Ford Transit 2006 Service Traning

New Product Introduction
Transit 2006.5 (04/2006-)
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The previous 2.0L Duratorq TDCi engines have been replaced by a modified generation upgraded to a cubic capacity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 1 General Information

Lesson 2 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 3 Powertrain
Engine System - General Information......................................................................................................
14
2.2L Duratorq-TDCi (Puma) diesel................................................................................................................................
16
General...................................................................................................................................................................................................
16
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 4 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 5 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-)
Internal designation:
Stability assist with active rollover protection
V347 = Front wheel drive
Reinforced front axle (for vehicle versions with high

payload)
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)
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 1
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)
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
At a glance
Introduction
IFS switch
The IFS switch is installed in the instrument panel

(passenger side).
(G542739)
Service Training
Lesson 2 Chassis
Front axle
Suspension System
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.
Strut and spring assembly (reinforced front axle)
Strut and spring assembly (standard front axle)
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)
Bolted ball joint (reinforced front axle)
Brake System - General Information
Lesson 2 Chassis
General
Front brake
Rear brake
Brake pad wear indicator
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
10
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.
(G542740)
Service Training
Lesson 2 Chassis
ABS system overview
HS-CAN data bus input/output signals
Gateway (GEM)
ABS module
ABS motor
ABS/HCU (Hydraulic Control Unit).
Stoplamp switch
Pressure sensor (in the ABS/HCU)
Yaw rate sensor and lateral acceleration sensor

(at the right-hand or left-hand foot controls)
Steering wheel rotation sensor (behind the

steering wheel)
10 Wheel speed sensors

11 Stability assist switch
11
HS-CAN input signals:

1. CKP (Crankshaft Position) sensor > GEM Gateway
> ABS module
Lesson 2 Chassis
7. ABS module > GEM Gateway > Instrument cluster

> Stability assist warning indicator ESP
2. Engine idle speed (from PCM) > ABS module
8. Signals of all four wheel speed sensors > ABS

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

ABS module
The following brake systems are available, depending

on the vehicle version:
4. Duration of driving cycle (from GEM) > Gateway

> ABS module
ABS (Bosch 8.0)
5. Tire circumference > GEM Gateway > ABS module
ABS/BTCS, stability assist, electronic EBA

(Emergency Brake Assist), active rollover protection
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
> ABS warning indicator
> Brake system warning indicator
12
ABS/BTCS
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.
(G542740)
Service Training
Lesson 2 Chassis
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.
13
Engine System - General Information
Lesson 3 Powertrain
Engine/transmission combinations
2.2L Duratorq-TDCi (Puma) diesel
VXT-75 5-speed manual transaxle
MT82 6-speed manual transmission
2.3L Duratec-HE (MI4)
MT-75 5-speed manual transmission
14
(G542741)
Service Training
Lesson 3 Powertrain
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 (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
Cubic capacity (drive)
2.2L (front wheel drive)
(previously 2.0L)
2.4L (rear wheel drive)
2.3L (rear wheel drive) petrol
The engine range consists of the following power

versions:
Power output PS (kW)
Torque (Nm)
85 (63)
250
110 (81)
285
130 (96)
310
100 (74)
285
115 (85)
320
140 (103)
375
145 (107)
200
15
Lesson 3 Powertrain
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.
16
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.
(G542741)
Service Training
Lesson 3 Powertrain
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.
Diagnosis
Diagnosis using WDS via the DLC (Data Link
Connector).
Engine data
Injection system
Denso
Fuel injectors
2.2L Duratorq-TDCi
(Puma) diesel
Engine code
P8FA (85 PS)

QVFA (110 PS)
QWFA (130 PS)
Cubic capacity
1,998 ccm
Engine management
Stroke
86 mm
Visteon
Bore
86 mm
EOBD (European On-board Diagnostic) for the

monitoring of emissions-related components.
Compression ratio
19: 1
Firing order
1-3-4-2
Engine emission control
Idle speed
900 rpm
High-pressure pump
Fuel injection supply manifold
Meets emission standard IV

Electrical EGR (Exhaust Gas Recirculation) valve
with water cooling
Max. power output, torque 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
Fuel
Diesel
17
Lesson 3 Powertrain
Power and torque curves
Torque (Nm)
Torque curve for 81 kW engine
Engine speed (rpm)
Power curve for 81 kW engine
Power output (kW)
18
(G542741)
Service Training
Lesson 3 Powertrain
Injection system
High-pressure pipe
Fuel metering valve
Leak-off pipe
Fuel pressure sensor
Fuel injection line
Fuel temperature sensor
Injector
10 High-pressure pump
Pressure relief valve
11 Fuel return
19
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.
Lesson 3 Powertrain
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
Fuel pressure sensor
Pressure relief valve
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.
20
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.
(G542741)
Service Training
Lesson 3 Powertrain
High-pressure pump coupling
Intake camshaft coupling
Flange for high-pressure pump
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.
21
Lesson 3 Powertrain
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.
Identification number (injector correction

factor)
Illustration shows the fuel injector from above
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.
22
Electrical connection, solenoid valve
16-digit identification number
Connection, leak-off pipe
(G542741)
Service Training
Lesson 3 Powertrain
To ensure optimum fuel metering, the PCM must be

informed when a new injector is installed.
Valve train
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.
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.
23
Lesson 3 Powertrain
Accessory drive
A
B
Accessory drive without A/C (Air Conditioning)

compressor
Tensioner
Tensioning rollers
Accessory drive with A/C compressor
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.
24
(G542741)
Service Training
Lesson 3 Powertrain
Power steering pump
Coolant pump
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.
25
Lesson 3 Powertrain
Cylinder head
Oil baffle plate
Aluminum support
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.
26
(G542741)
Service Training
Lesson 3 Powertrain
Hydraulic valve clearance compensation
Rocker arms
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.
27
Cylinder block
Lesson 3 Powertrain

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 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.
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
28
(G542741)
Service Training
Lesson 3 Powertrain
Engine management
Visteon
EOBD for the monitoring of emissions-related
components.
Engine data
2.4L Duratorq-TDCi
(Puma) diesel
Engine code
PHFA (100 PS)

JXFA (115 PS)
H9FB (140 PS)
Meets emission standard IV
Cubic capacity
2,402 ccm
Electrical EGR valve with water cooling
Stroke
94.6 mm
Bore
89.9 mm
Compression ratio
19:1
Firing order
1-3-4-2
Idle speed
900 rpm
Diagnosis
Diagnosis using WDS via the DLC
Max. power output, torque 74 kW (100 PS) at 3,500

85 kW (115 PS) at 3,500
103 kW (140 PS) at 3,500
Fuel
Diesel
29
Lesson 3 Powertrain
Power and torque curves
Torque (Nm)
Engine speed (rpm)
Power output (kW)
30
(G542741)
Service Training
Lesson 3 Powertrain
Centrifugal oil filter (140 PS version only)
Cover
Centrifuge (under the valve cover)
Oil pressure line to the centrifugal oil filter
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 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 centrifugal oil filter is located in the cylinder head

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

flows back into the oil circuit.
a cover cap (in the valve cover)
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.
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.
31
Lesson 3 Powertrain
Oil level/temperature sensor (103 kW version only)
Oil level/temperature sensor
Openings
Oil dipstick
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 temperature is simultaneously sensed via the

integrated temperature sensor. The temperature is used
as a correction factor in the calculation.
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 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.
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.
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.
The change in the voltage drop serves as an input

variable for calculation of the oil level.
32
(G542741)
Service Training
Lesson 3 Powertrain
Service instructions
on all vehicles with a diesel engine.
The interval indicator must be reset after an oil change
Please refer to the relevant Service literature for a

description of this procedure.
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.
33
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
Lesson 3 Powertrain
Engine data
Engine code
GZFA (emission standard

IV)
GZFB (emission standard
III)
Ignition system with ignition coil-on-plug
Cubic capacity
2,261 ccm
Electronic throttle valve
Stroke
94 mm
Bore
87.5 mm
Compression ratio
9.7:1
Firing order
1-3-4-2
Idle speed
rpm
Meets European emission standard IV
Max. power output
EOBD for the monitoring of emissions-related

components.
107 kW (145 PS)

at 5,250 rpm
Max. torque
210 Nm at 3,750 rpm
Diagnosis
Fuel
Premium 95 RON
Aluminum cylinder block with lower crankcase

Mechanical bucket tappets
Intake manifold runner control with swirl flaps
Balance shafts
Engine management
Visteon PCM
Knock control with one KS (Knock Sensor)
Diagnosis using WDS via the DLC
34
(G542741)
Service Training
Lesson 3 Powertrain
Power and torque curve (when using 95 RON fuel)
Torque (Nm)
Engine speed (rpm)
Power output (kW)
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.
35
Lesson 3 Powertrain
Accessory drive
Accessory drive with A/C
Accessory drive without A/C
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
36
(G542741)
Service Training
Lesson 3 Powertrain
Transmission
Shift mechanism
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).
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.
37
Instrument Cluster
Lesson 4 Electrical
Overview
HS-CAN data bus
MS-CAN data bus
Gateway (GEM)
Instrument cluster module
38
Displays in the instrument cluster
Multifunction switches ("set/reset" button, rotary

switch)
Digital tachograph
Brake pad wear indicator
(G542742)
Service Training
Lesson 4 Electrical
Instrument Cluster
MS-CAN input signals:
1. CKP sensor > GEM Gateway > Instrument cluster

> Tachometer
1. Ignition lock position > GEM Gateway > Instrument

cluster (power management)
2. Wheel speed sensor > ABS module > GEM Gateway

> Instrument cluster > Vehicle speed display (VSS
(Vehicle Speed Sensor))
2. Reversing lamp switch > GEM Gateway >

Instrument cluster

> Brake system warning indicator
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

> Stability assist warning indicator ESP
6. Water-in-fuel sensor > GEM Gateway > Instrument

cluster > Warning LED (Light Emitting Diode)
6. PCM-controlled battery charge > Generator > GEM

Gateway > Instrument cluster > Charging system
warning indicator

Instrument cluster > Ice warning indicator or
temperature gauge in the display in the message
center
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
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
9. PCM > GEM Gateway > Instrument cluster > Speed

control system warning indicator
10. PATS transceiver > GEM Gateway > Instrument

cluster > PATS indicator
10. PCM > GEM Gateway > Instrument cluster > MIL
warning indicator
11. Door contact/hood switch > GEM Gateway >

Instrument cluster > Door warning indicator or door
status display in the message center
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. Fuel level sensor > GEM Gateway > Instrument

cluster > Tank display or fuel reserve 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 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
39
Instrument Cluster
4. Instrument cluster > Audio unit > Time display (not

with RDS 1500)
Lesson 4 Electrical
5. Instrument cluster > DLC
Operation
Shown: Low equipment level
PATSLED
Brake pad wear warning indicator
Trip odometer reset button (not with high

equipment level)
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.
40
Time setting button (not with high equipment

level)
Multi-function display
Service reminder indicator
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.
(G542742)
Service Training
Lesson 4 Electrical
Instrument 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 (high

equipment 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.
41
Tachograph
General
Lesson 4 Electrical
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:
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
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).
two chip-card readers,
Diagnosis can only be carried out by authorized dealers.
an integrated printer for creating logs for drivers and

inspectors,
Note
a display containing important information, e.g. on

the current driving and rest-period account,
a real-time clock,
various controls.
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"
42
(G542799)
Service Training
Lesson 4 Electrical
Audio System
Overview
MS-CAN data bus
Gateway (instrument cluster)
Audio/navigation unit
Right-hand speaker
Left-hand speaker
Hands-free system/Bluetooth/voice control

module
Audio remote control
GPS/GSM (Global System for Mobile

Communication)/AM (Amplitude
Modulation)/FM (Frequency Modulation)
antenna
43
Audio System

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
Lesson 4 Electrical
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)
4. Microphone > Bluetooth/voice control module >

audio system
Setting time (from the audio unit to the GEM)
Reverse gear information
1. Instrument cluster gateway > Audio unit > Time
Diagnostics
display/setting (not with RDS 1500)
Vehicle speed information
Clear module
2. Audio unit > Bluetooth/voice control module
3. Audio remote control > Audio unit > Bluetooth/voice

control module
The new generation of audio units is available in the

following versions for the Transit:
1500 RDS
6000 CD
6006 CDC
44
(G829488)
Service Training
Lesson 4 Electrical
Audio System
1500 RDS
1500 RDS, RDS, 2 X 6 watt output, not connected to

the MS-CAN bus
45
Audio System
Lesson 4 Electrical
6000 CD
6000 CD (Compact Disc), larger display, CD player, 4

x 17 Watt output, Bluetooth-compatible
46
(G829488)
Service Training
Lesson 4 Electrical
Audio System
6006 CDC
6006 CDC, as 6000 CD, with integrated 6-disc changer
REG function can be disabled
Radio remote control is available for certain equipment

levels (same as Focus/Focus C-MAX).
No frequency display when the station name appears
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
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).
No PTY function
47
Audio System
Lesson 4 Electrical
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.
48
(G829488)
Service Training
Lesson 4 Electrical
Navigation System
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:
Simulation mode can be activated/deactivated

directly from the Menu button
4 x 20 W output power
NOTE: When installing a new navigation unit, the

navigation unit must be configured by selecting the
routine "Install programmable modules" in WDS.
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
The designation "RNS" has been dropped, no

reference to the manufacturer
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
49
Navigation System
Lesson 4 Electrical
Button combination
Description
S1 + MENU
Tuner test mode
S4 + 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
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.
50
(G829489)
Service Training
Lesson 4 Electrical
Cellular Phone
General
MS-CAN data bus input/output signals
Cellular phone
Gateway (instrument cluster)
GSM antenna
Hands-free system/Bluetooth/voice control

module
Handset holder
Microphone
Audio/navigation unit
51
Cellular Phone
Lesson 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
52
(G829490)
Service Training
Lesson 4 Electrical
General
Exterior Lighting
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.
The mounting points of the headlamps have changed

on account of the redesign of the headlamps.
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.
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.
53
Communications Network
Lesson 4 Electrical
Overview
MS-CAN data bus
Light/rain sensor
ISO 9141
Radio remote control reception module
Outgoing/incoming lines (RX/TX)
PATS transceiver unit
LIN data bus
10
HS-CAN data bus
Battery-buffered anti-theft alarm system horn

(BBS)
SRS (Supplemental Restraint System) module
11 Passenger compartment control sensor(s)
Phone / Bluetooth/voice control module
12 PCM
Instrument cluster
13 ABS module
Audio unit
14 Steering wheel rotation sensor
Parking aid module
15 Yaw rate/lateral acceleration sensor
GEM
16 DLC
17 Terminating resistors
54
(G542745)
Service Training
Lesson 4 Electrical
Up to four data bus systems can be used in the Transit

2006.5 depending on the model and equipment:
Fuel fired booster heater
HS-CAN bus
Parking aid module
MS-CAN bus
Instrument cluster
ISO 9141 protocol
RCM
2. MS-CAN for the audio system
LIN (Local Interconnect Network)
Instrument cluster
All systems can be diagnosed via the DLC.
Audio system
The following modules are implemented as gateways:
Bluetooth/voice control module
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.
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
MS-CAN
Light/rain sensor
Two separate MS-CAN networks are used in the Transit:

1. MS-CAN for all systems apart from the audio
system:
55
Lesson 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.
56
(G542745)
Service Training
Lesson 4 Electrical
Module Configuration
Previous configuration principle
GEM
Central module configuration principle
WDS
Control modules
CAN
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.
57
Module Configuration
Lesson 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.
58
(G542746)
Service Training
Lesson 4 Electrical
Module Controlled Functions
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.
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
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.
Function/system
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
A
C/D
MS-CAN Gateway
HS-CAN Gateway
Communication
59
Function/system
Lesson 4 Electrical
C/D
Number of digital inputs
29
49
50
Number of analog inputs
LIN (Local Interconnect Network)
ISO K-line (light/rain sensor)
ISO K-line for radio remote control
Interface for PATS transceiver
Central vehicle configuration main module
Network management
Clock
Number of fuses
20
20
20
Number of external relay slots
Number of integrated relays
11
Number of plugs/pins
79
119
139
Number of drivers (low side)
13
15
Number of drivers (high side)
Ignition lock status
Additional battery check
Power management (e.g. shipping mode)
Battery-saving function
Side lamps
High beams
Low beams
Rear fog lamp
Turn signal lamps
Headlamp switch input (light-on warning tone)
Hardware
Voltage supply
Exterior lighting
60
(G542749)
Service Training
Lesson 4 Electrical
Function/system
C/D
Reversing lamps
Stoplamps
Number-plate lamps
Hazard flasher
High mounted stoplamp (CHMSL)
Hazard flasher off (in case of standing start) *
Hazard flasher in case of accident *
One-touch turn signal function
Headlamp flasher
Low beam switch-off delay
Fog lamps
Daytime running lamps
Autolamps
Interior lighting system

Interior lighting upon locking/unlocking
Interior lighting, driver cab
Interior lighting, loadspace
Dimmer function
Fuel supply and fluid indicators
Fuel pump (petrol engines only)
Fuel gauge
Brake fluid level indicator
Engine off in case of crash
Heated windshield
Heated rear window(s)
Heated exterior mirrors
Heated windows
Wash/wipe system
61
Function/system
Lesson 4 Electrical
C/D
Wash/wipe function
Windshield wipers
Rear wiper (automatic when reverse gear is engaged)

Rain sensor
Locking and anti-theft protection

PATS function (reading in of key)
Door lock switch input
VIN identification
Alarm
Radio remote control (with external receiver)
Central/double locking system
Partial unlocking
Automatic relocking
Individual door relocking
Automatic locking on start of journey
Locking/unlocking visual/audible signal
Unlocking after failed locking (reverse cycling)
Individual door relocking (slam locking)
Configurable unlocking
Thatchham CAT 1 alarm (BBS horn, interior monitoring and

glass break sensors)
Other functions
Detection of APP
Detection of CPP (Clutch Pedal Position)
Parking brake status
Diagnosis of brake pedal (in addition to ABS)
Horn (for signaling central locking only)
Trailer towing
62
(G542749)
Service Training
Lesson 4 Electrical
Function/system
C/D
Sensing of the ambient air temperature
Service mode
Diagnosis 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.
The GEM is connected to the following modules via

the MS-CAN:
Instrument cluster
Parking aid module
RCM
Gateway
the HS-CAN:
PCM
ABS module
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.
The GEM is the gateway for the communications

between the MS-CAN and the HS-CAN.
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 LIN bus:
Battery-buffered alarm horn (BBS = Battery Back-up

Sounder)
Parking-aid module
Interior scanning sensors
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
63
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).
Lesson 4 Electrical
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 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.
64
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.
(G542749)
Service Training
Lesson 4 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:
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.
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 4 Electrical
Overview
66
(G542750)
Service Training
Lesson 4 Electrical
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)
Horn/alarm horn
Windshield washer pump
1. Vehicle speed signal: Wheel speed sensor > ABS
module > PCM > Gateway > GEM current
consumption for trip computer
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
2. PCM controlled battery charging: Generator > PCM

> Gateway > GEM (control of heated windshield)
HS-CAN output signals:
3. Total mileage: Instrument cluster > Gateway > GEM
2. Status BPP/CPP switch > GEM Gateway > PCM
4. Water-in-fuel sensor > PCM > Gateway > GEM

(warning indicator request to instrument cluster)
3. Speed control system > GEM Gateway > PCM
5. PCM > Gateway > GEM warning indicator request:
1. APP > GEM Gateway > PCM

PCM
Engine warning indicator
5. Status PATS key: PATS transceiver > GEM Gateway

> PCM (start approval)
Low oil pressure warning indicator
6. Ignition lock position status > GEM Gateway > PCM
MIL
67
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
Lesson 4 Electrical
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
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
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
68
(G542750)
Service Training
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
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.
69
Body
The front module is made of sheet steel and comprises

three bolted components that can be individually
replaced.
70
(G542751)
Service Training
Body
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.
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
2006.
These processing targets must be increased to 95%
(processing) and 85% (material processing, reuse) as of
2015.
(G542751)
Service Training
Body
Central door locking
73
Body
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)

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:
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.

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
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)
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
Body
Configuration 1
To unlock the
Driver door
Press unlock
button 1 x
Press unlock
button 2 x
Press liftgate
release 1 x
Press liftgate
release 1 x
Passenger door
Sliding door on driver side
Sliding door on passenger side
Rear door/liftgate
Configuration 2
To unlock the
Press unlock
button 1 x
Driver door
Passenger door
Press unlock
button 2 x
Press liftgate
release 1 x
Press liftgate
release 1 x
X
X
Rear door/liftgate
X
X
X
X
Configuration 3
To unlock the
Driver door
Press unlock
button 1 x
Press unlock
button 2 x
Press liftgate
release 1 x
Press liftgate
release 1 x
Passenger door
Rear door/liftgate
75
Body
Configuration 4
To unlock the
Press unlock
button 1 x
Driver door
Passenger door
Press unlock
button 2 x
Press liftgate
release 1 x
Press liftgate
release 1 x
X
X
Rear door/liftgate
Press unlock
button 1 x
Press unlock
button 2 x
Press liftgate
release 1 x
Press liftgate
release 1 x
Configuration 5
To unlock the
Driver door
Passenger door
X
X
X
X
Rear door/liftgate
X
X
X
X
Configuration 6
To unlock the
Driver door
Press unlock
button 1 x
Press unlock
button 2 x
Passenger door
Press liftgate
release 1 x
Press liftgate
release 1 x
X
X
Rear door/liftgate
76
(G542751)
Service Training
Body
SRS
MS-CAN data bus
Gateway (GEM)
ISO -9141
RCM
Driver air bag module
Passenger air bag module
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

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.
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

Ford Transit 2006 Service Traning

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Ford Transit 2006 Service Traning

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New Product Introduction

Transit 2006.5 (04/2006-)

Technical Service Training

Service Training (G542739)

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

Lesson 1 General Information

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

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

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

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

2.2L Duratorq-TDCi (Puma) diesel................................................................................................................................

2.4L Duratorq-TDCi (Puma) diesel................................................................................................................................

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

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

2.3L Duratec-HE (MI4)..................................................................................................................................................

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

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

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

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

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

Lesson 5 Body and Paint

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

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

Transit 2006.5 (03/2006-)

Stability assist with active rollover protection

V347 = Front wheel drive

Reinforced front axle (for vehicle versions with high

V348 = Rear wheel drive

Service Training (G542739)

Modified diesel engines with increased power and

Recharging function for the radio remote control

Modified 2.3L Duratec-HE (MI4) engine with

Anti-theft alarm system in accordance with Thatcham

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

Modified locking system with configurable locking

Latest generation of audio units and Travel Pilot EX

Speed control system

Position of electrical components

GEM behind glove compartment, passenger side

IFS (Inertia Fuel Shutoff) (vehicles with petrol

Hands-free kit/voice control module (beside

PCM (Powertrain Control Module) in left-hand

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

Receiver for radio remote control (in center of

ABS (Anti-lock Brake System) module, engine

Booster heater (vehicle underbody, driver side)

Trailer module (under driver seat)

GPS (Global Positioning System) antenna (in

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

RCM (Restraints Control Module) (next to the

Service Training (G542739)

The IFS switch is installed in the instrument panel

Here the ball joints are bolted between the transverse

Strut and spring assembly (reinforced front axle)

Strut and spring assembly (standard front axle)

In addition to the front axle installed as standard, a

Press-fit ball joint (standard front axle)

Bolted ball joint (reinforced front axle)

Service Training (G542798)

Brake System - General Information

Brake pad wear indicator

Larger brake discs as well as modified brake calipers

the right-hand brake caliper piston, apply pressure to