cg8171sen

New Product Introduction

Transit 2006.5 (04/2006-)

Service Information

Technical Service Training CG 8171/S en 12/2005 TN7002156H

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To the best of our knowledge, the illustrations, 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 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 permi ssion 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.





















Preface

Model year 2006.5 will see the introduction int roduction of a modified front end as well as a range of new functions and e quipment options for the Transit. Also 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, appe arance, the interior of the driver cab has also been completely completel y 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 The previous 2.0L Duratorq TDCi engines have been replaced by a modified generation upgraded to a cubic capacity of 2.2 liters.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. 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 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 effective diagnoses and/or repairs. The following product introduction, introduct ion, TN7002156H, CG 8171/S, should provide you with an overview of the vehicle's new systems and components. Please remember that our training literature l iterature 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 Technical Training Courses to gain extensive knowledge of both theory and practice.





















Table of Contents

PAGE

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

1

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

5

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

7

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

9

Front axle..................... axle............................................. ................................................ ................................................ ................................................ ................................................. ................................................. .......................... ..

9

Brake System - General Information In formation.................................. ...................................................................... ...................................................................... ..................................

10

General..................... General............................................. ................................................ ................................................ ................................................ ................................................ ................................................. ............................... ......

10

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

11

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

12

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

13

Lesson 3 – Powertrain Engine System - General Information................................ Information.................................................................... ...................................................................... ..................................

14

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

16

General................ General .................................. .................................... .................................... .................................... .................................... .................................... .................................... .................................... .................................... ................................... .................

16

Engine data................ data .................................. .................................... .................................... .................................... .................................... .................................... .................................... .................................... .................................... ............................. ...........

17

Injection system....................... system............................................... ................................................ ................................................ ................................................. ................................................. ...................................... ..............

19

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

20

Fuel injectors................ injectors .................................. .................................... .................................... .................................... .................................... .................................... .................................... .................................... .................................... .......................... ........

22





















Table of Contents

Cylinder head................. head ................................... .................................... .................................... .................................... .................................... .................................... .................................... .................................... .................................... ........................ ......

26

Cylinder block ..................................... ....................................................... .................................... .................................... .................................... .................................... .................................... .................................... .................................... ..................... ...

28

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

28

General................. General ................................... ..................................... ..................................... .................................... .................................... .................................... .................................... .................................... .................................... ................................. ...............

28

Engine data.................. data.................................... .................................... .................................... .................................... .................................... .................................... .................................... .................................... .................................... ........................... .........

29

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

31

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

32

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

33

Engine data.................. data.................................... .................................... .................................... .................................... .................................... .................................... .................................... .................................... .................................... ........................... .........

34

Transmission...................... Transmission .............................................. ................................................ ................................................ ................................................. ................................................. ............................................ ....................

37

Shift mechanism................... mechanism..................................... .................................... .................................... .................................... .................................... .................................... .................................... .................................... .................................... ..................

37

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

37

Lesson 4 – Electrical Instrument Cluster.................................... Cluster........................................................................ ......................................................................... ............................................................. ........................

38

Overview........................ Overview................................................ ................................................ ................................................. ................................................. ................................................ ................................................ ........................

38

Operation........................ Operation................................................ ................................................ ................................................. ................................................. ................................................ ................................................ ........................

40

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

41

Diagnostics................. Diagnostics .................................... ..................................... .................................... .................................... .................................... .................................... .................................... .................................... .................................... ........................... .........

41

Tachograph..................................... Tachograph ......................................................................... ........................................................................ ......................................................................... .....................................

42

General....................... General............................................... ................................................ ................................................ ................................................. ................................................. ................................................ ............................ ....

42

Audio System.................................. System...................................................................... ........................................................................ ......................................................................... .....................................

43

Overview........................ Overview................................................ ................................................ ................................................. ................................................. ................................................ ................................................ ........................

43

General....................... General............................................... ................................................ ................................................ ................................................. ................................................. ................................................ ............................ ....

44





















Table of Contents

Cellular Phone................................. Phone...................................................................... ......................................................................... ...................................................................... ..................................

51

General..................... General............................................. ................................................ ................................................ ................................................ ................................................ ................................................. ............................... ......

51

Exterior Lighting................................... Lighting........................................................................ ......................................................................... ................................................................ ............................

53

General..................... General............................................. ................................................ ................................................ ................................................ ................................................ ................................................. ............................... ......

53

Communications Network................................. Network..................................................................... ........................................................................ .................................................... ................

54

Overview...................... Overview .............................................. ................................................ ................................................ ................................................ ................................................. ................................................. .......................... ..

54

Module Configuration................................. Configuration...................................................................... ......................................................................... .......................................................... ......................

57

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

57

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

59

General..................... General............................................. ................................................ ................................................ ................................................ ................................................ ................................................. ............................... ......

59

Service instructions.................. instructions .................................... .................................... .................................... .................................... .................................... .................................... .................................... .................................... ................................ ..............

63

Power supply........................ supply................................................ ................................................ ................................................ ................................................ ................................................. ........................................... ..................

64

PATS..................... PATS............................................. ................................................ ................................................ ................................................ ................................................ ................................................. ................................... ..........

65

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

66

Overview...................... Overview .............................................. ................................................ ................................................ ................................................ ................................................. ................................................. .......................... ..

66

Lesson 5 – Body and Paint Body................................ Body .................................................................... ......................................................................... ......................................................................... .................................................... ................

69

General..................... General............................................. ................................................ ................................................ ................................................ ................................................ ................................................. ............................... ......

69

Interior................. Interior ................................... .................................... .................................... .................................... .................................... .................................... .................................... .................................... .................................... ................................... .................

71

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

71

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

71

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

73























Introduction

Transit 2006.5 (03/2006-)

At a glance





















At a glance

Introduction

Powertrain

•

Powe Powerr man manag agem emen entt

•

Modif Modified ied dies diesel el engine enginess with incr increas eased ed power power and and

•

Rechar Rechargin ging g functi function on for for the radio radio remo remote te contr control ol

lower consumption, emission standard IV,

•

Modif Modified ied locki locking ng system system with with config configura urable ble locki locking ng

second-generation common-rail technology •

Modif Modified ied 2.3L 2.3L Dura Duratec tec-HE -HE (MI4 (MI4)) engine engine with with

functions •

emission standard IV, LPG (Liquefied Petroleum Gas) (optional) •

CAT 1 •

2.4L 2.4L Durat Duratorq orq TDCi TDCi with with 85 kW (115 (115 PS) and 105 105 kW (143 PS) in conjunction with 6-gear manual

Gearshi Gearshift ft lev lever er in in the the instr instrume ument nt pane panell

Electrical system

Latest Latest gener generati ation on of audio audio units units and and Trav Travel el Pilot Pilot EX navigation system

•

transmission (rear wheel drive) •

Anti-t Anti-thef heftt alarm alarm system system in accor accordan dance ce with with Thatch Thatcham am

HandsHands-fre freee kit with with Bluet Bluetoot ooth h interfa interface ce and and voice voice control

Body

•

Impr Improv oved ed crash crash char charac acte teri rist stic icss

•

side side air air bag bag modu module less

•

New New fro front nt end end des desig ign n

•

New inst instrum rument ent panel panel with with numer numerous ous stor storage age optio options ns

•

Impr Improv oved ed corr corros osio ion n prote protect ctio ion n

•

Two new new veh vehic icle le vers versio ions ns

and HS-CAN HS-CAN bus

•

New New exter xterio iorr colo colors rs

•

New New instru instrumen mentt cluste clusterr with with dot matr matrix ix displ display ay

•

New New fab fabri ricc and and leat leathe herr sea seats ts

•

Spee Speed d con contr trol ol syst system em

•

Cent Centra rall modu module le con confi figu gura rati tion on

•

New GEM (Generic Electronic Module) with integrated PATS (Passive Anti-theft System) function

•

Comple Completely tely new newly ly devel develope oped d vehicl vehiclee electri electrical cal system with MS-CAN MS-CAN (Controller Area Network)





















Introduction

At a glance

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

1 2 3 4

GEM behind glove compartment, passenger side

9

IFS (Inertia Fuel Shutoff) (vehicles with petrol engine)

10

Right-hand crash sensor (with side air bag only) Receiver for radio remote control (in center of headliner)

11

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





















At a glance

IFS switch

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

Introduction





















Lesson 2 – Chassis

Front axle

Suspension System

Here the ball joints are bolted between the transverse control arm and strut and spring assembly (standard: press-fit) and larger wheel bearings installed. This requires a new procedure for installation and removal. Instructions for this can be found in the relevant Service literature.

Rear axle In addition to modified suspension points at the rear axle and a reinforced differential, modified final drive ratios are also available. Vehicles with front wheel drive feature a VXT75 manual transaxle as standard with a final drive ratio of 4,23:1 or 4,54:1 depending on the payload. Vehicles with rear wheel drive feature final drive ratios of 3,73:1 or 5,88:1 in conjunction with MT75 or MT82 manual transmissions.

A

Strut and spring assembly (reinforced front axle)

B

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.























Brake System - General Information

General























ABS system overview























HS-CAN HS-CAN input signals: 1. CKP (Crankshaft Position) sensor > GEM Gateway > ABS module 2. Engine Engine idle idle speed speed (fro (from m PCM) PCM) > ABS module 3. Engine status status (OFF (OFF,, idling, idling, stalling) stalling) (from (from PCM) PCM) > ABS module 4. Duration Duration of of drivin driving g cycle cycle (from GEM) GEM) > Gateway > ABS module 5. Tire Tire circ circumf umfere erence nce > GEM Gateway > ABS module 6. Ignitio Ignition n lock lock positio position n > GEM Gateway > ABS


7. ABS module > GEM Gateway > Instrument cluster > Stability assist warning indicator ESP 8. Signals Signals of all all four four wheel speed sensors 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), Assist), active rollover protection

module 7. Torqu orquee (fro (from m PCM) PCM) > ABS module

Bosch 8.0 ABS system

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 >

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






















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 /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 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






















Engine System - General Information

Engine/transmission combinations

Lesson 3 – Powertrain

























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

(rear wheel drive)

following engine/transmission combinations: •

•

2.2L 2.2L Durator Duratorq-T q-TDCi DCi (Puma (Puma)) diesel diesel with with VXT VXT-75 5-speed manual transaxle (front wheel drive)

•

2.3L DuratecDuratec-HE HE (MI4) (MI4) with with MT MT-75 5-speed 5-speed manua manuall transmission (rear wheel drive)

The engine range consists of the following power

2.4L 2.4L Durator Duratorq-T q-TDCi DCi (Puma (Puma)) diesel diesel with with MT-75 MT-75

versions:

(5-speed) and MT82 (6-speed) manual transmission Cubic capacity (drive)

2.2L (front wheel drive)

Power output PS (kW)

Torque (Nm)

85 (63)

250

110 (81)

285

130 (96)

310

100 (74)

285

(previously 2.0L)

2.4L (rear wheel drive)






















2.2L Duratorq-TDCi (Puma) diesel























•

The 81 81 kW versi version on additi additional onally ly has has oil spray spray nozzle nozzless


Diagnosis

for cooling the piston crown. •

The 96 kW kW versi version on has has a turb turboch ochar arger ger with with electrically adjustable guide vane geometry as well

•

Diag Diagno nosi siss usin using g WDS via the DLC (Data Link Connector). Connector).

as fuel injector nozzles with an increased flow rate.

Engine data Injection system Denso •

Fuel in injectors

•

High High-p -pre ress ssur uree pump pump

•

Fuel Fuel inj injec ecti tion on sup suppl ply y mani manifo fold ld

2.2L Duratorq-TDCi (Puma) diesel

Engine code

QVFA (110 PS) QWFA (130 PS) Cubic capacity

Engine management

P8FA (85 PS)

1,998 ccm






















Power and torque curves























Injection system


























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

The pressure relief valve opens at a fuel pressure of

see the previously used Delphi common-rail system

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

replaced by the Denso common-rail system.

of a malfunction in the high-pressure system. This

This has achieved an increase in engine power while at the same time reducing fuel consumption.

prevents damage caused by excessive fuel pressure in the high-pressure system. Any triggering of the pressure relief valve is detected

Fuel injection supply manifold

by the PCM, PCM, which then sets an appropriate DTC
















































Fuel injectors

























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, WDS, the injectors must also be configured. This is achieved by entering the 16-digit identification number into the PCM using WDS, WDS, taking into account the relevant cylinder.


Valve train
























Accessory drive






























































































































































































































































































































































































































































































































































































































































Lesson 4 – Electrical

Module Controlled Functions

Function/system

A

B

C/D

Speed control system

X

Sensing of the ambient air temperature

X

Service mode

X

X

X

Diagnosis with WDS

X

X

X

* May be deactivated in the factory, depending on market

All variants of the GEM contain a clock and an alarm function. The clock time is routed to other modules via

The GEM is connected to the following modules via the MS-CAN MS-CAN::

the CAN network. The clock time is adjusted via the

•

Inst Instru rume ment nt clus cluste terr

radio or the instrument cluster.

•

Parki arkin ng aid aid modu odule

•

RCM

Gateway The GEM is connected to the following modules via the HS-CAN HS-CAN:: •

PCM

•

ABS module

The GEM is connected to the following modules via the MS-CAN MS-CAN::

The GEM is connected to the following modules via serial interfaces: •

Remo Remote te cont contro roll rece receiv iver er

•

PATS transceiver (ring antenna)

•

Ligh Light/ t/ra rain in sen senso sorr

Hazard warning lights for an accident

•

Inst Instru rume ment nt clus cluste terr

Accident detection is carried out by the RCM The signal

•

Park arking ing aid aid modu odule

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

•

RCM

If an event is detected, the hazard warning lights are

The GEM is the gateway for the communications

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

between the MS-CAN MS-CAN and the HS-CAN HS-CAN..

switched off via the hazard flasher switch.

The GEM is connected to the following modules via the LIN bus: •

Battery Battery-b -buf uffer fered ed alarm alarm horn horn (BBS (BBS = Battery Battery Back Back-up -up Sounder)

•

Parki arking ng-a -aid id modu module le

•

Inter Interio iorr sca scann nnin ing g sen senso sors rs

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: •

Swit Switch ch off off the the ign ignit itio ion n

•

Ensure Ensure that that the alarm alarm syst system em is deacti deactiva vated ted






















•

•


Ensure Ensure that that diag diagnos nostic tic mode mode or or progra programmi mming ng mode mode

Both batteries are charged when the engine is running,

is not activated

however however a cutoff relay means that only one of the two t wo

Press Press one one of the the two fron frontt door door lock lock switch switches es eight eight

batteries can be discharged when the ignition key is in

times within 10 seconds

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

Entry into service mode is confirmed by an audible

is always available for the engine start.

signal; the turn signals as well as the turn signal

The "Smart Starting" strategy is still integrated. Here

indicators on the instrument cluster flash twice.

the power supply to the starter motor is interrupted as

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

soon as the engine reaches a set engine idle speed. This decreases power consumption and increases the service life of the starter motor.

flash once. It is not possible to check the output signals during the

Radio remote control

self-test.

The radio remote control is integrated i nto the key. A

The GEM automatically ends service mode under any

charging function for the remote control batteries is

of the following conditions:

integrated into the remote control. Here, the rechargeable

•

20 secon seconds ds pass pass witho without ut anyth anything ing bein being g select selected ed or

battery which is integrated in the key (previously it was

operated.

a non-rechargeable battery) is continuously recharged

•

The head headlam lamp p flashe flasherr is opera operated ted and and the the igniti ignition on is

while the ignition is switched on.

switched OFF at the same time.

The charge function of the accumulator is effected by

•

Ignitio Ignition n lock lock posi positio tion n III III (engin (enginee start start))

an induction circuit which has previously been used for

•

The volt voltage age supp supply ly is too too low low (< 9 Volt). olt).

•

The volt voltage age supp supply ly is too too high high (> 16 16 Volt Volt). ).

operation of the PATS transponder. transponder. Additional components are therefore not required. The charging process is initiated and executed by the

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

GEM via the ring antenna of the transceiver at the ignition lock once the PATS key query has been performed.

literature. The recharging function provides a power supply which ensures that the remote control remains operative at all

Power supply

times.

The power supply includes a range of measures to ensure

A charging time of approx. 20 minutes generates enough

reliable operation of the vehicle at all times.

power to transmit a radio signal between the transmitter

The generator outputs 150 A as standard. A second battery (590 Ah) is installed as standard on all rear wheel drive versions. versions. This is available as an

and the receiver approx. 32 times. The remote control housing is additionally sealed and watertight. It is possible to identify the key by its blue housing. Replacement of the battery is not possible.
























Power management


The GEM automatically switches to normal mode once shipping mode is deactivated.

Power management facilitates an effective effective supply of power appropriate to the respective requirements of the individual modules by means of various modes.

Normal mode:

•

entire electrical systems.

The power management function is integrated into the GEM. GEM. One of four different vehicle modes is used depending

Normal Normal mode mode guara guarantees ntees the full full functi functionali onality ty of of the the

Crash mode:

•

Cras Crash h mode mode is acti activa vated ted as as soon soon as as the the RCM registers a vehicle impact of appropriate force.

on the operating status of the vehicle: •

Factory mo mode

The following functions are carried out:

•

Shipping ing mode

•

•

Standard mode

•

Crash mode

Factory mode:

•

Factory Factory mode is activ activated ated during during produc production tion 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

The vehi vehicle cle will will be centr centrally ally unlo unlocke cked d if it is locked locked at the time of impact.

•

Activ Activate atess the the hazar hazard d warn warning ing lamps. lamps.

•

The fuel fuel-f -fire ired d booste boosterr heater heater is deac deacti tiva vated ted..

Crash mode is deactivated as soon as the ignition key is turned to position "0" and then back to position "II" again. The hazard flashers are deactivated by pressing the hazard flasher switch.

shipping mode is act ivated. Shipping mode:

•

•

Shippi Shipping ng mode mode is activ activate ated d en route route from from the facto factory ry

The PATS functionality is integrated into the GEM. GEM.

to the dealer. The vehicle can be driven without

Accordingly, Accordingly, the transceiver t ransceiver unit is directly connected

impairment of the driving safety systems.

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

Indiv Individu idual al modules modules and/o and/orr electric electrical al system systemss (e.g. (e.g. anti-theft alarm system, clock and radio remote control) are deactivated when the ignition is switched off.

•

PATS

This ensures ensures that the batter battery y has has enough enough power power when when

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 HS-CAN data bus. Depending on this query and on the key status, starting





















Multifunction Electronic Modules

Overview
























1

HS-CAN HS-CAN data bus

14 Fuel level sensor

2

MS-CAN MS-CAN data bus

15 APP sensor

3

Gateway (GEM (GEM))

16 Reversing lamp switch

4

GEM

17 PATS transceiver

5

Windshield wiper motor

18 Multifunction switches (wiper, light)

6

Rear window wiper motor(s)

19 Speed control switch

7

FPDM (Fuel Pump Driver Module)

20 Heated windshield switch

8

Headlamp

21 Heated rear window switch

9

Heated rear window w indow,, heated exterior mirrors

22 Hazard flasher switch

10 Heated windshield

23 Ambient air temperature sensor

11 Instrument cluster

24 Headlight switch

12 Ignition lock

25 Brake fluid level switch

13 Stoplamp switch, BPP switch, CPP switch

26 Light/rain sensor (ISO 9141)

Not shown:

– Oil change

•

Parki arking ng brak brakee swi switc tch h

– Glow plug indicator indicator (vehicles (vehicles with diesel diesel engines) engines)

•

Trailer mo module

– Engi Engine ne cool coolan antt tempe tempera ratu ture re ECT

•

Door swit witches

– PATS

•

Batt Batter ery y cut cutof offf rel relay ay

– Char Charge ge indi indica cato torr lam lamp p

•

Fuel Fuel pump pump (veh (vehicl icles es with with petrol petrol engine engine))

– Spee Speed d cont contro roll syst system em

•

Horn Horn/a /ala larrm horn horn

•

Winds indshi hiel eld d wash washer er pump pump

HS-CAN HS-CAN input signals: 1. Vehicle speed speed signal: signal: Wheel Wheel speed speed sensor sensor > ABS module > PCM > Gateway > GEM current

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






















7. Parking Parking brake brake control control statu statuss > GEM Gateway > ABS module/ PCM PCM 8. Fuel Fuel leve levell statu statuss > GEM Gateway > PCM MS-CAN MS-CAN input signals: 1. Setting Setting the time/alar time/alarm m time: Instrum Instrument ent cluster cluster > GEM 2. Cras Crash h sig signa nall > RCM > GEM MS-CAN MS-CAN output signals: 1. PCM > Gateway > GEM warning indicator request: – MIL – Engi Engine ne war warni ning ng ind indic icat ator or – Low Low oil pressu pressure re warn warning ing indica indicator tor – Oil change – Glow plug indicator indicator (vehic (vehicles les with with diesel diesel engines) engines) – Engine Engine Coolan Coolantt Tempera emperatur turee ECT – PATS – Char Charge ge indi indica cato torr lam lamp p – Spee Speed d cont contro roll syst system em 2. Headl Headlam amp p switc switch h > GEM Gateway > Instrument cluster > Lighting indicator or light-on warning tone 3. Door Door contac contact/h t/hood ood switc switch h > 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 Fuel leve levell sens sensor or > GEM Gateway > Instrument cluster > Tank display or fuel reserve warning


9. Brake Brake fluid fluid leve levell switch 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. Windshie Windshield ld moisture moisture status status > Rain Rain sensor sensor > GEM 2. Ambient Ambient light light status status > Light sensor sensor > GEM





















Lesson 5 – Body and Paint

General The front end of the Transit 2006.5 has undergone significant modification in comparison with the previous

Body

•

Bumpers

•

Rad Radiato iatorr gril grille le

•

Front mo module

model: •

Headlamp

•

Hood

The modification of the headlamps has permitted an improvement in luminous efficiency. Visually, the

There are two steps in the lower area of the bumper. bumper. These provide easy access to the windshield and/or the wiper blades.























Body

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























Interior

Body





















Body

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


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






















Central door locking

Body





















Body


1

HS-CAN HS-CAN data bus

9

2

MS-CAN MS-CAN data bus

10 Ignition lock

3

Gateway (GEM (GEM))

4

GEM

5

Active anti-theft sounder

12 Radio remote control receiver

6

Liftgate latch/rear door motor(s)

13 Hood switch

7

Door latch motor(s)

8

Interior light

11

Radio remote control

Passenger compartment monitoring sensors (LIN)

Locking unit (signals from door ajar switch, 14 "set/reset" button and "lock/unlock" switch, liftgate latch/rear door/sliding door switch)

HS-CAN HS-CAN input signals: 1. Vehicle speed speed signal signal > Wheel Wheel speed sensor sensorss > ABS

Recharging function for the remote control

module > PCM > GEM Gateway > Automatic

A charging function for the radio remote control

locking

batteries is available as an option. More detailed

MS-CAN MS-CAN output signals:

information can be found in the description descri ption of the GEM. GEM.

1. Door ajar switch/ switch/liftg liftgate ate latch switch/l switch/lid id ajar switch switch > GEM > Instrument cluster > Door ajar warning

Individual door relocking

indicator or message in message center LIN input/output signals 1. Interi Interior or scanni scanning ng sensor sensorss

If a door is opened during the locking operation, all other doors (with the exception of the sliding doors)
































































SRS

Body





















Body

MS-CAN 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. GEM. It is connected via the MS-CAN MS-CAN data bus. Diagnosis is performed via a separate ISO 9141 line. The RCM may be reused up to five times.






















List of Abbreviations

A/C

Air Conditioning

IFS

Inertia Fuel Shutoff

ABS

Anti-lock Brake System

KS

Knock Sensor

AM

Amplitude Modulation

LED

Light Emitting Diode

APP

Accelerator Pedal Position

LHD

Left-hand Drive

BPP

Brake Pedal Position

LPG

Liquefied Petroleum Gas

BTCS

Brake Traction Control System

MIL

Malfunction Indicator Lamp

CAN

Controller Area Network

OASIS

On-line Automotive Service Information System

CD

Compact Disc

CKP

Crankshaft Position

PATS

Passive Passive Anti-theft System

PCM

Powertrain Control Module

cg8171sen

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