multigroove belts.



Power steering pump1

Coolant pump2

The coolant pump is located on the front of the engine

and is flanged on directly behind the power steering

pump. Both pumps are connected by means of a shaft

and driven via a pulley.

The pumps can be replaced separately during servicing.

Instructions for this can be found in the relevant Service

literature.



Cylinder head

Oil baffle plate1

Aluminum support2

The mounting as well as the oil supply of the rocker

arms has been modified. The previously installed rocker

shafts have been discontinued. The rocker arms are now

mounted on a separate aluminum support.



Hydraulic valve clearance compensation1

Rocker arms2

The components for hydraulic valve clearance

compensation are integrated in the rocker arms. The

changes to the procedure for assembly/disassembly of

the cylinder head are described in the relevant service

literature.



Cylinder block

The cylinder block has been modified. One significant

change in comparison with the 2.0L Duratorq-TDCi

(Puma) diesel engine is the omission of the bearings for

the balance shafts.

This modifies the reference point for installation of the

reinforcing frame between the engine block and oil pan.

Please refer to the relevant Service literature for

instructions on installing the reinforcing frame.

2.4L Duratorq-TDCi (Puma) diesel

General

• The 2.4L Duratorq-TDCi (Puma) diesel engine is

essentially based on the previously installed 2.4-liter

engine. It is available in three different power output

versions of 74 kW, 85 kW and 103 kW.

• Like the 2.2-liter version, the engine features a

modified valve train as well as a modified accessory

drive.

• The introduction of the Transit 2006.5 (03/2006-)

will see the previously used Delphi common-rail

system replaced by the Denso common-rail system.

– The fuel injection pump is still driven by the

timing chain of the valve train.

• The service interval is 25,000 km or one year for all

versions other than the 103 kW version.

• The service interval for the 103 kW version is 50,000

km or two years. A service interval indicator in the

instrument cluster alerts the driver when servicing

is required.

• The 74 kW version is the entry-level version for the

rear wheel drive vehicles.

• The 85 kW version additionally has oil spray nozzles

for cooling the piston crown as well as fuel injector

nozzles with an increased flow rate.

• The 103 kW version has an electrical actuator for

turbocharger guide vane adjustment, an oil

level/temperature sensor and a centrifugal oil filter.

Injection System

Denso

• Fuel injectors

• High-pressure pump

• Fuel injection supply manifold



Engine management

• Visteon

• EOBD for the monitoring of emissions-related

components.


• Meets emission standard IV

• Electrical EGR valve with water cooling

Diagnosis

• Diagnosis using WDS via the DLC

Engine data

2.4L Duratorq-TDCi

(Puma) diesel

PHFA (100 PS)

JXFA (115 PS)

H9FB (140 PS)

Engine code


94.6 mmStroke

89.9 mmBore

19:1Compression ratio

1-3-4-2Firing order

900 rpmIdle speed

74 kW (100 PS) at 3,500


85 kW (115 PS) at 3,500


103 kW (140 PS) at 3,500


Max. power output, torque

DieselFuel



Power and torque curves

Torque (Nm)A

Engine speed (rpm)B

Power output (kW)C









Centrifugal oil filter (140 PS version only)

Cover1

Centrifuge (under the valve cover)2

Oil pressure line to the centrifugal oil filter3

The 103-kW version of the 2.4L Duratorq-TDCi (Puma)

diesel engine features a centrifugal oil filter. In

conjunction with a calculation algorithm in the PCM

and an additional oil level/temperature sensor, this

permits a service interval of up to 50,000 km.

The centrifugal oil filter is located in the cylinder head

and comprises:

• a cover cap (in the valve cover)

• a replaceable rotor (centrifuge)

The oil from the oil pan is pumped into the rotor via an

additional pressure line installed on the outside of the

engine block. Inside the rotor is a pivot axis with two

outlet openings on opposite sides.

The oil pressure and the shape of the rotor cause this

pivot axis to turn, forcing the oil in the rotor outwards.

The centrifugal force presses the particles floating in

the oil (contamination particles) against the outer wall

of the rotor, where they form a solid mass.

The oil in the rotor is filtered in this manner and then

flows back into the oil circuit.

The centrifugal oil filter can even catch small particles

of dirt that cannot be filtered using normal oil filters.

This increases the service life of the oil.



Oil level/temperature sensor (103 kW version only)

Oil level/temperature sensor1

Openings2

Oil dipstick3

An oil level/temperature sensor located on the front of

the engine directly beside the engine oil dipstick is

provided for the service interval indicator.

The oil level is measured by means of a wire coil located

inside the sensor. A continuous current is applied to this

wire coil.

The resistance and consequently the voltage drop at the

wire coil changes according to how deeply the sensor

is immersed in the oil. The measured values are

registered by the PCM.

The change in the voltage drop serves as an input

variable for calculation of the oil level.

The oil temperature is simultaneously sensed via the

integrated temperature sensor. The temperature is used

as a correction factor in the calculation.

The PCM calculates the next oil change on the basis of

an integrated strategy (which also takes into account

the mileage and engine operating conditions) and

displays it in the instrument cluster.

In addition, a separate indicator in conjunction with a

corresponding message in the instrument cluster display

warns the driver when the oil quantity falls below the

minimum level.



Service instructions

The interval indicator must be reset after an oil change

on all vehicles with a diesel engine.

Please refer to the relevant Service literature for a

description of this procedure.

2.3L Duratec-HE (MI4)

The 2.3L Duratec-HE (MI4) engine is essentially based

on the 2.0L Duratec-HE (MI4) already used in the Focus

C-MAX 2003.75 and 2004.75 Focus.



The main features of the engine are as follows:

• Longitudinally installed four-cylinder in-line engine

with two chain-driven overhead camshafts and 16

valves

• Aluminum cylinder block with lower crankcase

• Mechanical bucket tappets

• Intake manifold runner control with swirl flaps

• Ignition system with ignition coil-on-plug

• Electronic throttle valve

• Balance shafts

Engine management

• Visteon PCM

• Knock control with one KS (Knock Sensor)


• Meets European emission standard IV

• EOBD for the monitoring of emissions-related

components.

Diagnosis

• Diagnosis using WDS via the DLC

Engine data

2.3L Duratec-HE (MI4)

GZFA (emission standard

IV)

GZFB (emission standard

III)

Engine code


94 mmStroke

87.5 mmBore

9.7:1Compression ratio

1-3-4-2Firing order

rpmIdle speed

107 kW (145 PS)

at 5,250 rpm

Max. power output

210 Nm at 3,750 rpmMax. torque

Premium 95 RONFuel



Power and torque curve (when using 95 RON fuel)

Torque (Nm)A

Engine speed (rpm)B

Power output (kW)C


The valve clearance of the engine only needs to be

monitored if the engine is converted to operation using

alternative fuel (every 60,000 km).

Conversion of the engine to operation with alternative

fuel requires no modification to the engine as the valve

seats are reinforced as standard. All that is required is

an adaptation of the fuel system.

The service interval is 20,000 km or one year.



Accessory drive

Accessory drive with A/CA

Accessory drive without A/CB

For further information on the engine, please refer to

the following Student Information publications:

• New Product Information TN7002114S, Mondeo

2001, 1.8L and 2.0L Duratec-HE Petrol Engines,

CG 7870/S

• New Product Information TN7002142H, Focus

C-MAX 2003.75 (06/2003-), CG 8037/S

• New Product Information TN7002151H, Focus

2004.75 (07/2004-), CG 8144/S



Transmission

Shift mechanism

The gearshift lever is located on the instrument panel.

The reverse gear lock is overcome by lifting a

ring-shaped securing lever (previously knock-over

function).

A gearshift mechanism with control cable is used for

the first time for the rear wheel drive versions with

MT75 and MT82 manual transmissions.

A new special tool 308-650 is available for adjusting

the gearshift mechanism on all transmissions.

Please refer to the relevant Service literature for

instructions on adjusting the gearshift mechanism.

Clutch assembly

All rear wheel drive versions as well as the VXT75

manual transaxle in conjunction with the 96 kW

Duratorq TDCi engine are equipped with a dual mass

flywheel (LUK).



Overview

HS-CAN data bus1

MS-CAN data bus2

Gateway (GEM)3

Instrument cluster module4

Displays in the instrument cluster5

Multifunction switches ("set/reset" button, rotary

switch)6

Digital tachograph7

Brake pad wear indicator8


Lesson 4 – ElectricalInstrument Cluster


1. CKP sensor > GEM Gateway > Instrument cluster

> Tachometer

2. Wheel speed sensor > ABS module > GEM Gateway

> Instrument cluster > Vehicle speed display (VSS

(Vehicle Speed Sensor))


> Brake system warning indicator




> Stability assist warning indicator ESP

6. PCM-controlled battery charge > Generator > GEM

Gateway > Instrument cluster > Charging system

warning indicator

7. PCM > GEM Gateway > Instrument cluster > Glow

plug warning indicator (vehicles with diesel engine)

8. ECT (Engine Coolant Temperature) sensor > PCM

> GEM Gateway > Instrument cluster > Temperature

display

9. PCM > GEM Gateway > Instrument cluster > Speed

control system warning indicator

10. PCM > GEM Gateway > Instrument cluster > MIL

warning indicator

11. PCM > GEM Gateway > Instrument cluster >

Powertrain warning indicator or display in the

message center

12. Oil pressure switch > PCM > GEM Gateway >

Instrument cluster > EOP (Engine Oil Pressure)

warning indicator

13. Oil level/temperature sensor > PCM > GEM

Gateway > Instrument cluster > Engine oil level

warning indicator or oil change warning in message

center display

MS-CAN input signals:

1. Ignition lock position > GEM Gateway > Instrument

cluster (power management)

2. Reversing lamp switch > GEM Gateway >

Instrument cluster

3. Time > GEM Gateway > Time display in instrument

cluster (with RDS 1500 or without radio)

4. Alarm time > GEM Gateway > Instrument cluster

5. Brake fluid level sensor GEM Gateway > Instrument

cluster > Parking brake warning indicator

6. Water-in-fuel sensor > GEM Gateway > Instrument

cluster > Warning LED (Light Emitting Diode)


Instrument cluster > Ice warning indicator or

temperature gauge in the display in the message

center

8. RCM > Instrument cluster > Air bag warning

indicator or safety belt warning indicator

9. Headlamp switch > GEM Gateway > Instrument

cluster > Lighting indicator or light-on warning tone

10. PATS transceiver > GEM Gateway > Instrument

cluster > PATS indicator

11. Door contact/hood switch > GEM Gateway >

Instrument cluster > Door warning indicator or door

status display in the message center



13. Fuel level sensor > GEM Gateway > Instrument

cluster > Tank display or fuel reserve warning

indicator

MS-CAN output signals:

1. Instrument cluster > GEM Gateway > ABS module

> Mileage

2. Instrument cluster > Audio unit > Vehicle speed

signal

3. Instrument cluster > Audio unit > Reverse gear signal


Instrument ClusterLesson 4 – Electrical

4. Instrument cluster > Audio unit > Time display (not

with RDS 1500)

5. Instrument cluster > DLC

Operation

Shown: Low equipment level

PATSLED1

Brake pad wear warning indicator2

Trip odometer reset button (not with high

equipment level)3

Time setting button (not with high equipment

level)4

Multi-function display5

Service reminder indicator6

The instrument cluster is available in two versions

depending on the vehicle equipment. The version with

high equipment level has a full dot-matrix display as

well as an info LED between the large analog displays.

Messages are shown in the instrument cluster via the

display and the LED. The LED lights up yellow or red

according to the significance of the message.

The instrument cluster is connected to the MS-CAN bus

and forms the interface between the MS-CAN bus of

the audio system and the MS-CAN bus of the rest of

the module communications network. It contains three

120 Ohm terminating resistors; two for the audio

network and one for the rest of the MS-CAN network.


Lesson 4 – ElectricalInstrument Cluster

The instrument cluster is part of the central vehicle

configuration and saves the configuration data of all the

modules stored in the GEM. However, this data serves

only as a backup copy in the event that the GEM needs

to be replaced.

It is not possible to change and/or enter the mileage

following replacement. The original mileage will be

automatically read in and saved via the central vehicle

configuration.

Configuration of the message center (highequipment level)

By pressing the "Set/Reset" buttons on the steering

column control lever, a sub-menu can be selected or a

setting can be changed.

By operating the rotary switch on the steering column

lever, you can scroll through the displays within a

particular menu.

Diagnostics

The instrument cluster can be diagnosed using the WDS.

Observe the instructions on module configuration when

replacing the instrument cluster.


Instrument ClusterLesson 4 – Electrical

General

A digital tachograph (Siemens VDO, type DTCO 1381)

is available for the Transit 2006.5.

This tachograph works with the aid of chip cards which

store all the necessary information. These chip cards

are driver-specific and must be inserted in the card

reader before departure.

The data of two drivers can be registered in parallel

using two chip-card readers. Further instructions on

operation can be found in the relevant Owner's

Handbook.

The tachograph in 1-DIN radio format is installed above

the instrument panel and includes

• two chip-card readers,

• an integrated printer for creating logs for drivers and

inspectors,

• a display containing important information, e.g. on

the current driving and rest-period account,

• a real-time clock,

• various controls.

The tachograph registers

• driving, working and rest times for the driver and

passenger,

• speed (24 hours in mass memory) and distance

driven,

• operation-specific parameters such as speed, other

work operations on the vehicle and events such as

information on calibration and/or periodic testing.

The data is stored:

• vehicle-specifically in an integrated mass memory

unit with capacity for recording the activities for

approx. 365 days

• driver-specifically on the personal driver card with

capacity for approx. 28 days

A separate VSS that transmits a digitally encrypted

signal directly to the tachograph is installed at the

transmission during installation of the tachograph.

The sensor is secured against tampering by a lead seal.

Installation and calibration of the system is carried out

by authorized service partners.

The tachograph is supplied with separate operating

instructions (from Siemens).

Diagnosis can only be carried out by authorized dealers.

Note

The introduction of digital tachographs in commercial

vehicles with a permissible gross weight of more than

3.5 tons and vehicles with more than nine seats came

into force on August 5, 2005 (European Legislation

EEC No 3820/85 and 3821/85).

Digital tachographs have been permitted on new vehicles

since mid-2005. It must be noted here that digital

tachographs may only be diagnosed and/or repaired by

authorized Siemens dealers. Further instructions on this

can be found in TSB 59/2005.

Further information at "http://www.vdo.com"


Lesson 4 – ElectricalTachograph

Overview

MS-CAN data bus1

Gateway (instrument cluster)2

Audio/navigation unit3

Right-hand speaker4

Left-hand speaker5

Hands-free system/Bluetooth/voice control

module6

Audio remote control7

GPS/GSM (Global System for Mobile

Communication)/AM (Amplitude

Modulation)/FM (Frequency Modulation)

antenna

8


Audio SystemLesson 4 – Electrical


1. Vehicle speed signal > Wheel speed sensor > ABS

module > GEM Gateway (MS-CAN) > Instrument

cluster gateway > Audio unit

2. Ignition lock > GEM Gateway > Instrument cluster

gateway > Audio unit

3. Reversing lamp switch > GEM Gateway >

Instrument cluster gateway > Audio unit > Reverse

gear signal

4. Microphone > Bluetooth/voice control module >

audio system


1. Instrument cluster gateway > Audio unit > Time

display/setting (not with RDS 1500)

2. Audio unit > Bluetooth/voice control module

3. Audio remote control > Audio unit > Bluetooth/voice

control module

General

All multimedia devices (audio units, navigation devices

and hands-free kit) are connected to each other via a

separate MS-CAN network (audio network).

The instrument cluster, which acts as a gateway between

the audio network and the rest of the MS-CAN network,

enables the following functions:

• Time (from the GEM to the audio unit)

• Setting time (from the audio unit to the GEM)

• Vehicle speed information

• Reverse gear information

• Diagnostics

• Clear module

• Central module configuration

The new generation of audio units is available in the

following versions for the Transit:

• 1500 RDS

• 6000 CD

• 6006 CDC


Lesson 4 – ElectricalAudio System

1500 RDS

1500 RDS, RDS, 2 X 6 watt output, not connected to

the MS-CAN bus



6000 CD

6000 CD (Compact Disc), larger display, CD player, 4

x 17 Watt output, Bluetooth-compatible



6006 CDC

6006 CDC, as 6000 CD, with integrated 6-disc changer

Radio remote control is available for certain equipment

levels (same as Focus/Focus C-MAX).

The time is shown in the display of all units with the

exception of the 1500 RDS. The radio display serves

exclusively to show and set the time. The actual clock

is located in the GEM.

For vehicles equipped with 1500 RDS or vehicles

without radio, the time is displayed in the instrument

cluster.

It is not possible to display the RDS time in the audio

unit (deactivated in the radio software).

Function changes compared with the devices installed

in the Focus 2004.75 and Mondeo 2001 (does not apply

to 1500 RDS):

• Separate CLOCK button

• No PTY function

• REG function can be disabled

• No frequency display when the station name appears

One significant change to the 6000 CD and 6006 CDC

in comparison with the units installed in the Focus and

Mondeo is the discontinuation of the program type code

(PTY) function. The PTY button has been replaced by

a new phone button bearing a handset symbol instead

of the inscription "PHONE".

The phone button has been replaced by a button with

the inscription "CLOCK" for setting the time. This

makes it easier to set the time by means of direct access

to the appropriate menu.

In addition, all audio units feature a modified anti-theft

protection system. This system works on the basis of

the VIN (Vehicle Identification Number) identification

rather than entry of a key code (see also central vehicle

configuration).



Instructions about the function and operation of the

audio units can be found in the Owner's Handbook

"Audio", CG3454 or 6S6J-19C104-HA 10/2005

20050920142621.

VIN locking function

A new type of anti-theft protection is being introduced

during production.

The VIN is, as was the case previously, transmitted to

the audio unit via the MS-CAN bus and saved in the

unit while still in the factory.

However, the keycode function is disabled, and instead

the VIN of the audio unit is read in and checked every

time the ignition is switched on.

As soon as the audio unit is correctly identified when

the ignition is switched on (even when the battery has

been disconnected), it can be operated without any

further input.

If an audio unit whose VIN does not match that of the

vehicle is identified, the audio unit remains disabled.

It is not possible to manually enter or change the VIN.

Installing a previously configured unit (with saved VIN)

in another vehicle requires access to OASIS (On-line

Automotive Service Information System) in conjunction

with WDS.



Travel Pilot EX

A factory-installed navigation system is available in the

Transit for the first time. The Travel Pilot EX

corresponds in function to the unit available in the Focus

2004.75 (11/2004-) and offers the following features:

• 4 x 20 W output power

• Large 4-inch monochrome display

• MP3-compatible CD drive

• Bluetooth-compatible

• Turn-by-turn navigation (displays the street names

even if no route is calculated)

• Corridor function (additional area either side of the

route. In this corridor, the system takes into account

the most up-to-date traffic information).

• Voice output without navigation CD-ROM (in

conjunction with corridor function)

• Navigation CD with detailed and additional data

• Simulation mode can be activated/deactivated

directly from the Menu button

• The designation "RNS" has been dropped, no

reference to the manufacturer

NOTE: When installing a new navigation unit, the

navigation unit must be configured by selecting the

routine "Install programmable modules" in WDS.

Further information on operation is provided in the

Owner's Handbook CG 3474.


The Travel Pilot EX can be diagnosed using two

different menus:

• Tuner test mode

• Dealer service mode


Navigation SystemLesson 4 – Electrical

DescriptionButton combination

Tuner test modeS1 + MENU

Dealer service mode

FM steps: This sets the size of the steps for the station search, usually 100 kHz, 50

kHz when cable connected in demo stand.

Version: Displays different versions (hardware, software, CD-ROM (Read Only

Memory))

Display test: Different patterns are shown on the display, enabling individual faulty

pixels to be detected

Faults: Stored diagnostic trouble codes are displayed here; this item cannot be

selected if no faults are stored

Navigation download: Loads the navigation software from the CD-ROM into the

unit's memory

System download: Loads the system software from the CD-ROM into the unit's

memory

GPS information: Displays the latitude and longitude for the current position and

the number of satellites received

CD eject: Allows the CD eject button to be locked (e.g. for hire cars, demonstration

units, etc.)

System test: Different tests can be selected, the sensor test is important for service

S4 + MENU

All menus are exited when the unit is switched off or

the "ESC" (Escape) button is pressed when in the main

menu. The revised settings will then be stored.

Some of the information available in the dealer menu

can also be retrieved by pressing the NAV button and

then the preset button S5 or S6 (in the EXTRA display).

A diagnostic trouble code table is contained in FordEtis,

Group 419-07B.


Lesson 4 – ElectricalNavigation System

General

MS-CAN data bus input/output signals1

Gateway (instrument cluster)2

Hands-free system/Bluetooth/voice control

module3

Audio/navigation unit4

Cellular phone5

GSM antenna6

Handset holder7

Microphone8


Cellular PhoneLesson 4 – Electrical

A factory-installed hands-free kit is available in the

Transit for the first time.

Three types of system are available regardless of the

audio unit installed:

A. Hands-free kit with handset holder

B. Hands-free kit without handset holder, with

Bluetooth and voice control

C. Hands-free kit with handset holder, Bluetooth and

voice control

With all versions, voice output is via the vehicle

loudspeakers. The function of the system essentially

corresponds to that in the Mondeo 2001 (06/2003-),

Focus C-MAX 2003.75 (06/2003-) and Focus 2004.75

(07/2004-). Further information is provided in the

training literature "Infotainment – Fundamentals"

TC4012031H, CG 8140/S and "Infotainment – Service

and Diagnosis" TC4012032H, CG8141/S and in the

Owner's Handbook CG3527.


1. Audio remote control > Audio unit > Bluetooth/voice

control module

2. Station buttons > Audio unit > Bluetooth/voice

control module



Audio unit


Navigation system


Lesson 4 – ElectricalCellular Phone

General

The mounting points of the headlamps have changed

on account of the redesign of the headlamps.

In order to install new bulbs, the headlamp must be

removed. Please refer to the Service literature for

instructions.

In addition to the normal functions, the following

functions are also available:

• Low beam switch-off delay

• Autolamps (in conjunction with rain sensor)

The low beam switch-off delay feature is activated by

pressing the high-beam lever when the ignition key is

in position "0". Activation is confirmed by a short

audible signal.

The low beam switch-off delay feature, when activated,

keeps the side lamps, the low beams and the

number-plate lamp on for approx. 30 seconds after the

last door is closed (this can be extended to max. 180

seconds through configuration).

If a vehicle door or the liftgate is opened, the switch-off

delay is increased to 180 seconds. After the last door

has been closed, the switch-off time is reset to 30

seconds.

The dipped beam switch-off delay function is

deactivated:

• when the ignition is switched on

• by pressing the high-beam lever again

The autolamp feature works in the same way as on the

Mondeo 2001 (06/2003-), Focus C-MAX 2003.75

(06/2003-) and Focus 2004.75 (07/2003-).

All models with the exception of the flatback versions

feature a high mounted stoplamp. The design of the rear

lights has been modified through the use of a clear-glass

cover.

Also integrated is a one-touch turn signal function, i.e.

briefly touching the direction indicator control triggers

three short flashes of the turn signal.


Exterior LightingLesson 4 – Electrical

Overview

MS-CAN data busA

ISO 9141B

Outgoing/incoming lines (RX/TX)C

LIN data busD

HS-CAN data busE

SRS (Supplemental Restraint System) module1

Phone / Bluetooth/voice control module2

Instrument cluster3

Audio unit4

Parking aid module5

GEM6

Light/rain sensor7

Radio remote control reception module8

PATS transceiver unit9

Battery-buffered anti-theft alarm system horn

(BBS)10

Passenger compartment control sensor(s)11

PCM12

ABS module13

Steering wheel rotation sensor14

Yaw rate/lateral acceleration sensor15

DLC16

Terminating resistors17


Lesson 4 – ElectricalCommunications Network

Up to four data bus systems can be used in the Transit

2006.5 depending on the model and equipment:

• HS-CAN bus

• MS-CAN bus

• ISO 9141 protocol

• LIN (Local Interconnect Network)

All systems can be diagnosed via the DLC.

The following modules are implemented as gateways:

– GEM Gateway between the HS-CAN and the central

electrics MS-CAN

– Instrument cluster gateway between the central

electrics MS-CAN and the audio system MS-CAN

.

HS-CAN

The following systems are connected to the HS-CAN

bus:

• ABS

– Steering wheel rotation sensor

– Yaw rate/lateral acceleration sensor

• PCM

• GEM (Gateway to the HS-CAN)

The two terminating resistors, 120 Ohm each, of the

HS-CAN data bus are integrated into the PCM and the

GEM.

Given the fact that both 120-ohm resistors are connected

in parallel, the total resistance is 60 ohms (measured at

the DLC). When a control module is disconnected, 120

ohms must be measured at the DLC.

MS-CAN

Two separate MS-CAN networks are used in the Transit:

1. MS-CAN for all systems apart from the audio

system:

Fuel fired booster heater–

– RCM

– Parking aid module

– Instrument cluster

2. MS-CAN for the audio system

– Instrument cluster

– Audio system

– Bluetooth/voice control module

Here, the instrument cluster acts as a gateway to the

MS-CAN network of the audio system. This gateway

provides the information required for the audio system

and the Bluetooth/voice control module (see the

description of the audio systems).

This eases the data transfer load on the remaining

MS-CAN network and reduces potential sources of

faults.

The two terminating resistors, each of 120 ohm, of the

MS-CAN data bus are integrated into the GEM and into

the instrument cluster. The total resistance of the central

electrics MS-CAN amounts to 60 ohms, measured at

the DLC.

The two terminating resistors of the MS-CAN audio

system are installed together in the instrument cluster.

As this network is not connected to the DLC, the total

resistance cannot be measured at the DLC.

ISO

The following systems are connected using the

ISO-9141 protocol:

• Receiver for radio remote control

• PATS transceiver

• Light/rain sensor


Communications NetworkLesson 4 – Electrical

LIN bus

The following systems are connected to the LIN bus

(only for vehicles with Thatcham CAT 1 alarm and

closed driver cab):

• Ultrasonic sensors

• Battery-buffered alarm horn

LIN is a standard specifically designed for cost-effective

communication between intelligent sensors and actuators

in vehicles. It is used wherever the bandwidth and

versatility of a CAN are not required.

Within a LIN bus the transfer rate can reach up to 20

kbit/s. On the Transit, the speed is approx. 9,600 baud

(9.6 kbit/s).

A LIN network comprises a LIN master and one or more

LIN slaves. The LIN master, which is the GEM in the

case of the Transit, has information on the temporal

sequence of all the data to be transmitted.

This data is transmitted by the relevant LIN slaves (e.g.

ultrasonic sensors) when requested by the LIN master.

LIN is a single-wire bus, i.e. the data is transferred in

the cable via one wire. The same cable normally also

supplies the power.

The ground for the power supply voltage is also the

ground for data transfer.

No terminating resistors are used in the LIN network.


Lesson 4 – ElectricalCommunications Network

Central module configuration

Previous configuration principleA

Central module configuration principleB

Control modules1

GEM2

WDS3

CAN4

The modules in the vehicle were previously configured

using WDS and the "Module Programming"

(inhale/exhale) function.

In this case, the actual status of the relevant module is

read into WDS and then stored on the new module.

The Transit 2006.5 uses a new method of module

configuration, so-called central module configuration.

Here, all the required configuration parameters are

stored in the GEM at the factory, and from there they

are transmitted via the CAN bus network to all the

individual modules.

WDS now contains a new routine for replacing or

retrospectively changing the configuration data. This

new routine is used to perform the central module

configuration.

In this case, however, the data is not read into WDS as

previously, instead it is transferred by the GEM to the

corresponding module. The WDS merely initiates and

monitors the procedure.

For safety reasons, all the configuration data which are

saved in the GEM are also backed up in the instrument

cluster. Then, if the GEM has to be replaced, this allows

the necessary configuration data to be read out from the

instrument cluster with the aid of WDS and transferred

to the new GEM.


Module ConfigurationLesson 4 – Electrical

The GEM checks the configuration data for consistency

and stores a DTC in the event of a fault. Operation of

the GEM may be restricted in the event of an error.

If the GEM is replaced, the keys for both the remote

control and for the PATS will need to be re-adapted.

The procedure for this is the same as for current

vehicles.

VIN identification

The VIN is saved in the individual modules at the

factory for the purpose of VIN identification.

As soon as a module is identified when the ignition is

switched on (even when the battery is disconnected), it

can be operated without any further input.

If no VIN or an invalid VIN is read in by a module, it

is stored in a memory. Subsequent operation of the

module may be restricted depending on its purpose.


Lesson 4 – ElectricalModule Configuration

General

The GEM is located underneath the dashboard behind

the glove compartment. The glove compartment can be

folded down by pressing together the two sides.

GEM functions

The GEM is made up of a power distribution section

(including fuses and relays) and an electronics module,

which controls the operation of most of the electronic

convenience systems.

Three different types of GEM are installed, depending

on the equipment version. Only the fully equipped

version is available for service:

• Version A (low equipment level); Part No.:

6C1T-14A073-AX

• Version B (middle equipment level); Part No.:

6C1T-14A073-BX

• Version C (high equipment level); Part No.:

6C1T-14A073-CX

• Version D (for Service department only, corresponds

to Version C); Part No.: 6C1T-14A073-DX

C/DBAFunction/system

Communication

XXXMS-CAN Gateway

XXXHS-CAN Gateway


Module Controlled FunctionsLesson 4 – Electrical


504929Number of digital inputs

522Number of analog inputs

XLIN (Local Interconnect Network)

XISO K-line (light/rain sensor)

XXISO K-line for radio remote control

XXXInterface for PATS transceiver

XXXCentral vehicle configuration main module

XXXNetwork management

XXXClock

Hardware

202020Number of fuses

000Number of external relay slots

1184Number of integrated relays

13911979Number of plugs/pins

15137Number of drivers (low side)

432Number of drivers (high side)

Voltage supply

XXXIgnition lock status

XXXAdditional battery check

XXXPower management (e.g. shipping mode)

XXXBattery-saving function

Exterior lighting

XXXSide lamps

XXXHigh beams

XXXLow beams

XXXRear fog lamp

XXXTurn signal lamps

XXXHeadlamp switch input (light-on warning tone)


Lesson 4 – ElectricalModule Controlled Functions


XXXReversing lamps

XXXStoplamps

XXXNumber-plate lamps

XXXHazard flasher

XXXHigh mounted stoplamp (CHMSL)

XXXHazard flasher off (in case of standing start) *

XXXHazard flasher in case of accident *

XXXOne-touch turn signal function

XXXHeadlamp flasher

XXXLow beam switch-off delay

XXFog lamps

XDaytime running lamps

XAutolamps

Interior lighting system

XXXInterior lighting upon locking/unlocking

XXXInterior lighting, driver cab

XXXInterior lighting, loadspace

XXDimmer function

Fuel supply and fluid indicators

XFuel pump (petrol engines only)

XXXFuel gauge

XXXBrake fluid level indicator

XXXEngine off in case of crash

Heated windows

XXHeated windshield

XXHeated rear window(s)

XXHeated exterior mirrors

Wash/wipe system




XXXWash/wipe function

XXXWindshield wipers

XXRear wiper (automatic when reverse gear is engaged)

XRain sensor

Locking and anti-theft protection

XXXPATS function (reading in of key)

XXXDoor lock switch input

XXXVIN identification

XXAlarm

XXRadio remote control (with external receiver)

XXCentral/double locking system

XXPartial unlocking

XXAutomatic relocking

XXIndividual door relocking

XXAutomatic locking on start of journey

XXLocking/unlocking – visual/audible signal

XXUnlocking after failed locking (reverse cycling)

XXIndividual door relocking (slam locking)

XConfigurable unlocking

XThatchham CAT 1 alarm (BBS horn, interior monitoring and

glass break sensors)

Other functions

XXXDetection of APP

XXXDetection of CPP (Clutch Pedal Position)

XXXParking brake status

XXXDiagnosis of brake pedal (in addition to ABS)

XXXHorn (for signaling central locking only)

XXXTrailer towing




XSpeed control system

XSensing of the ambient air temperature

XXXService mode

XXXDiagnosis with WDS

* May be deactivated in the factory, depending on market

All variants of the GEM contain a clock and an alarm

function. The clock time is routed to other modules via

the CAN network. The clock time is adjusted via the

radio or the instrument cluster.

Gateway

The GEM is connected to the following modules via

the HS-CAN:

• PCM

• ABS module


the MS-CAN:

• Instrument cluster

• Parking aid module

• RCM

The GEM is the gateway for the communications

between the MS-CAN and the HS-CAN.


the LIN bus:

• Battery-buffered alarm horn (BBS = Battery Back-up

Sounder)

• Parking-aid module

• Interior scanning sensors


the MS-CAN:

• Instrument cluster

• Parking aid module

• RCM


serial interfaces:

• Remote control receiver

• PATS transceiver (ring antenna)

• Light/rain sensor

Hazard warning lights for an accident

Accident detection is carried out by the RCM The signal

is transmitted via the MS-CAN bus to the GEM.

If an event is detected, the hazard warning lights are

actuated by the GEM (see also: crash mode). It can be

switched off via the hazard flasher switch.


The GEM features a service mode, which enables

checking of the various input and output signals.

Proceed as follows to activate the service mode:

• Switch off the ignition

• Ensure that the alarm system is deactivated



• Ensure that diagnostic mode or programming mode

is not activated

• Press one of the two front door lock switches eight

times within 10 seconds

Entry into service mode is confirmed by an audible

signal; the turn signals as well as the turn signal

indicators on the instrument cluster flash twice.

The input signals can then be checked. Each input signal

is indicated by an audible signal; the turn signals as well

as the turn signal indicators on the instrument cluster

flash once.

It is not possible to check the output signals during the

self-test.

The GEM automatically ends service mode under any

of the following conditions:

• 20 seconds pass without anything being selected or

operated.

• The headlamp flasher is operated and the ignition is

switched OFF at the same time.

• Ignition lock position III (engine start)

• The voltage supply is too low (< 9 Volt).

• The voltage supply is too high (> 16 Volt).

A signal tone sounds twice to indicate that the service

mode has been exited. Further information on

diagnostics can be found in the relevant service

literature.

Power supply

The power supply includes a range of measures to ensure

reliable operation of the vehicle at all times.

The generator outputs 150 A as standard.

A second battery (590 Ah) is installed as standard on

all rear wheel drive versions. This is available as an

option on the front wheel drive versions.

Both batteries are charged when the engine is running,

however a cutoff relay means that only one of the two

batteries can be discharged when the ignition key is in

position "I". This means that the full power of the battery

is always available for the engine start.

The "Smart Starting" strategy is still integrated. Here

the power supply to the starter motor is interrupted as

soon as the engine reaches a set engine idle speed. This

decreases power consumption and increases the service

life of the starter motor.

Radio remote control

The radio remote control is integrated into the key. A

charging function for the remote control batteries is

integrated into the remote control. Here, the rechargeable

battery which is integrated in the key (previously it was

a non-rechargeable battery) is continuously recharged

while the ignition is switched on.

The charge function of the accumulator is effected by

an induction circuit which has previously been used for

operation of the PATS transponder. Additional

components are therefore not required.

The charging process is initiated and executed by the

GEM via the ring antenna of the transceiver at the

ignition lock once the PATS key query has been

performed.

The recharging function provides a power supply which

ensures that the remote control remains operative at all

times.

A charging time of approx. 20 minutes generates enough

power to transmit a radio signal between the transmitter

and the receiver approx. 32 times.

The remote control housing is additionally sealed and

watertight. It is possible to identify the key by its blue

housing. Replacement of the battery is not possible.



Power management

Power management facilitates an effective supply of

power appropriate to the respective requirements of the

individual modules by means of various modes.

The power management function is integrated into the

GEM.

One of four different vehicle modes is used depending

on the operating status of the vehicle:

• Factory mode

• Shipping mode

• Standard mode

• Crash mode

Factory mode:

• Factory mode is activated during production of the

vehicle. In this mode, relays are shut off to reduce

the power supply to a minimum. When the vehicle

leaves the factory, factory mode is deactivated and

shipping mode is activated.

Shipping mode:

• Shipping mode is activated en route from the factory

to the dealer. The vehicle can be driven without

impairment of the driving safety systems.

• Individual modules and/or electrical systems (e.g.

anti-theft alarm system, clock and radio remote

control) are deactivated when the ignition is switched

off.

• This ensures that the battery has enough power when

the vehicle is handed over to the customer.

If the engine is started while the system is in shipping

mode, the mode is interrupted only temporarily. It is

resumed again as soon as the ignition is switched back

off.

Shipping mode must be deactivated by the dealer.

This is done by pressing the brake pedal five times

and the hazard flasher switch twice within 10 seconds

when the ignition is switched off.

The GEM automatically switches to normal mode once

shipping mode is deactivated.

Normal mode:

• Normal mode guarantees the full functionality of the

entire electrical systems.

Crash mode:

• Crash mode is activated as soon as the RCM registers

a vehicle impact of appropriate force.

The following functions are carried out:

• The vehicle will be centrally unlocked if it is locked

at the time of impact.

• Activates the hazard warning lamps.

• The fuel-fired booster heater is deactivated.

Crash mode is deactivated as soon as the ignition key

is turned to position "0" and then back to position "II"

again. The hazard flashers are deactivated by pressing

the hazard flasher switch.

PATS

The PATS functionality is integrated into the GEM.

Accordingly, the transceiver unit is directly connected

to the GEM (previously it was connected to the PCM).

After the key code is read in (in ignition lock position

II), the appropriate information is transmitted from the

GEM to the PCM via the HS-CAN data bus.

Depending on this query and on the key status, starting

is then enabled by the PCM.

NOTE: When replacing the GEM, it is necessary to

reprogram the PATS keys. Instructions for this can be

found in the relevant service literature.

The key has a plastic transponder. Coded access is used

during programming of the key.



Overview


Lesson 4 – ElectricalMultifunction Electronic Modules

HS-CAN data bus1

MS-CAN data bus2

Gateway (GEM)3

GEM4

Windshield wiper motor5

Rear window wiper motor(s)6

FPDM (Fuel Pump Driver Module)7

Headlamp8

Heated rear window, heated exterior mirrors9

Heated windshield10

Instrument cluster11

Ignition lock12

Stoplamp switch, BPP switch, CPP switch13

Fuel level sensor14

APP sensor15

Reversing lamp switch16

PATS transceiver17

Multifunction switches (wiper, light)18

Speed control switch19

Heated windshield switch20

Heated rear window switch21

Hazard flasher switch22

Ambient air temperature sensor23

Headlight switch24

Brake fluid level switch25

Light/rain sensor (ISO 9141)26

Not shown:

• Parking brake switch

• Trailer module

• Door switches

• Battery cutoff relay

• Fuel pump (vehicles with petrol engine)

• Horn/alarm horn

• Windshield washer pump


1. Vehicle speed signal: Wheel speed sensor > ABS

module > PCM > Gateway > GEM current

consumption for trip computer

2. PCM controlled battery charging: Generator > PCM

> Gateway > GEM (control of heated windshield)

3. Total mileage: Instrument cluster > Gateway > GEM

4. Water-in-fuel sensor > PCM > Gateway > GEM

(warning indicator request to instrument cluster)

5. PCM > Gateway > GEM warning indicator request:

– MIL

– Engine warning indicator

– Low oil pressure warning indicator

– Oil change

– Glow plug indicator (vehicles with diesel engines)

– Engine coolant temperature ECT

– PATS

– Charge indicator lamp

– Speed control system

6. PCM > Gateway > GEM (fuel pump ON/OFF

request)

7. CKP sensor > GEM Gateway > Engine speed

8. ABS module > GEM Gateway > Request for ABS

brake system warning indicator and stability assist

warning in instrument cluster

HS-CAN output signals:

1. APP > GEM Gateway > PCM

2. Status BPP/CPP switch > GEM Gateway > PCM

3. Speed control system > GEM Gateway > PCM


PCM

5. Status PATS key: PATS transceiver > GEM Gateway

> PCM (start approval)

6. Ignition lock position status > GEM Gateway > PCM


Multifunction Electronic ModulesLesson 4 – Electrical

7. Parking brake control status > GEM Gateway > ABS

module/PCM

8. Fuel level status > GEM Gateway > PCM


1. Setting the time/alarm time: Instrument cluster >

GEM

2. Crash signal > RCM > GEM


1. PCM > Gateway > GEM warning indicator request:

– MIL

– Engine warning indicator

– Low oil pressure warning indicator

– Oil change

– Glow plug indicator (vehicles with diesel engines)

– Engine Coolant Temperature ECT

– PATS

– Charge indicator lamp

– Speed control system


cluster > Lighting indicator or light-on warning tone

3. Door contact/hood switch > GEM Gateway >

Instrument cluster > Door warning indicator or door

status display in the message center



5. Fuel level sensor > GEM Gateway > Instrument

cluster > Tank display or fuel reserve warning

indicator


cluster > Headlamp/front fog lamp/rear fog lamp

indicator

7. High-beam switch > GEM Gateway > Instrument

cluster > High-beam indicator

8. Turn signal lamp switch > GEM Gateway >

Instrument cluster > Turn signal indicator

9. Brake fluid level switch > GEM Gateway >

Instrument cluster > Parking brake/brake system

warning indicator


Instrument cluster > Outside air temperature display

11. Trailer module > GEM Gateway > Instrument cluster

> Trailer warning indicator display

ISO 9141 input/output signals:

1. Windshield moisture status > Rain sensor > GEM

2. Ambient light status > Light sensor > GEM


Lesson 4 – ElectricalMultifunction Electronic Modules

General

The front end of the Transit 2006.5 has undergone

significant modification in comparison with the previous

model:

• Headlamp

• Hood

• Bumpers

• Radiator grille

• Front module

The modification of the headlamps has permitted an

improvement in luminous efficiency. Visually, the

headlamp design is characterized by a clear-glass cover

and a vertical arrangement.

The hood contains the air intake vents for the blower

box as well as integrated washer jets.

The front bumper in the area of the radiator grille is

optionally available in the vehicle color.

There are two steps in the lower area of the bumper.

These provide easy access to the windshield and/or the

wiper blades.

The side sections of the bumper are designed as separate

components as previously.

The radiator grille is fully integrated in the bumper and

contains large openings for the cooling air.


BodyLesson 5 – Body and Paint

The front module is made of sheet steel and comprises

three bolted components that can be individually

replaced.


Lesson 5 – Body and PaintBody

Interior

The instrument panel has been completely redesigned.

It is available in a two-tone design and has two storage

compartments for bottles up to 2 liters and a removable

glove compartment. The air outlet vents have also been

modified.

Above the air bag is a storage compartment with lid, in

the center is a large A4-size storage compartment

(provided there is no tachograph installed).

The gearshift lever is mounted on the instrument panel,

thereby providing unimpeded passage between the driver

and passenger sides.

A four-spoke steering wheel is optionally available.

Anti-corrosion protection

The Transit 2006.5 is available with a warranty against

corrosion perforation of 10 years, depending on the

market. The number of zinc-coated sheet metal parts

has been increased and an innovative PVC (Polyvinyl

Chloride) underbody protection applied to this end.

End of Life Vehicles Directive

The Transit 2006.5 conforms to the new End of Life

Vehicles Directive of the European Union. This includes

constructing vehicles in a recycle- and

processing-friendly manner as well as adhering to the

targets for the reuse, recycling and processing of

materials used in vehicles.



This means that manufacturers, importers and disposal

companies must together ensure that at least 85% of the

average weight of an end of life vehicle is recycled and

at least 80% of the materials processed or reused as of

2006.

These processing targets must be increased to 95%

(processing) and 85% (material processing, reuse) as of

2015.



Central door locking



HS-CAN data bus1

MS-CAN data bus2

Gateway (GEM)3

GEM4

Active anti-theft sounder5

Liftgate latch/rear door motor(s)6

Door latch motor(s)7

Interior light8

Radio remote control9

Ignition lock10

Passenger compartment monitoring sensors

(LIN)11

Radio remote control receiver12

Hood switch13

Locking unit (signals from door ajar switch,

"set/reset" button and "lock/unlock" switch,

liftgate latch/rear door/sliding door switch)

14


1. Vehicle speed signal > Wheel speed sensors > ABS

module > PCM > GEM Gateway > Automatic

locking


1. Door ajar switch/liftgate latch switch/lid ajar switch

> GEM > Instrument cluster > Door ajar warning

indicator or message in message center

LIN input/output signals

1. Interior scanning sensors

2. Battery-buffered alarm horn (with Thatcham CAT

1 alarm only)

Depending on the equipment version, the following

central-locking functions are available:

• Central locking with single locking

• Central locking with double locking

• One-touch central unlocking

• Two-touch central unlocking

• Automatic locking upon setting off (as of 7 km/h)

• Automatic relocking (45 seconds after unlocking

without any other activity)

• Individual door relocking

• Configurable unlocking

The locking/unlocking status is indicated via an audible

and/or visual signal.

Recharging function for the remote control

A charging function for the radio remote control

batteries is available as an option. More detailed

information can be found in the description of the GEM.

Individual door relocking

If a door is opened during the locking operation, all

other doors (with the exception of the sliding doors)

will be locked once. If the open door is then closed, it

will also be locked once.

The double-locking mechanism will not work if there

is a door open.

Individual door relocking can be deactivated.

Configurable unlocking

Configurable unlocking enables different unlocking

options and sequences to be set. Six different

configurations are available for this purpose.

The following tables provide an overview of the

configurations. The configuration can be changed using

WDS.



Configuration 1

Press liftgate

release 1 x

Press liftgate

release 1 x

Press unlock

button 2 x

Press unlock

button 1 x

To unlock the

XXDriver door

XPassenger door

XXXSliding door on driver side

XXSliding door on passenger side

XXRear door/liftgate

Configuration 2

Press liftgate

release 1 x

Press liftgate

release 1 x

Press unlock

button 2 x

Press unlock

button 1 x

To unlock the

XDriver door

XXPassenger door

XXSliding door on driver side

XXXSliding door on passenger side


Configuration 3

Press liftgate

release 1 x

Press liftgate

release 1 x

Press unlock

button 2 x

Press unlock

button 1 x

To unlock the

XXDriver door

XPassenger door



XXXRear door/liftgate



Configuration 4

Press liftgate

release 1 x

Press liftgate

release 1 x

Press unlock

button 2 x

Press unlock

button 1 x

To unlock the

XDriver door

XXPassenger door




Configuration 5

Press liftgate

release 1 x

Press liftgate

release 1 x

Press unlock

button 2 x

Press unlock

button 1 x

To unlock the

XXXDriver door

XXXPassenger door


XXXSliding door on passenger side


Configuration 6

Press liftgate

release 1 x

Press liftgate

release 1 x

Press unlock

button 2 x

Press unlock

button 1 x

To unlock the

XXDriver door

XPassenger door






SRS

MS-CAN data bus1

Gateway (GEM)2

ISO -91413

RCM4

Driver air bag module5

Passenger air bag module6

Side air bag (driver side, passenger side with

separate seat only)7

Seat belt tensioner (driver side, passenger side

with separate seat only)8

Crash sensors (driver and passenger side, with

side air bags only)9




1. RCM > Instrument cluster > Air bag indicator

The Transit 2006 (03/2006-) is equipped with a driver

air bag as standard. The volume of the passenger air bag

(optional) has been increased to 120 liters.

Side air curtains are available as an option for the front

seats in conjunction with belt tensioners (with separate

passenger seat only)

The RCM is installed under the instrument panel directly

next to the GEM. It is connected via the MS-CAN data

bus.

Diagnosis is performed via a separate ISO 9141 line.

The RCM may be reused up to five times.

The crash sensors for the side air bags are installed in

the footwell near the B pillars and can be reused

following detonation.

The air bags/belt tensioners are triggered using direct

voltage.

ISOfix points are installed for the second seat row on

some models. These are marked by an indication

embroidered into the seat covering.



Air ConditioningA/C

Anti-lock Brake SystemABS

Amplitude ModulationAM

Accelerator Pedal PositionAPP

Brake Pedal PositionBPP

Brake Traction Control SystemBTCS

Controller Area NetworkCAN

Compact DiscCD

Crankshaft PositionCKP

Clutch Pedal PositionCPP

Data Link ConnectorDLC

Diagnostic Trouble CodeDTC

Diagnostic Trouble Code- WDS

Emergency Brake AssistEBA

Engine Coolant TemperatureECT

Exhaust Gas RecirculationEGR

European On-board DiagnosticEOBD

Engine Oil PressureEOP

Frequency ModulationFM

Fuel Pump Driver ModuleFPDM

Generic Electronic ModuleGEM

Global Positioning SystemGPS

Global System For Mobile CommunicationGSM

Hydraulic Control UnitHCU

Inertia Fuel ShutoffIFS

Knock SensorKS

Light Emitting DiodeLED

Left-hand DriveLHD

Liquefied Petroleum GasLPG

Malfunction Indicator LampMIL

On-line Automotive Service Information

System

OASIS

Passive Anti-theft SystemPATS

Powertrain Control ModulePCM

Polyvinyl ChloridePVC

Restraints Control ModuleRCM

Right-hand DriveRHD

Read Only MemoryROM

Supplemental Restraint SystemSRS

Vehicle Identification NumberVIN

Vehicle Speed SensorVSS

Worldwide Diagnostic SystemWDS

79Service Training

List of Abbreviations

ford transit 2006 service traning

Documents

new interior

new body versions

range of new functions

modified generation

ford training purposes

anavigation system

locking system

data processing system