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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 The previous 2.0L Duratorq TDCi engines have been replaced by a modified generation upgraded to a cubic capacity of 2.2 liters.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)

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Table of Contents

PAGE

Preface.............................................................................................................................. At a glance.......................................................................................................................
Position of electrical components...................................................................................................................................

1 5
7

Lesson 1 – General Information Lesson 2 – Chassis
Suspension System......................................................................................................................................
Front axle........................................................................................................................................................................

9
9

Brake System - General Information........................................................................................................
General............................................................................................................................................................................ ABS system overview..................................................................................................................................................... Bosch 8.0 ABS system.................................................................................................................................................... Active rollover protection...............................................................................................................................................

10
10 11 12 13

Lesson 3 – Powertrain
Engine System - General Information......................................................................................................
2.2L Duratorq-TDCi (Puma) diesel................................................................................................................................
General................................................................................................................................................................................................... Engine data.............................................................................................................................................................................................

14
16
16 17

Injection system..............................................................................................................................................................
High-pressure pump............................................................................................................................................................................... Fuel injectors.......................................................................................................................................................................................... Valve train.............................................................................................................................................................................................. Accessory drive......................................................................................................................................................................................

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20 22 23 24

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Service Training

Table of Contents

Cylinder head......................................................................................................................................................................................... Cylinder block........................................................................................................................................................................................

26 28

2.4L Duratorq-TDCi (Puma) diesel................................................................................................................................
General................................................................................................................................................................................................... Engine data............................................................................................................................................................................................. Centrifugal oil filter (140 PS version only)............................................................................................................................................ Oil level/temperature sensor (103 kW version only).............................................................................................................................

28
28 29 31 32

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

33
34

Transmission...................................................................................................................................................................
Shift mechanism.....................................................................................................................................................................................

37
37

Clutch assembly..............................................................................................................................................................

37

Lesson 4 – Electrical
Instrument Cluster.....................................................................................................................................
Overview......................................................................................................................................................................... Operation.........................................................................................................................................................................
Configuration of the message center (high equipment level)................................................................................................................. Diagnostics.............................................................................................................................................................................................

38
38 40
41 41

Tachograph..................................................................................................................................................
General............................................................................................................................................................................

42
42

Audio System...............................................................................................................................................
Overview......................................................................................................................................................................... General............................................................................................................................................................................

43
43 44

Navigation System......................................................................................................................................
Travel Pilot EX................................................................................................................................................................

49
49

Service Training

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Table of Contents

Cellular Phone............................................................................................................................................
General............................................................................................................................................................................

51
51

Exterior Lighting........................................................................................................................................
General............................................................................................................................................................................

53
53

Communications Network.........................................................................................................................
Overview.........................................................................................................................................................................

54
54

Module Configuration................................................................................................................................
Central module configuration.........................................................................................................................................

57
57

Module Controlled Functions....................................................................................................................
General............................................................................................................................................................................
Service instructions................................................................................................................................................................................

59
59
63

Power supply................................................................................................................................................................... PATS................................................................................................................................................................................

64 65

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

66
66

Lesson 5 – Body and Paint
Body.............................................................................................................................................................
General............................................................................................................................................................................
Interior.................................................................................................................................................................................................... Anti-corrosion protection....................................................................................................................................................................... End of Life Vehicles Directive...............................................................................................................................................................

69
69
71 71 71

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

73 77

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

79

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Service Training

Introduction

At a glance

Transit 2006.5 (03/2006-)

Internal designation: • V347 = Front wheel drive • V348 = Rear wheel drive Chassis • Improved drivability through fine-tuning of springs, shock absorbers and steering • Modified brake system (disc brakes on the rear axle)

• Stability assist with active rollover protection • Reinforced front axle (for vehicle versions with high payload)

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At a glance

Introduction

Powertrain • Modified diesel engines with increased power and lower consumption, emission standard IV, second-generation common-rail technology • Modified 2.3L Duratec-HE (MI4) engine with emission standard IV, LPG (Liquefied Petroleum Gas) (optional) • 2.4L Duratorq TDCi with 85 kW (115 PS) and 105 kW (143 PS) in conjunction with 6-gear manual transmission (rear wheel drive) • Gearshift lever in the instrument panel Electrical system • Central module configuration • New GEM (Generic Electronic Module) with integrated PATS (Passive Anti-theft System) function • Completely newly developed vehicle electrical system with MS-CAN (Controller Area Network) and HS-CAN bus • New instrument cluster with dot matrix display • Speed control system

• Power management • Recharging function for the radio remote control • Modified locking system with configurable locking functions • Anti-theft alarm system in accordance with Thatcham CAT 1 • Latest generation of audio units and Travel Pilot EX navigation system • Hands-free kit with Bluetooth interface and voice control Body • Improved crash characteristics • side air bag modules • New front end design • New instrument panel with numerous storage options • Improved corrosion protection • Two new vehicle versions • New exterior colors • New fabric and leather seats

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Service Training

Introduction

At a glance

Position of electrical components
Shown: LHD (Left-hand Drive)

1 2 3 4 5 6 7 8

GEM behind glove compartment, passenger side IFS (Inertia Fuel Shutoff) (vehicles with petrol engine) Right-hand crash sensor (with side air bag only) Receiver for radio remote control (in center of headliner) Booster heater (vehicle underbody, driver side) Trailer module (under driver seat) Left-hand crash sensor (with side air bag only) Instrument cluster

9 10 11 12 13

Hands-free kit/voice control module (beside instrument panel) PCM (Powertrain Control Module) in left-hand side of engine compartment ABS (Anti-lock Brake System) module, engine compartment, underneath brake master cylinder GPS (Global Positioning System) antenna (in center of instrument panel) RCM (Restraints Control Module) (next to the GEM)

Service Training (G542739)

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At a glance

Introduction

IFS switch

The IFS switch is installed in the instrument panel (passenger side).

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Service Training

Lesson 2 – Chassis

Suspension System

Front axle

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.

A B

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.

1 2

Press-fit ball joint (standard front axle) Bolted ball joint (reinforced front axle)

Service Training (G542798)

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Brake System - General Information

Lesson 2 – Chassis

General

A B 1

Front brake Rear brake Brake pad wear indicator 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.

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

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Service Training

Lesson 2 – Chassis

Brake System - General Information

ABS system overview

1 2 3 4 5 6

HS-CAN data bus input/output signals Gateway (GEM) ABS module ABS motor ABS/HCU (Hydraulic Control Unit). Stoplamp switch

7 8 9

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

Service Training (G542740)

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Brake System - General Information

Lesson 2 – Chassis

HS-CAN input signals: 1. CKP (Crankshaft Position) sensor > GEM Gateway > ABS module 2. Engine idle speed (from PCM) > ABS module 3. Engine status (OFF, idling, stalling) (from PCM) > ABS module 4. Duration of driving cycle (from GEM) > Gateway > ABS module 5. Tire circumference > GEM Gateway > ABS module 6. Ignition lock position > GEM Gateway > ABS module 7. Torque (from PCM) > ABS module 8. APP (Accelerator Pedal Position) position > GEM Gateway > ABS module 9. BPP (Brake Pedal Position) switch > PCM > ABS module 10. Parking brake switch > GEM Gateway > ABS module 11. Outside air temperature sensor > GEM Gateway > ABS module 12. Total mileage > GEM Gateway > ABS module 13. GEM Gateway > Instrument cluster > Data for central vehicle configuration HS-CAN output signals: 1. Vehicle speed signal > ABS module > GEM Gateway 2. Intervention BTCS (Brake Traction Control System) > ABS module > PCM 3. Torque adaptation request > ABS module > PCM 4. ABS module > GEM Gateway > Instrument cluster > ABS warning indicator 5. ABS module > GEM Gateway > Instrument cluster > Brake system warning indicator 6. ABS module > GEM Gateway > Instrument cluster > ABS warning indicator

7. ABS module > GEM Gateway > Instrument cluster > Stability assist warning indicator ESP 8. Signals of all four wheel speed sensors > ABS module > PCM The following brake systems are available, depending on the vehicle version: – ABS (Bosch 8.0) – ABS/BTCS – ABS/BTCS, stability assist, electronic EBA (Emergency Brake Assist), active rollover protection

Bosch 8.0 ABS system
The Bosch 8.0 ABS system is an enhancement of the previously installed Bosch 5.3 system. The hydraulic ABS unit and the rear brake calipers are service pre-filled. The front brake calipers and the cylinders of the rear drum brake are not pre-filled. The steering wheel rotation sensor is integrated together with the clockspring in a housing and is located behind the steering wheel. The steering wheel rotation sensor works according to the principle of magnetoresistance and permits absolute sensing of the steering wheel position. NOTE: When replacing the sensor, make sure that the new sensor is installed centrally and is calibrated using WDS (Worldwide Diagnostic System). Instructions for this can be found in the relevant Service literature. The yaw rate/lateral acceleration sensor is accommodated in a housing and is located on a separate bracket to the left of the foot controls (LHD and RHD (Right-hand Drive)). Stability assist can be deactivated via a switch in the instrument panel.

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Service Training

Lesson 2 – Chassis

Brake System - General Information

Active rollover protection
The active rollover protection (ARM = Active Roll-over Mitigation) is a function of the stability assist program and is integrated as software in the – ABS/stability assist module as standard. This function does not require any further components.

Operation
If a sudden evasive maneuver by the driver is registered during driving, the outside front wheel is braked for a brief period. Evasive maneuvers are detected by the steering wheel rotation sensor. For this purpose, a rotational angle speed of more than 512 ° per second must be detected. The vehicle is stabilized through the braking of the outside front wheel. The active rollover protection is active and effects braking in a vehicle speed range between approx. 30 and 130 km/h. As soon as the rollover protection is activated, this is indicated by the stability assist warning indicator in the instrument cluster. If the stability assist is deactivated, the rollover protection nevertheless remains on standby.

Service Training (G542740)

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Engine System - General Information

Lesson 3 – Powertrain

Engine/transmission combinations

1 2 3

2.2L Duratorq-TDCi (Puma) diesel 2.4L Duratorq-TDCi (Puma) diesel 2.3L Duratec-HE (MI4)

4 5 6

VXT-75 5-speed manual transaxle MT82 6-speed manual transmission MT-75 5-speed manual transmission

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Service Training

Lesson 3 – Powertrain

Engine System - General Information

The Transit 2006.5 (03/2006-) is available with the following engine/transmission combinations: • 2.2L Duratorq-TDCi (Puma) diesel with VXT-75 5-speed manual transaxle (front wheel drive) • 2.4L Duratorq-TDCi (Puma) diesel with MT-75 (5-speed) and MT82 (6-speed) manual transmission Cubic capacity (drive) 2.2L (front wheel drive) (previously 2.0L)

(rear wheel drive) • 2.3L Duratec-HE (MI4) with MT-75 5-speed manual transmission (rear wheel drive) The engine range consists of the following power versions:

Power output PS (kW) 85 (63)

Torque (Nm) 250

110 (81) 130 (96) 2.4L (rear wheel drive) 100 (74) 115 (85) 140 (103) 2.3L (rear wheel drive) petrol 145 (107)

285 310 285 320 375 200

Service Training (G542741)

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Engine System - General Information

Lesson 3 – Powertrain

2.2L Duratorq-TDCi (Puma) diesel

General
• The previously installed 2.0L TDCi engine will be replaced by a modified 2.2-liter version. • The 2.2L Duratorq-TDCi (Puma) diesel is essentially based on the previously installed 2.0-liter engine. It is available in three different power output versions of 63 kW, 81 kW and 96 kW.

• The engine features a modified valve train as well as a modified accessory drive. • The oil change interval is 25,000 km or one year. • The 63 kW version is the entry-level version for the front wheel drive vehicles. A turbocharger with a wastegate is used.

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Service Training

Lesson 3 – Powertrain

Engine System - General Information

• 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 • High-pressure pump • Fuel injection supply manifold Cubic capacity 2.2L Duratorq-TDCi (Puma) diesel Engine code P8FA (85 PS) QVFA (110 PS) QWFA (130 PS) 1,998 ccm 86 mm 86 mm 19 : 1 1-3-4-2 900 rpm

Engine management
• Visteon • EOBD (European On-board Diagnostic) for the monitoring of emissions-related components.

Stroke Bore Compression ratio Firing order Idle speed

Engine emission control
• 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 rpm, 285 Nm at 1,750 rpm 96 kW (130 PS) at 3,500 rpm, 310 Nm at 1,600 rpm Fuel Diesel

Service Training (G542741)

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Engine System - General Information

Lesson 3 – Powertrain

Power and torque curves

A B C 1 2

Torque (Nm) Engine speed (rpm) Power output (kW) Torque curve for 96 kW engine Power curve for 96 kW engine

3 4 5 6

Torque curve for 81 kW engine Power curve for 81 kW engine Torque curve for 63 kW engine Power curve for 63 kW engine

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Service Training

Lesson 3 – Powertrain

Engine System - General Information

Injection system

1 2 3 4 5 6

High-pressure pipe Leak-off pipe Fuel injection line Injector Pressure relief valve Fuel injection supply manifold

7 8 9

Fuel metering valve Fuel pressure sensor Fuel temperature sensor

10 High-pressure pump 11 Fuel return

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Engine System - General Information

Lesson 3 – Powertrain

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.

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.

Fuel injection supply manifold

High-pressure pump

1 2 3

Fuel pressure sensor Pressure relief valve Fuel injection supply manifold

NOTE: The pressure relief valve operates as a disposable valve. This means that it must be replaced after it has been triggered once, as the fuel-tightness of the valve can no longer be guaranteed.

The high-pressure pump is flanged onto the left of the cylinder head in the direction of travel and is driven by the intake camshaft.

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Service Training

Lesson 3 – Powertrain

Engine System - General Information

1 2 3

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.

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Engine System - General Information

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. The associated high-pressure lines must also be replaced. Instructions for this can be found in the relevant Service literature. Further information on the Denso common-rail injection system can be found in the Student Information "Diesel Fuel Injection and Engine Management Systems – Common-Rail Systems", CG 8180/S.

Identification number (injector correction factor)
Illustration shows the fuel injector from above

1 2 3

Electrical connection, solenoid valve 16-digit identification number Connection, leak-off pipe

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Service Training

Lesson 3 – Powertrain

Engine System - General Information

To ensure optimum fuel metering, the PCM must be informed when a new injector is installed. Furthermore, after new PCM software has been loaded via WDS, the injectors must also be configured. This is achieved by entering the 16-digit identification number into the PCM using WDS, taking into account the relevant cylinder. Note: If the identification numbers are not entered properly with WDS, the following faults can occur: • Increased black smoke formation, • Irregular idling, • Increased combustion noise.

Valve train

The valve train has been adapted to the new position of the high-pressure pump. The timing chain now only drives the two camshafts. Consequently, the housing as well as the routing of the timing chain have been modified.

Service Training (G542741)

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Engine System - General Information

Lesson 3 – Powertrain

Accessory drive

A B

Accessory drive without A/C (Air Conditioning) compressor Accessory drive with A/C compressor

1 2

Tensioner Tensioning rollers

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.

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Lesson 3 – Powertrain

Engine System - General Information

1 2

Power steering pump Coolant pump The pumps can be replaced separately during servicing. Instructions for this can be found in the relevant Service literature.

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.

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Engine System - General Information

Lesson 3 – Powertrain

Cylinder head

1 2

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.

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Service Training

Lesson 3 – Powertrain

Engine System - General Information

1 2

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.

Service Training (G542741)

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Engine System - General Information

Lesson 3 – Powertrain

Cylinder block

2.4L Duratorq-TDCi (Puma) diesel
General
• The 2.4L Duratorq-TDCi (Puma) diesel engine is essentially based on the previously installed 2.4-liter engine. It is available in three different power output versions of 74 kW, 85 kW and 103 kW. • Like the 2.2-liter version, the engine features a modified valve train as well as a modified accessory drive. • The introduction of the Transit 2006.5 (03/2006-) will see the previously used Delphi common-rail system replaced by the Denso common-rail system. – The fuel injection pump is still driven by the timing chain of the valve train. • The service interval is 25,000 km or one year for all versions other than the 103 kW version. • The service interval for the 103 kW version is 50,000 km or two years. A service interval indicator in the instrument cluster alerts the driver when servicing is required.

The 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 • Fuel injection supply manifold

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Lesson 3 – Powertrain

Engine System - General Information

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) 2,402 ccm 94.6 mm 89.9 mm 19:1 1-3-4-2 900 rpm

Engine emission control
• Meets emission standard IV • Electrical EGR valve with water cooling Cubic capacity Stroke Bore

Diagnosis
• Diagnosis using WDS via the DLC

Compression ratio Firing order Idle speed

Max. power output, torque 74 kW (100 PS) at 3,500 rpm, 285 Nm at 1,600 rpm 85 kW (115 PS) at 3,500 rpm, 310 Nm at 1,750 rpm 103 kW (140 PS) at 3,500 rpm, 375 Nm at 2,000 rpm Fuel Diesel

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Engine System - General Information

Lesson 3 – Powertrain

Power and torque curves

A B C 1 2

Torque (Nm) Engine speed (rpm) Power output (kW) Torque curve for 103 kW engine Power curve for 103 kW engine

3 4 5 6

Torque curve for 85 kW engine Power curve for 85 kW engine Torque curve for 74 kW engine Power curve for 74 kW engine

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Service Training

Lesson 3 – Powertrain

Engine System - General Information

Centrifugal oil filter (140 PS version only)

1 2 3

Cover Centrifuge (under the valve cover) Oil pressure line to the centrifugal oil filter The oil pressure and the shape of the rotor cause this pivot axis to turn, forcing the oil in the rotor outwards. The centrifugal force presses the particles floating in the oil (contamination particles) against the outer wall of the rotor, where they form a solid mass. The oil in the rotor is filtered in this manner and then flows back into the oil circuit. The centrifugal oil filter can even catch small particles of dirt that cannot be filtered using normal oil filters. This increases the service life of the oil.

The 103-kW version of the 2.4L Duratorq-TDCi (Puma) diesel engine features a centrifugal oil filter. In conjunction with a calculation algorithm in the PCM and an additional oil level/temperature sensor, this permits a service interval of up to 50,000 km. The centrifugal oil filter is located in the cylinder head and comprises: • a cover cap (in the valve cover) • a replaceable rotor (centrifuge) The oil from the oil pan is pumped into the rotor via an additional pressure line installed on the outside of the engine block. Inside the rotor is a pivot axis with two outlet openings on opposite sides.

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Engine System - General Information

Lesson 3 – Powertrain

Oil level/temperature sensor (103 kW version only)

1 2 3

Oil level/temperature sensor Openings Oil dipstick The oil temperature is simultaneously sensed via the integrated temperature sensor. The temperature is used as a correction factor in the calculation. The PCM calculates the next oil change on the basis of an integrated strategy (which also takes into account the mileage and engine operating conditions) and displays it in the instrument cluster. In addition, a separate indicator in conjunction with a corresponding message in the instrument cluster display warns the driver when the oil quantity falls below the minimum level.

An oil level/temperature sensor located on the front of the engine directly beside the engine oil dipstick is provided for the service interval indicator. The oil level is measured by means of a wire coil located inside the sensor. A continuous current is applied to this wire coil. The resistance and consequently the voltage drop at the wire coil changes according to how deeply the sensor is immersed in the oil. The measured values are registered by the PCM. The change in the voltage drop serves as an input variable for calculation of the oil level.

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Service Training

Lesson 3 – Powertrain

Engine System - General Information

Service instructions
The interval indicator must be reset after an oil change

on all vehicles with a diesel engine. Please refer to the relevant Service literature for a description of this procedure.

2.3L Duratec-HE (MI4)

The 2.3L Duratec-HE (MI4) engine is essentially based on the 2.0L Duratec-HE (MI4) already used in the Focus C-MAX 2003.75 and 2004.75 Focus.

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Engine System - General Information

Lesson 3 – Powertrain

The main features of the engine are as follows: • Longitudinally installed four-cylinder in-line engine with two chain-driven overhead camshafts and 16 valves • Aluminum cylinder block with lower crankcase • Mechanical bucket tappets • Intake manifold runner control with swirl flaps • Ignition system with ignition coil-on-plug • Electronic throttle valve • Balance shafts Engine management • Visteon PCM • Knock control with one KS (Knock Sensor) Engine emission control • Meets European emission standard IV • EOBD for the monitoring of emissions-related components. Diagnosis • Diagnosis using WDS via the DLC

Engine data
2.3L Duratec-HE (MI4) Engine code GZFA (emission standard IV) GZFB (emission standard III) 2,261 ccm 94 mm 87.5 mm 9.7:1 1-3-4-2 rpm 107 kW (145 PS) at 5,250 rpm 210 Nm at 3,750 rpm Premium 95 RON

Cubic capacity Stroke Bore Compression ratio Firing order Idle speed Max. power output

Max. torque Fuel

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Service Training

Lesson 3 – Powertrain

Engine System - General Information

Power and torque curve (when using 95 RON fuel)

A B C

Torque (Nm) Engine speed (rpm) Power output (kW) 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.

Service instructions
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).

Service Training (G542741)

35

Engine System - General Information

Lesson 3 – Powertrain

Accessory drive

A B

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

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Service Training

Lesson 3 – Powertrain

Engine System - General Information

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.

Service Training (G542741)

37

Instrument Cluster

Lesson 4 – Electrical

Overview

1 2 3 4

HS-CAN data bus MS-CAN data bus Gateway (GEM) Instrument cluster module

5 6 7 8

Displays in the instrument cluster Multifunction switches ("set/reset" button, rotary switch) Digital tachograph Brake pad wear indicator

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Service Training

Lesson 4 – Electrical

Instrument Cluster

HS-CAN input signals: 1. CKP sensor > GEM Gateway > Instrument cluster > Tachometer 2. Wheel speed sensor > ABS module > GEM Gateway > Instrument cluster > Vehicle speed display (VSS (Vehicle Speed Sensor)) 3. ABS module > GEM Gateway > Instrument cluster > Brake system warning indicator 4. ABS module > GEM Gateway > Instrument cluster > ABS warning indicator 5. ABS module > GEM Gateway > Instrument cluster > Stability assist warning indicator ESP 6. PCM-controlled battery charge > Generator > GEM Gateway > Instrument cluster > Charging system warning indicator 7. PCM > GEM Gateway > Instrument cluster > Glow plug warning indicator (vehicles with diesel engine) 8. ECT (Engine Coolant Temperature) sensor > PCM > GEM Gateway > Instrument cluster > Temperature display 9. PCM > GEM Gateway > Instrument cluster > Speed control system warning indicator 10. PCM > GEM Gateway > Instrument cluster > MIL warning indicator 11. PCM > GEM Gateway > Instrument cluster > Powertrain warning indicator or display in the message center 12. Oil pressure switch > PCM > GEM Gateway > Instrument cluster > EOP (Engine Oil Pressure) warning indicator 13. Oil level/temperature sensor > PCM > GEM Gateway > Instrument cluster > Engine oil level warning indicator or oil change warning in message center display

MS-CAN input signals: 1. Ignition lock position > GEM Gateway > Instrument cluster (power management) 2. Reversing lamp switch > GEM Gateway > Instrument cluster 3. Time > GEM Gateway > Time display in instrument cluster (with RDS 1500 or without radio) 4. Alarm time > GEM Gateway > Instrument cluster 5. Brake fluid level sensor GEM Gateway > Instrument cluster > Parking brake warning indicator 6. Water-in-fuel sensor > GEM Gateway > Instrument cluster > Warning LED (Light Emitting Diode) 7. Outside air temperature sensor > GEM Gateway > Instrument cluster > Ice warning indicator or temperature gauge in the display in the message center 8. RCM > Instrument cluster > Air bag warning indicator or safety belt warning indicator 9. Headlamp switch > GEM Gateway > Instrument cluster > Lighting indicator or light-on warning tone 10. PATS transceiver > GEM Gateway > Instrument cluster > PATS indicator 11. Door contact/hood switch > GEM Gateway > Instrument cluster > Door warning indicator or door status display in the message center 12. GEM Gateway > Instrument cluster > Data for central vehicle configuration 13. Fuel level sensor > GEM Gateway > Instrument cluster > Tank display or fuel reserve warning indicator MS-CAN output signals: 1. Instrument cluster > GEM Gateway > ABS module > Mileage 2. Instrument cluster > Audio unit > Vehicle speed signal 3. Instrument cluster > Audio unit > Reverse gear signal

Service Training (G542742)

39

Instrument Cluster

Lesson 4 – Electrical

4. Instrument cluster > Audio unit > Time display (not with RDS 1500)

5. Instrument cluster > DLC

Operation
Shown: Low equipment level

1 2 3

PATSLED Brake pad wear warning indicator Trip odometer reset button (not with high equipment level)

4 5 6

Time setting button (not with high equipment level) Multi-function display Service reminder indicator

The instrument cluster is available in two versions depending on the vehicle equipment. The version with high equipment level has a full dot-matrix display as well as an info LED between the large analog displays. Messages are shown in the instrument cluster via the display and the LED. The LED lights up yellow or red according to the significance of the message.

The instrument cluster is connected to the MS-CAN bus and forms the interface between the MS-CAN bus of the audio system and the MS-CAN bus of the rest of the module communications network. It contains three 120 Ohm terminating resistors; two for the audio network and one for the rest of the MS-CAN network.

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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.

Service Training (G542742)

41

Tachograph

Lesson 4 – Electrical

General

The tachograph registers • driving, working and rest times for the driver and passenger, • speed (24 hours in mass memory) and distance driven, • operation-specific parameters such as speed, other work operations on the vehicle and events such as information on calibration and/or periodic testing. The data is stored: • vehicle-specifically in an integrated mass memory unit with capacity for recording the activities for approx. 365 days • driver-specifically on the personal driver card with capacity for approx. 28 days A separate VSS that transmits a digitally encrypted signal directly to the tachograph is installed at the transmission during installation of the tachograph. The sensor is secured against tampering by a lead seal. Installation and calibration of the system is carried out by authorized service partners. The tachograph is supplied with separate operating instructions (from Siemens). Diagnosis can only be carried out by authorized dealers.

A digital tachograph (Siemens VDO, type DTCO 1381) is available for the Transit 2006.5. This tachograph works with the aid of chip cards which store all the necessary information. These chip cards are driver-specific and must be inserted in the card reader before departure. The data of two drivers can be registered in parallel using two chip-card readers. Further instructions on operation can be found in the relevant Owner's Handbook. The tachograph in 1-DIN radio format is installed above the instrument panel and includes • two chip-card readers, • an integrated printer for creating logs for drivers and inspectors, • a display containing important information, e.g. on the current driving and rest-period account, • a real-time clock, • various controls.

Note
The introduction of digital tachographs in commercial vehicles with a permissible gross weight of more than 3.5 tons and vehicles with more than nine seats came into force on August 5, 2005 (European Legislation EEC No 3820/85 and 3821/85). Digital tachographs have been permitted on new vehicles since mid-2005. It must be noted here that digital tachographs may only be diagnosed and/or repaired by authorized Siemens dealers. Further instructions on this can be found in TSB 59/2005. Further information at "http://www.vdo.com"

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Service Training

Lesson 4 – Electrical

Audio System

Overview

1 2 3 4 5

MS-CAN data bus Gateway (instrument cluster) Audio/navigation unit Right-hand speaker Left-hand speaker

6 7

Hands-free system/Bluetooth/voice control module Audio remote control GPS/GSM (Global System for Mobile Communication)/AM (Amplitude Modulation)/FM (Frequency Modulation) antenna

8

Service Training (G829488)

43

Audio System

Lesson 4 – Electrical

MS-CAN input signals: 1. Vehicle speed signal > Wheel speed sensor > ABS module > GEM Gateway (MS-CAN) > Instrument cluster gateway > Audio unit 2. Ignition lock > GEM Gateway > Instrument cluster gateway > Audio unit 3. Reversing lamp switch > GEM Gateway > Instrument cluster gateway > Audio unit > Reverse gear signal 4. Microphone > Bluetooth/voice control module > audio system MS-CAN output signals: 1. Instrument cluster gateway > Audio unit > Time display/setting (not with RDS 1500) 2. Audio unit > Bluetooth/voice control module 3. Audio remote control > Audio unit > Bluetooth/voice control module

General
All multimedia devices (audio units, navigation devices and hands-free kit) are connected to each other via a separate MS-CAN network (audio network). The instrument cluster, which acts as a gateway between the audio network and the rest of the MS-CAN network, enables the following functions: • Time (from the GEM to the audio unit) • Setting time (from the audio unit to the GEM) • Vehicle speed information • Reverse gear information • Diagnostics • Clear module • Central module configuration The new generation of audio units is available in the following versions for the Transit: • 1500 RDS • 6000 CD • 6006 CDC

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Service Training

Lesson 4 – Electrical

Audio System

1500 RDS

1500 RDS, RDS, 2 X 6 watt output, not connected to the MS-CAN bus

Service Training (G829488)

45

Audio System

Lesson 4 – Electrical

6000 CD

6000 CD (Compact Disc), larger display, CD player, 4 x 17 Watt output, Bluetooth-compatible

46

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Service Training

Lesson 4 – Electrical

Audio System

6006 CDC

6006 CDC, as 6000 CD, with integrated 6-disc changer Radio remote control is available for certain equipment levels (same as Focus/Focus C-MAX). The time is shown in the display of all units with the exception of the 1500 RDS. The radio display serves exclusively to show and set the time. The actual clock is located in the GEM. For vehicles equipped with 1500 RDS or vehicles without radio, the time is displayed in the instrument cluster. It is not possible to display the RDS time in the audio unit (deactivated in the radio software). Function changes compared with the devices installed in the Focus 2004.75 and Mondeo 2001 (does not apply to 1500 RDS): • Separate CLOCK button • No PTY function

• REG function can be disabled • No frequency display when the station name appears One significant change to the 6000 CD and 6006 CDC in comparison with the units installed in the Focus and Mondeo is the discontinuation of the program type code (PTY) function. The PTY button has been replaced by a new phone button bearing a handset symbol instead of the inscription "PHONE". The phone button has been replaced by a button with the inscription "CLOCK" for setting the time. This makes it easier to set the time by means of direct access to the appropriate menu. In addition, all audio units feature a modified anti-theft protection system. This system works on the basis of the VIN (Vehicle Identification Number) identification rather than entry of a key code (see also central vehicle configuration).

Service Training (G829488)

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.

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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: • 4 x 20 W output power • Large 4-inch monochrome display • MP3-compatible CD drive • Bluetooth-compatible • Turn-by-turn navigation (displays the street names even if no route is calculated) • Corridor function (additional area either side of the route. In this corridor, the system takes into account the most up-to-date traffic information). • Voice output without navigation CD-ROM (in conjunction with corridor function) • Navigation CD with detailed and additional data

• Simulation mode can be activated/deactivated directly from the Menu button • The designation "RNS" has been dropped, no reference to the manufacturer NOTE: When installing a new navigation unit, the navigation unit must be configured by selecting the routine "Install programmable modules" in WDS. Further information on operation is provided in the Owner's Handbook CG 3474.

Service instructions
The Travel Pilot EX can be diagnosed using two different menus: • Tuner test mode • Dealer service mode

Service Training (G829489)

49

Navigation System

Lesson 4 – Electrical

Button combination S1 + MENU S4 + MENU Tuner test mode

Description

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

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Service Training

Lesson 4 – Electrical

Cellular Phone

General

1 2 3 4

MS-CAN data bus input/output signals Gateway (instrument cluster) Hands-free system/Bluetooth/voice control module Audio/navigation unit

5 6 7 8

Cellular phone GSM antenna Handset holder Microphone

Service Training (G829490)

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. MS-CAN input signals: 1. Audio remote control > Audio unit > Bluetooth/voice control module 2. Station buttons > Audio unit > Bluetooth/voice control module MS-CAN output signals: 1. Microphone > Bluetooth/voice control module > Audio unit 2. Microphone > Bluetooth/voice control module > Navigation system

52

(G829490)

Service Training

Lesson 4 – Electrical

Exterior Lighting

General

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. 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.

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.

Service Training (G542744)

53

Communications Network

Lesson 4 – Electrical

Overview

A B C D E 1 2 3 4 5 6

MS-CAN data bus ISO 9141 Outgoing/incoming lines (RX/TX) LIN data bus HS-CAN data bus SRS (Supplemental Restraint System) module Phone / Bluetooth/voice control module Instrument cluster Audio unit Parking aid module GEM

7 8 9 10

Light/rain sensor Radio remote control reception module PATS transceiver unit Battery-buffered anti-theft alarm system horn (BBS)

11 Passenger compartment control sensor(s) 12 PCM 13 ABS module 14 Steering wheel rotation sensor 15 Yaw rate/lateral acceleration sensor 16 DLC 17 Terminating resistors

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Service Training

Lesson 4 – Electrical

Communications Network

Up to four data bus systems can be used in the Transit 2006.5 depending on the model and equipment: • HS-CAN bus • MS-CAN bus • ISO 9141 protocol • LIN (Local Interconnect Network) All systems can be diagnosed via the DLC. The following modules are implemented as gateways: – GEM Gateway between the HS-CAN and the central electrics MS-CAN – Instrument cluster gateway between the central electrics MS-CAN and the audio system MS-CAN .

– Fuel fired booster heater – RCM – Parking aid module – Instrument cluster 2. MS-CAN for the audio system – Instrument cluster – Audio system – Bluetooth/voice control module Here, the instrument cluster acts as a gateway to the MS-CAN network of the audio system. This gateway provides the information required for the audio system and the Bluetooth/voice control module (see the description of the audio systems). This eases the data transfer load on the remaining MS-CAN network and reduces potential sources of faults. The two terminating resistors, each of 120 ohm, of the MS-CAN data bus are integrated into the GEM and into the instrument cluster. The total resistance of the central electrics MS-CAN amounts to 60 ohms, measured at the DLC. The two terminating resistors of the MS-CAN audio system are installed together in the instrument cluster. As this network is not connected to the DLC, the total resistance cannot be measured at the DLC.

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.

ISO
The following systems are connected using the ISO-9141 protocol: • Receiver for radio remote control • PATS transceiver

MS-CAN
Two separate MS-CAN networks are used in the Transit: 1. MS-CAN for all systems apart from the audio system:

• Light/rain sensor

Service Training (G542745)

55

Communications Network

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.

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Service Training

Lesson 4 – Electrical

Module Configuration

Central module configuration

A B 1

Previous configuration principle Central module configuration principle Control modules

2 3 4

GEM WDS 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.

Service Training (G542746)

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.

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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 • 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 B C/D

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 Communication MS-CAN Gateway HS-CAN Gateway

X X

X X

X X

Service Training (G542749)

59

Module Controlled Functions

Lesson 4 – Electrical

Function/system Number of digital inputs 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 Hardware Number of fuses Number of external relay slots Number of integrated relays Number of plugs/pins Number of drivers (low side) Number of drivers (high side) Voltage supply Ignition lock status Additional battery check Power management (e.g. shipping mode) Battery-saving function Exterior lighting Side lamps High beams Low beams Rear fog lamp Turn signal lamps Headlamp switch input (light-on warning tone)

A 29 2

B 49 2

C/D 50 5 X X

X X X X X X X X X

X X X X X

20 0 4 79 7 2

20 0 8 119 13 3

20 0 11 139 15 4

X X X X

X X X X

X X X X

X X X X X X

X X X X X X

X X X X X X

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Service Training

Lesson 4 – Electrical

Module Controlled Functions

Function/system 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 windows Heated windshield Heated rear window(s) Heated exterior mirrors Wash/wipe system

A X X X X X X X X X X

B X X X X X X X X X X X

C/D X X X X X X X X X X X X X

X X X

X X X X

X X X X

X X X X X X X X X X

X X X

X X X

Service Training (G542749)

61

Module Controlled Functions

Lesson 4 – Electrical

Function/system 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

A X X

B X X X

C/D X X X X

X X X

X X X X X X X X X X X X X

X X X X X X X X X X X X X X X

X X X X X X

X X X X X X

X X X X X X

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Service Training

Lesson 4 – Electrical

Module Controlled Functions

Function/system Speed control system Sensing of the ambient air temperature Service mode Diagnosis with WDS
* May be deactivated in the factory, depending on market

A

B

C/D X X

X X

X X

X X

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 GEM is connected to the following modules via the HS-CAN: • PCM • ABS module The GEM is connected to the following modules via the MS-CAN: • Instrument cluster • Parking aid module • RCM The GEM is the gateway for the communications between the MS-CAN and the HS-CAN. The GEM is connected to the following modules via the LIN bus: • Battery-buffered alarm horn (BBS = Battery Back-up Sounder) • Parking-aid module • Interior scanning sensors

The GEM is connected to the following modules via serial interfaces: • Remote control receiver • PATS transceiver (ring antenna) • Light/rain sensor

Hazard warning lights for an accident
Accident detection is carried out by the RCM The signal is transmitted via the MS-CAN bus to the GEM. If an event is detected, the hazard warning lights are actuated by the GEM (see also: crash mode). It can be switched off via the hazard flasher switch.

Service instructions
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

Service Training (G542749)

63

Module Controlled Functions

Lesson 4 – Electrical

• Ensure that diagnostic mode or programming mode is not activated • Press one of the two front door lock switches eight times within 10 seconds Entry into service mode is confirmed by an audible signal; the turn signals as well as the turn signal indicators on the instrument cluster flash twice. The input signals can then be checked. Each input signal is indicated by an audible signal; the turn signals as well as the turn signal indicators on the instrument cluster flash once. It is not possible to check the output signals during the self-test. The GEM automatically ends service mode under any of the following conditions: • 20 seconds pass without anything being selected or operated. • The headlamp flasher is operated and the ignition is switched OFF at the same time. • Ignition lock position III (engine start) • The voltage supply is too low (< 9 Volt). • The voltage supply is too high (> 16 Volt). A signal tone sounds twice to indicate that the service mode has been exited. Further information on diagnostics can be found in the relevant service literature.

Both batteries are charged when the engine is running, however a cutoff relay means that only one of the two batteries can be discharged when the ignition key is in position "I". This means that the full power of the battery is always available for the engine start. The "Smart Starting" strategy is still integrated. Here the power supply to the starter motor is interrupted as soon as the engine reaches a set engine idle speed. This decreases power consumption and increases the service life of the starter motor.

Radio remote control
The radio remote control is integrated into the key. A charging function for the remote control batteries is integrated into the remote control. Here, the rechargeable battery which is integrated in the key (previously it was a non-rechargeable battery) is continuously recharged while the ignition is switched on. The charge function of the accumulator is effected by an induction circuit which has previously been used for operation of the PATS transponder. Additional components are therefore not required. The charging process is initiated and executed by the GEM via the ring antenna of the transceiver at the ignition lock once the PATS key query has been performed. The recharging function provides a power supply which ensures that the remote control remains operative at all times. A charging time of approx. 20 minutes generates enough power to transmit a radio signal between the transmitter and the receiver approx. 32 times. The remote control housing is additionally sealed and watertight. It is possible to identify the key by its blue housing. Replacement of the battery is not possible.

Power 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.

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Module Controlled Functions

Power management
Power management facilitates an effective supply of power appropriate to the respective requirements of the individual modules by means of various modes. The power management function is integrated into the GEM. One of four different vehicle modes is used depending on the operating status of the vehicle: • Factory mode • Shipping mode • Standard mode • Crash mode Factory mode: • Factory mode is activated during production of the vehicle. In this mode, relays are shut off to reduce the power supply to a minimum. When the vehicle leaves the factory, factory mode is deactivated and shipping mode is activated. Shipping mode: • Shipping mode is activated en route from the factory to the dealer. The vehicle can be driven without impairment of the driving safety systems. • Individual modules and/or electrical systems (e.g. anti-theft alarm system, clock and radio remote control) are deactivated when the ignition is switched off. • This ensures that the battery has enough power when the vehicle is handed over to the customer. If the engine is started while the system is in shipping mode, the mode is interrupted only temporarily. It is resumed again as soon as the ignition is switched back off. Shipping mode must be deactivated by the dealer. This is done by pressing the brake pedal five times and the hazard flasher switch twice within 10 seconds when the ignition is switched off.

The GEM automatically switches to normal mode once shipping mode is deactivated. Normal mode: • Normal mode guarantees the full functionality of the entire electrical systems. Crash mode: • Crash mode is activated as soon as the RCM registers a vehicle impact of appropriate force. The following functions are carried out: • The vehicle will be centrally unlocked if it is locked at the time of impact. • Activates the hazard warning lamps. • The fuel-fired booster heater is deactivated. Crash mode is deactivated as soon as the ignition key is turned to position "0" and then back to position "II" again. The hazard flashers are deactivated by pressing the hazard flasher switch.

PATS
The PATS functionality is integrated into the GEM. Accordingly, the transceiver unit is directly connected to the GEM (previously it was connected to the PCM). After the key code is read in (in ignition lock position II), the appropriate information is transmitted from the GEM to the PCM via the HS-CAN data bus. Depending on this query and on the key status, starting is then enabled by the PCM. NOTE: When replacing the GEM, it is necessary to reprogram the PATS keys. Instructions for this can be found in the relevant service literature. The key has a plastic transponder. Coded access is used during programming of the key.

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Multifunction Electronic Modules

Lesson 4 – Electrical

Overview

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Multifunction Electronic Modules

1 2 3 4 5 6 7 8 9

HS-CAN data bus MS-CAN data bus Gateway (GEM) GEM Windshield wiper motor Rear window wiper motor(s) FPDM (Fuel Pump Driver Module) Headlamp Heated rear window, heated exterior mirrors

14 Fuel level sensor 15 APP sensor 16 Reversing lamp switch 17 PATS transceiver 18 Multifunction switches (wiper, light) 19 Speed control switch 20 Heated windshield switch 21 Heated rear window switch 22 Hazard flasher switch 23 Ambient air temperature sensor 24 Headlight switch 25 Brake fluid level switch 26 Light/rain sensor (ISO 9141) – Oil change – Glow plug indicator (vehicles with diesel engines) – Engine coolant temperature ECT – PATS – Charge indicator lamp – Speed control system 6. PCM > Gateway > GEM (fuel pump ON/OFF request) 7. CKP sensor > GEM Gateway > Engine speed 8. ABS module > GEM Gateway > Request for ABS brake system warning indicator and stability assist warning in instrument cluster HS-CAN output signals: 1. APP > GEM Gateway > PCM 2. Status BPP/CPP switch > GEM Gateway > PCM 3. Speed control system > GEM Gateway > PCM 4. Outside air temperature sensor > GEM Gateway > PCM 5. Status PATS key: PATS transceiver > GEM Gateway > PCM (start approval) 6. Ignition lock position status > GEM Gateway > PCM

10 Heated windshield 11 Instrument cluster 12 Ignition lock 13 Stoplamp switch, BPP switch, CPP switch

Not shown: • Parking brake switch • Trailer module • Door switches • Battery cutoff relay • Fuel pump (vehicles with petrol engine) • Horn/alarm horn • Windshield washer pump HS-CAN input signals: 1. Vehicle speed signal: Wheel speed sensor > ABS module > PCM > Gateway > GEM current consumption for trip computer 2. PCM controlled battery charging: Generator > PCM > Gateway > GEM (control of heated windshield) 3. Total mileage: Instrument cluster > Gateway > GEM 4. Water-in-fuel sensor > PCM > Gateway > GEM (warning indicator request to instrument cluster) 5. PCM > Gateway > GEM warning indicator request: – MIL – Engine warning indicator – Low oil pressure warning indicator

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Multifunction Electronic Modules

Lesson 4 – Electrical

7. Parking brake control status > GEM Gateway > ABS module/PCM 8. Fuel level status > GEM Gateway > PCM MS-CAN input signals: 1. Setting the time/alarm time: Instrument cluster > GEM 2. Crash signal > RCM > GEM MS-CAN output signals: 1. PCM > Gateway > GEM warning indicator request: – MIL – Engine warning indicator – Low oil pressure warning indicator – Oil change – Glow plug indicator (vehicles with diesel engines) – Engine Coolant Temperature ECT – PATS – Charge indicator lamp – Speed control system 2. Headlamp switch > GEM Gateway > Instrument 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 4. GEM Gateway > Instrument cluster > Data for central vehicle configuration 5. Fuel level sensor > GEM Gateway > Instrument cluster > Tank display or fuel reserve warning indicator 6. Headlamp switch > GEM Gateway > Instrument cluster > Headlamp/front fog lamp/rear fog lamp indicator 7. High-beam switch > GEM Gateway > Instrument cluster > High-beam indicator 8. Turn signal lamp switch > GEM Gateway > Instrument cluster > Turn signal indicator

9. Brake fluid level switch > GEM Gateway > Instrument cluster > Parking brake/brake system warning indicator 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: 1. Windshield moisture status > Rain sensor > GEM 2. Ambient light status > Light sensor > GEM

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Body

General
The front end of the Transit 2006.5 has undergone significant modification in comparison with the previous model: • Headlamp • Hood

• Bumpers • Radiator grille • Front module

The modification of the headlamps has permitted an improvement in luminous efficiency. Visually, the headlamp design is characterized by a clear-glass cover and a vertical arrangement. The hood contains the air intake vents for the blower box as well as integrated washer jets. The front bumper in the area of the radiator grille is optionally available in the vehicle color.

There are two steps in the lower area of the bumper. These provide easy access to the windshield and/or the wiper blades. The side sections of the bumper are designed as separate components as previously. The radiator grille is fully integrated in the bumper and contains large openings for the cooling air.

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Body

Lesson 5 – Body and Paint

The front module is made of sheet steel and comprises three bolted components that can be individually replaced.

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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.

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Body

Lesson 5 – Body and Paint

This means that manufacturers, importers and disposal companies must together ensure that at least 85% of the average weight of an end of life vehicle is recycled and at least 80% of the materials processed or reused as of

2006. These processing targets must be increased to 95% (processing) and 85% (material processing, reuse) as of 2015.

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Body

Central door locking

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Body

Lesson 5 – Body and Paint

1 2 3 4 5 6 7 8

HS-CAN data bus MS-CAN data bus Gateway (GEM) GEM Active anti-theft sounder Liftgate latch/rear door motor(s) Door latch motor(s) Interior light

9

Radio remote control

10 Ignition lock 11 Passenger compartment monitoring sensors (LIN)

12 Radio remote control receiver 13 Hood switch Locking unit (signals from door ajar switch, 14 "set/reset" button and "lock/unlock" switch, liftgate latch/rear door/sliding door switch)

HS-CAN input signals: 1. Vehicle speed signal > Wheel speed sensors > ABS module > PCM > GEM Gateway > Automatic locking MS-CAN output signals: 1. Door ajar switch/liftgate latch switch/lid ajar switch > GEM > Instrument cluster > Door ajar warning indicator or message in message center LIN input/output signals 1. Interior scanning sensors 2. Battery-buffered alarm horn (with Thatcham CAT 1 alarm only) Depending on the equipment version, the following central-locking functions are available: • Central locking with single locking • Central locking with double locking • One-touch central unlocking • Two-touch central unlocking • Automatic locking upon setting off (as of 7 km/h) • Automatic relocking (45 seconds after unlocking without any other activity) • Individual door relocking • Configurable unlocking The locking/unlocking status is indicated via an audible and/or visual signal. 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.

Recharging function for the remote control
A charging function for the radio remote control batteries is available as an option. More detailed information can be found in the description of the GEM.

Individual door relocking
If a door is opened during the locking operation, all other doors (with the exception of the sliding doors) will be locked once. If the open door is then closed, it will also be locked once. The double-locking mechanism will not work if there is a door open. Individual door relocking can be deactivated.

Configurable unlocking

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Body

Configuration 1 To unlock the Press unlock button 1 x X Press unlock button 2 x X X X X X X X X X Press liftgate release 1 x Press liftgate release 1 x

Driver door 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

Press unlock button 2 x X

Press liftgate release 1 x

Press liftgate release 1 x

Driver door Passenger door Sliding door on driver side Sliding door on passenger side Rear door/liftgate Configuration 3 To unlock the Press unlock button 1 x X X

X X X X X X X X

Press unlock button 2 x X X X X X

Press liftgate release 1 x

Press liftgate release 1 x

Driver door Passenger door Sliding door on driver side Sliding door on passenger side Rear door/liftgate

X X X X

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Body

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Configuration 4 To unlock the Press unlock button 1 x Press unlock button 2 x X X X X X X X X X X Press liftgate release 1 x Press liftgate release 1 x

Driver door Passenger door Sliding door on driver side Sliding door on passenger side Rear door/liftgate Configuration 5 To unlock the Press unlock button 1 x X

Press unlock button 2 x X X

Press liftgate release 1 x

Press liftgate release 1 x X

Driver door Passenger door Sliding door on driver side Sliding door on passenger side Rear door/liftgate Configuration 6 To unlock the

X

X X

X

X X X X

X X

Press unlock button 1 x X

Press unlock button 2 x X X

Press liftgate release 1 x

Press liftgate release 1 x

Driver door Passenger door Sliding door on driver side Sliding door on passenger side Rear door/liftgate

X

X X X X

X X X

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Body

SRS

1 2 3 4 5 6

MS-CAN data bus Gateway (GEM) ISO -9141 RCM Driver air bag module Passenger air bag module

7 8 9

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)

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Body

Lesson 5 – Body and Paint

MS-CAN output signals: 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.

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List of Abbreviations

A/C ABS AM APP BPP BTCS CAN CD CKP CPP DLC DTC

Air Conditioning Anti-lock Brake System Amplitude Modulation Accelerator Pedal Position Brake Pedal Position Brake Traction Control System Controller Area Network Compact Disc

IFS KS LED LHD LPG MIL OASIS

Inertia Fuel Shutoff Knock Sensor Light Emitting Diode Left-hand Drive Liquefied Petroleum Gas Malfunction Indicator Lamp On-line Automotive Service Information System Passive Anti-theft System Powertrain Control Module Polyvinyl Chloride Restraints Control Module Right-hand Drive Read Only Memory Supplemental Restraint System Vehicle Identification Number Vehicle Speed Sensor Worldwide Diagnostic System

PATS Crankshaft Position PCM Clutch Pedal Position PVC Data Link Connector RCM Diagnostic Trouble Code RHD Diagnostic Trouble Code- WDS ROM EBA ECT EGR EOBD EOP FM FPDM GEM GPS GSM HCU Emergency Brake Assist SRS Engine Coolant Temperature VIN Exhaust Gas Recirculation VSS European On-board Diagnostic WDS Engine Oil Pressure Frequency Modulation Fuel Pump Driver Module Generic Electronic Module Global Positioning System Global System For Mobile Communication Hydraulic Control Unit

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