New Product Introduction 2006.50 Transit Service Information Technical Service Training CG 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) Preface 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on the rear axle Furthermore, stability assist is available as an option The previous 2.0L Duratorq TDCi engines have been replaced by a modified generation upgraded to a cubic capacity of 2.2 liters The 2.4L Duratorq TDCi engine versions have also been modified, while consumption has been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 Service Training (G542739) Table of Contents PAGE Preface At a glance Position of electrical components Lesson – General Information Lesson – Chassis Suspension System Front axle Brake System - General Information 10 General 10 ABS system overview 11 Bosch 8.0 ABS system 12 Active rollover protection 13 Lesson – Powertrain Engine System - General Information 14 2.2L Duratorq-TDCi (Puma) diesel 16 General 17 Engine data 17 Injection system 19 High-pressure pump 20 Fuel injectors 22 Valve train 23 Accessory drive 24 Service Training Table of Contents Cylinder head 26 Cylinder block 28 2.4L Duratorq-TDCi (Puma) diesel 28 General 28 Engine data 29 Centrifugal oil filter (140 PS version only) 31 Oil level/temperature sensor (103 kW version only) 32 2.3L Duratec-HE (MI4) 33 Engine data 34 Transmission 37 Shift mechanism 37 Clutch assembly 37 Lesson – Electrical Instrument Cluster 38 Overview 38 Operation 40 Configuration of the message center (high equipment level) 41 Diagnostics 41 Tachograph 42 General 42 Audio System 43 Overview 43 General 44 Navigation System 49 Travel Pilot EX 49 Service Training Table of Contents Cellular Phone 51 General 51 Exterior Lighting 53 General 53 Communications Network 54 Overview 54 Module Configuration 57 Central module configuration 57 Module Controlled Functions 59 General 59 Service instructions 63 Power supply 64 PATS 65 Multifunction Electronic Modules 66 Overview 66 Lesson – Body and Paint Body 69 General 69 Interior 71 Anti-corrosion protection 71 End of Life Vehicles Directive 71 Central door locking 73 SRS 77 List of Abbreviations 79 Service Training Introduction At a glance Transit 2006.5 (03/2006-) E73654 Internal designation: Chassis • V347 = Front wheel drive • Improved drivability through fine-tuning of springs, shock absorbers and steering • V348 = Rear wheel drive • Modified brake system (disc brakes on the rear axle) • Stability assist with active rollover protection • Reinforced front axle (for vehicle versions with high payload) Service Training (G542739) At a glance Introduction Powertrain • Power management • Modified diesel engines with increased power and lower consumption, emission standard IV, second-generation common-rail technology • Recharging function for the radio remote control • Modified 2.3L Duratec-HE (MI4) engine with emission standard IV, LPG (Liquefied Petroleum Gas) (optional) • Anti-theft alarm system in accordance with Thatcham CAT • 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 • Modified locking system with configurable locking functions • 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 • Speed control system (G542739) Service Training Introduction At a glance Position of electrical components Shown: LHD (Left-hand Drive) 13 12 11 10 E64649 GEM behind glove compartment, passenger side IFS (Inertia Fuel Shutoff) (vehicles with petrol engine) Hands-free kit/voice control module (beside instrument panel) 10 PCM (Powertrain Control Module) in left-hand side of engine compartment Right-hand crash sensor (with side air bag only) Receiver for radio remote control (in center of headliner) 11 ABS (Anti-lock Brake System) module, engine compartment, underneath brake master cylinder Booster heater (vehicle underbody, driver side) 12 Trailer module (under driver seat) GPS (Global Positioning System) antenna (in center of instrument panel) Left-hand crash sensor (with side air bag only) 13 RCM (Restraints Control Module) (next to the GEM) Instrument cluster Service Training (G542739) At a glance Introduction IFS switch E74568 The IFS switch is installed in the instrument panel (passenger side) (G542739) Service Training Lesson – Electrical 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: Module Controlled Functions 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 • Factory mode The following functions are carried out: • Shipping mode • The vehicle will be centrally unlocked if it is locked at the time of impact • 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 • 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 Shipping mode: PATS • Shipping mode is activated en route from the factory to the dealer The vehicle can be driven without impairment of the driving safety systems 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) • 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 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 • 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 Service Training (G542749) 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 65 Multifunction Electronic Modules Lesson – Electrical Overview 26 25 24 23 21 22 20 19 18 17 16 10 15 11 14 13 12 E64632 66 (G542750) Service Training Lesson – Electrical Multifunction Electronic Modules HS-CAN data bus 14 Fuel level sensor MS-CAN data bus 15 APP sensor Gateway (GEM) 16 Reversing lamp switch GEM 17 PATS transceiver Windshield wiper motor 18 Multifunction switches (wiper, light) Rear window wiper motor(s) 19 Speed control switch FPDM (Fuel Pump Driver Module) 20 Heated windshield switch Headlamp 21 Heated rear window switch Heated rear window, heated exterior mirrors 22 Hazard flasher switch 10 Heated windshield 23 Ambient air temperature sensor 11 Instrument cluster 24 Headlight switch 12 Ignition lock 25 Brake fluid level switch 13 Stoplamp switch, BPP switch, CPP switch 26 Light/rain sensor (ISO 9141) Not shown: – Oil change • Parking brake switch – Glow plug indicator (vehicles with diesel engines) • Trailer module – Engine coolant temperature ECT • Door switches – PATS • Battery cutoff relay – Charge indicator lamp • Fuel pump (vehicles with petrol engine) – Speed control system • Horn/alarm horn • Windshield washer pump HS-CAN input signals: Vehicle speed signal: Wheel speed sensor > ABS module > PCM > Gateway > GEM current consumption for trip computer PCM > Gateway > GEM (fuel pump ON/OFF request) CKP sensor > GEM Gateway > Engine speed ABS module > GEM Gateway > Request for ABS brake system warning indicator and stability assist warning in instrument cluster PCM controlled battery charging: Generator > PCM > Gateway > GEM (control of heated windshield) HS-CAN output signals: Total mileage: Instrument cluster > Gateway > GEM Status BPP/CPP switch > GEM Gateway > PCM Water-in-fuel sensor > PCM > Gateway > GEM (warning indicator request to instrument cluster) Speed control system > GEM Gateway > PCM PCM > Gateway > GEM warning indicator request: APP > GEM Gateway > PCM Outside air temperature sensor > GEM Gateway > PCM – Engine warning indicator Status PATS key: PATS transceiver > GEM Gateway > PCM (start approval) – Low oil pressure warning indicator Ignition lock position status > GEM Gateway > PCM – MIL Service Training (G542750) 67 Multifunction Electronic Modules Parking brake control status > GEM Gateway > ABS module/PCM Fuel level status > GEM Gateway > PCM MS-CAN input signals: Setting the time/alarm time: Instrument cluster > GEM Crash signal > RCM > GEM MS-CAN output signals: PCM > Gateway > GEM warning indicator request: – MIL Lesson – Electrical Brake fluid level switch > GEM Gateway > Instrument cluster > Parking brake/brake system warning indicator 10 Outside air temperature sensor > GEM Gateway > Instrument cluster > Outside air temperature display 11 Trailer module > GEM Gateway > Instrument cluster > Trailer warning indicator display ISO 9141 input/output signals: Windshield moisture status > Rain sensor > GEM Ambient light status > Light sensor > GEM – 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 Headlamp switch > GEM Gateway > Instrument cluster > Lighting indicator or light-on warning tone Door contact/hood switch > GEM Gateway > Instrument cluster > Door warning indicator or door status display in the message center GEM Gateway > Instrument cluster > Data for central vehicle configuration Fuel level sensor > GEM Gateway > Instrument cluster > Tank display or fuel reserve warning indicator Headlamp switch > GEM Gateway > Instrument cluster > Headlamp/front fog lamp/rear fog lamp indicator High-beam switch > GEM Gateway > Instrument cluster > High-beam indicator Turn signal lamp switch > GEM Gateway > Instrument cluster > Turn signal indicator 68 (G542750) Service Training Lesson – Body and Paint General Body • Bumpers • Radiator grille The front end of the Transit 2006.5 has undergone significant modification in comparison with the previous model: • Front module • Headlamp • Hood E64633 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 Service Training (G542751) 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 69 Body Lesson – Body and Paint E64634 The front module is made of sheet steel and comprises three bolted components that can be individually replaced 70 (G542751) Service Training Lesson – Body and Paint Body Interior E64635 The instrument panel has been completely redesigned It is available in a two-tone design and has two storage compartments for bottles up to 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 Service Training (G542751) 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 71 Body 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 72 Lesson – Body and Paint 2006 These processing targets must be increased to 95% (processing) and 85% (material processing, reuse) as of 2015 (G542751) Service Training Lesson – Body and Paint Body Central door locking 14 13 12 11 10 E64637 Service Training (G542751) 73 Body Lesson – Body and Paint HS-CAN data bus MS-CAN data bus 10 Ignition lock Gateway (GEM) GEM Active anti-theft sounder 12 Radio remote control receiver Liftgate latch/rear door motor(s) 13 Hood switch Door latch motor(s) Interior light Locking unit (signals from door ajar switch, 14 "set/reset" button and "lock/unlock" switch, liftgate latch/rear door/sliding door switch) 11 Radio remote control Passenger compartment monitoring sensors (LIN) HS-CAN input signals: Vehicle speed signal > Wheel speed sensors > ABS module > PCM > GEM Gateway > Automatic locking MS-CAN output signals: 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 Interior scanning sensors Battery-buffered alarm horn (with Thatcham CAT alarm only) Depending on the equipment version, the following central-locking functions are available: 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 • Central locking with single locking • Central locking with double locking Configurable unlocking • One-touch central unlocking • Two-touch central unlocking • Automatic locking upon setting off (as of km/h) • Automatic relocking (45 seconds after unlocking without any other activity) • Individual door relocking • 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 The locking/unlocking status is indicated via an audible and/or visual signal 74 (G542751) Service Training Lesson – Body and Paint Body Configuration To unlock the Driver door Press unlock button x Press unlock button x X X Press liftgate release x Press liftgate release x X X Passenger door X Sliding door on driver side X Sliding door on passenger side X X Rear door/liftgate X X Configuration To unlock the Press unlock button x Driver door Passenger door Press unlock button x Press liftgate release x Press liftgate release x X X X Sliding door on driver side X Sliding door on passenger side X Rear door/liftgate X X X X X Configuration To unlock the Driver door Press unlock button x Press unlock button x X X Press liftgate release x Press liftgate release x Passenger door X Sliding door on driver side X X Sliding door on passenger side X X Rear door/liftgate X Service Training (G542751) X X 75 Body Lesson – Body and Paint Configuration To unlock the Press unlock button x Driver door Passenger door Press unlock button x Press liftgate release x Press liftgate release x X X X Sliding door on driver side X X Sliding door on passenger side X X Rear door/liftgate X X X Press unlock button x Press unlock button x Press liftgate release x Press liftgate release x X X Configuration To unlock the Driver door Passenger door Sliding door on driver side X X X X X Sliding door on passenger side X Rear door/liftgate X X X X X X Configuration To unlock the Driver door Press unlock button x Press unlock button x X X Passenger door Sliding door on driver side Press liftgate release x Press liftgate release x X X X Sliding door on passenger side X X Rear door/liftgate X 76 X X (G542751) X Service Training Lesson – Body and Paint Body SRS E64636 MS-CAN data bus Gateway (GEM) ISO -9141 RCM Driver air bag module Passenger air bag module Service Training (G542751) Side air bag (driver side, passenger side with separate seat only) Seat belt tensioner (driver side, passenger side with separate seat only) Crash sensors (driver and passenger side, with side air bags only) 77 Body Lesson – Body and Paint MS-CAN output signals: 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 78 (G542751) Service Training List of Abbreviations A/C Air Conditioning IFS Inertia Fuel Shutoff ABS Anti-lock Brake System KS Knock Sensor AM Amplitude Modulation LED Light Emitting Diode APP Accelerator Pedal Position LHD Left-hand Drive BPP Brake Pedal Position LPG Liquefied Petroleum Gas BTCS Brake Traction Control System MIL Malfunction Indicator Lamp CAN Controller Area Network OASIS On-line Automotive Service Information System CD Compact Disc PATS Passive Anti-theft System CKP Crankshaft Position PCM Powertrain Control Module CPP Clutch Pedal Position PVC Polyvinyl Chloride DLC Data Link Connector RCM Restraints Control Module DTC Diagnostic Trouble Code RHD Right-hand Drive ROM Read Only Memory SRS Supplemental Restraint System VIN Vehicle Identification Number VSS Vehicle Speed Sensor WDS Worldwide Diagnostic System Diagnostic Trouble Code- WDS EBA Emergency Brake Assist ECT Engine Coolant Temperature EGR Exhaust Gas Recirculation EOBD European On-board Diagnostic EOP Engine Oil Pressure FM Frequency Modulation FPDM Fuel Pump Driver Module GEM Generic Electronic Module GPS Global Positioning System GSM Global System For Mobile Communication HCU Hydraulic Control Unit Service Training 79 [...]... diesel 5 MT82 6-speed manual transmission 3 2.3L Duratec-HE (MI4) 6 MT-75 5-speed manual transmission 14 (G542741) Service Training Lesson 3 – Powertrain Engine System - General Information The Transit 2006. 5 (03 /2006- ) is available with the following engine/transmission combinations: (rear wheel drive) • 2.3L Duratec-HE (MI4) with MT-75 5-speed manual transmission (rear wheel drive) • 2.2L Duratorq-TDCi... Injector 10 High-pressure pump 5 Pressure relief valve 11 Fuel return 6 Fuel injection supply manifold Service Training (G542741) 19 Engine System - General Information 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... 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 ... 77 List of Abbreviations 79 Service Training Introduction At a glance Transit 2006. 5 (03 /2006- ) E73654 Internal designation: Chassis • V347 = Front wheel drive • Improved drivability... (G542741) Service Training Lesson – Powertrain Engine System - General Information The Transit 2006. 5 (03 /2006- ) is available with the following engine/transmission combinations: (rear wheel drive)... Service Training (G542741) 19 Engine System - General Information The introduction of the Transit 2006. 5 (03 /2006- ) will see the previously used Delphi common-rail system replaced by the Denso common-rail