New Product Introduction

2006.50 Transit

Service Information

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


To the best of our knowledge, the illustrations, technical information, data and descriptions in this issue were correct at the time
of going to print. The right to change prices, specifications, equipment and maintenance instructions at any time without notice
is reserved as part of FORD policy of continuous development and improvement for the benefit of our customers.
No part of this publication may be reproduced, stored in a data processing system or transmitted in any form, electronic,
mechanical, photocopy, recording, translation or by any other means without prior permission of Ford-Werke GmbH. No liability
can be accepted for any inaccuracies in this publication, although every possible care has been taken to make it as complete and
accurate as possible.
Copyright ©2006

Ford-Werke GmbH
Service training programs D-F/GT1 (GB)


Preface

Model year 2006.5 will see the introduction of a modified front end as well as a range of new functions and equipment
options for the Transit. Also available will be two new body versions; one with a higher payload as well as a van
with medium wheelbase and flat roof (front wheel drive).
As well as the modification of the outer appearance, the interior of the driver cab has also been completely redesigned.
In addition to a multitude of storage compartments, the new interior offers the latest generation of audio units, a

navigation system, a hands-free kit, a Bluetooth interface and voice control for the phone and audio functions ex
works.
The 1,850 kg front axle load version has been added to the range. Disc brakes are installed on the rear axle.
Furthermore, stability assist is available as an option.
The previous 2.0L Duratorq TDCi engines have been replaced by a modified generation upgraded to a cubic capacity
of 2.2 liters. The 2.4L Duratorq TDCi engine versions have also been modified, while consumption has been
reduced. All engines meet emission standard IV.
The vehicle electrical system has undergone significant modification; in addition to providing an instrument cluster
with message center it now also permits some custom setting options for the locking system. A second battery
(standard on all rear wheel drive versions) as well as a function for charging the radio remote control represent a
marked improvement in terms of the power supply.
Protection against theft and ease of repair with regard to the control modules have been notably improved by an
innovative Controller Area Network.
The body has again been modified with regard to its crash characteristics. In addition, side air bags and ISOfix
mounting points are now available on the Transit for the first time.
You should get to know the new systems, their operation and their function in good time. Only then will you be
able to interpret customer complaints correctly and carry out fast and effective diagnoses and/or repairs.
The following product introduction, TN7002156H, CG 8171/S, should provide you with an overview of the vehicle's
new systems and components.
Please remember that our training literature has been prepared for FORD TRAINING PURPOSES only. Repairs
and adjustments MUST always be carried out according to the instructions and specifications in the workshop
literature. Please make full use of the training offered by Ford Technical Training Courses to gain extensive
knowledge of both theory and practice.

Service Training (G542739)

1


Table of Contents


PAGE

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

1

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

5

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

7

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

9

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

9

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

10

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


10

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

11

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

12

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

13

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

14

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

16

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

17

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


17

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

19

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

20

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

22

Valve train..............................................................................................................................................................................................

23

Accessory drive......................................................................................................................................................................................

24

2

Service Training


Table of Contents

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


26

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

28

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

28

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

28

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

29

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

31

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

32

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

33


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

34

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

37

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

37

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

37

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

38

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

38

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

40


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

41

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

41

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

42

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

42

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

43

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

43

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

44

Navigation System......................................................................................................................................


49

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

49

Service Training

3


Table of Contents

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

51

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

51

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

53

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

53

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


54

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

54

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

57

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

57

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

59

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

59

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

63

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

64


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

65

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

66

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

66

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

69

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

69

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

71

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

71


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

71

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

73

SRS..................................................................................................................................................................................

77

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

79

4

Service Training


Introduction

At a glance

Transit 2006.5 (03/2006-)

E73654

Internal designation:


Chassis

• V347 = Front wheel drive

• Improved drivability through fine-tuning of springs,
shock absorbers and steering

• V348 = Rear wheel drive

• Modified brake system (disc brakes on the rear axle)
• Stability assist with active rollover protection
• Reinforced front axle (for vehicle versions with high
payload)

Service Training (G542739)

5


At a glance

Introduction

Powertrain

• Power management

• Modified diesel engines with increased power and
lower consumption, emission standard IV,

second-generation common-rail technology

• Recharging function for the radio remote control

• Modified 2.3L Duratec-HE (MI4) engine with
emission standard IV, LPG (Liquefied Petroleum
Gas) (optional)

• Anti-theft alarm system in accordance with Thatcham
CAT 1

• 2.4L Duratorq TDCi with 85 kW (115 PS) and 105
kW (143 PS) in conjunction with 6-gear manual
transmission (rear wheel drive)
• Gearshift lever in the instrument panel
Electrical system
• Central module configuration
• New GEM (Generic Electronic Module) with
integrated PATS (Passive Anti-theft System)
function
• Completely newly developed vehicle electrical
system with MS-CAN (Controller Area Network)
and HS-CAN bus
• New instrument cluster with dot matrix display

• Modified locking system with configurable locking
functions

• Latest generation of audio units and Travel Pilot EX
navigation system

• Hands-free kit with Bluetooth interface and voice
control
Body
• Improved crash characteristics
• side air bag modules
• New front end design
• New instrument panel with numerous storage options
• Improved corrosion protection
• Two new vehicle versions
• New exterior colors
• New fabric and leather seats

• Speed control system

6

(G542739)

Service Training


Introduction

At a glance

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

1


2

3

4
13

5
12

6

11
10

9

8

7

E64649

1

GEM behind glove compartment, passenger side

2

IFS (Inertia Fuel Shutoff) (vehicles with petrol

engine)

9

Hands-free kit/voice control module (beside
instrument panel)

10

PCM (Powertrain Control Module) in left-hand
side of engine compartment

3

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

4

Receiver for radio remote control (in center of
headliner)

11

ABS (Anti-lock Brake System) module, engine
compartment, underneath brake master cylinder

5

Booster heater (vehicle underbody, driver side)


12

6

Trailer module (under driver seat)

GPS (Global Positioning System) antenna (in
center of instrument panel)

7

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

13

RCM (Restraints Control Module) (next to the
GEM)

8

Instrument cluster

Service Training (G542739)

7


At a glance

Introduction


IFS switch

E74568

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

8

(G542739)

Service Training


Lesson 2 – Chassis

Front axle

Suspension System

Here the ball joints are bolted between the transverse
control arm and strut and spring assembly (standard:
press-fit) and larger wheel bearings installed.

A

B

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.

E64598

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.

1


2

E64599

1

Press-fit ball joint (standard front axle)

2

Bolted ball joint (reinforced front axle)

Service Training (G542798)

9


Brake System - General Information

Lesson 2 – Chassis

General

A

1

B

E64590


A

Front brake

B

Rear brake

1

Brake pad wear indicator

Larger brake discs as well as modified brake calipers
are installed on the front axle depending on the engine.
Disc brakes are installed as standard on the rear axle
(except optional version).
The rear brake calipers are similar to those in the
Mondeo 2001. The special tool 206-085 is needed to
reset the brake caliper piston.
NOTE: To reset the left-hand brake caliper piston,
apply pressure to the brake caliper piston while
simultaneously turning it counter-clockwise. To reset

10

the right-hand brake caliper piston, apply pressure to
the brake caliper piston while simultaneously turning it
clockwise.
All vehicles feature a brake pad wear indicator at the

disc brakes. The sensors for the brake pad wear indicator
are installed at the inner brake pads and connected in
series.
If one of the sensors is interrupted, the instrument cluster
registers a missing ground and activates a warning
indicator in the instrument cluster.

(G542740)

Service Training


Lesson 2 – Chassis

Brake System - General Information

ABS system overview

E64591

1

HS-CAN data bus input/output signals

2

Gateway (GEM)

3


ABS module

4

ABS motor

5

ABS/HCU (Hydraulic Control Unit).

6

Stoplamp switch

Service Training (G542740)

7

Pressure sensor (in the ABS/HCU)

8

Yaw rate sensor and lateral acceleration sensor
(at the right-hand or left-hand foot controls)

9

Steering wheel rotation sensor (behind the
steering wheel)


11


Brake System - General Information

10 Wheel speed sensors

HS-CAN input signals:
1. CKP (Crankshaft Position) sensor > GEM Gateway
> ABS module

Lesson 2 – Chassis

11 Stability assist switch
7. ABS module > GEM Gateway > Instrument cluster
> Stability assist warning indicator ESP

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

8. Signals of all four wheel speed sensors > ABS
module > PCM

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

The following brake systems are available, depending
on the vehicle version:

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


– ABS (Bosch 8.0)

5. Tire circumference > GEM Gateway > ABS module

– ABS/BTCS, stability assist, electronic EBA
(Emergency Brake Assist), active rollover protection

6. Ignition lock position > GEM Gateway > ABS
module
7. Torque (from PCM) > ABS module
8. APP (Accelerator Pedal Position) position > GEM
Gateway > ABS module
9. BPP (Brake Pedal Position) switch > PCM > ABS
module
10. Parking brake switch > GEM Gateway > ABS
module
11. Outside air temperature sensor > GEM Gateway >
ABS module
12. Total mileage > GEM Gateway > ABS module
13. GEM Gateway > Instrument cluster > Data for
central vehicle configuration
HS-CAN output signals:
1. Vehicle speed signal > ABS module > GEM
Gateway
2. Intervention BTCS (Brake Traction Control System)
> ABS module > PCM
3. Torque adaptation request > ABS module > PCM
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

12

– ABS/BTCS

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

instrument panel.

(G542740)

Service Training


Lesson 2 – Chassis

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)

13


Engine System - General Information

Lesson 3 – Powertrain

Engine/transmission combinations

1

4

2

3

5

6

E68390


1

2.2L Duratorq-TDCi (Puma) diesel

4

VXT-75 5-speed manual transaxle

2

2.4L Duratorq-TDCi (Puma) diesel

5

MT82 6-speed manual transmission

3

2.3L Duratec-HE (MI4)

6

MT-75 5-speed manual transmission

14

(G542741)

Service Training



Lesson 3 – Powertrain

Engine System - General Information

The Transit 2006.5 (03/2006-) is available with the
following engine/transmission combinations:

(rear wheel drive)
• 2.3L Duratec-HE (MI4) with MT-75 5-speed manual
transmission (rear wheel drive)

• 2.2L Duratorq-TDCi (Puma) diesel with VXT-75
5-speed manual transaxle (front wheel drive)
• 2.4L Duratorq-TDCi (Puma) diesel with MT-75
(5-speed) and MT82 (6-speed) manual transmission
Cubic capacity (drive)
2.2L (front wheel drive)
(previously 2.0L)

2.4L (rear wheel drive)

2.3L (rear wheel drive) petrol

Service Training (G542741)

The engine range consists of the following power
versions:

Power output PS (kW)


Torque (Nm)

85 (63)

250

110 (81)

285

130 (96)

310

100 (74)

285

115 (85)

320

140 (103)

375

145 (107)

200


15


Engine System - General Information

Lesson 3 – Powertrain

2.2L Duratorq-TDCi (Puma) diesel

E64592

16

(G542741)

Service Training


Lesson 3 – Powertrain

Engine System - General Information

General

Engine emission control

• The previously installed 2.0L TDCi engine will be
replaced by a modified 2.2-liter version.


• Meets emission standard IV

• 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.

• Electrical EGR (Exhaust Gas Recirculation) valve
with water cooling

Diagnosis
• Diagnosis using WDS via the DLC (Data Link
Connector).

• The oil change interval is 25,000 km or one year.
• The 63 kW version is the entry-level version for the
front wheel drive vehicles. A turbocharger with a
wastegate is used.
• The 81 kW version additionally has oil spray nozzles
for cooling the piston crown.

Engine data
2.2L Duratorq-TDCi
(Puma) diesel
Engine code

P8FA (85 PS)
QVFA (110 PS)

QWFA (130 PS)

Cubic capacity

1,998 ccm

Stroke

86 mm

Bore

86 mm

Compression ratio

19 : 1

Firing order

1-3-4-2

• Fuel injection supply manifold

Idle speed

900 rpm

Engine management


Max. power output, torque 63 kW (85 PS) at 3,500
rpm, 250 Nm at 1,500 rpm

• The 96 kW version has a turbocharger with
electrically adjustable guide vane geometry as well
as fuel injector nozzles with an increased flow rate.

Injection system
Denso
• Fuel injectors
• High-pressure pump

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

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

Service Training (G542741)

Diesel

17


Engine System - General Information


Lesson 3 – Powertrain

Power and torque curves
320

100
2

1
300

90
4

280
260

70

240

60

220
A

80

3


50

6
5

200

40

180

30

160

20

140

10

120

0

C

100
80

1000

1500

2000

2500 B 3000

3500

4000

4500

E68430

A

Torque (Nm)

3

Torque curve for 81 kW engine

B

Engine speed (rpm)

4


Power curve for 81 kW engine

C

Power output (kW)

5

Torque curve for 63 kW engine

1

Torque curve for 96 kW engine

6

Power curve for 63 kW engine

2

Power curve for 96 kW engine

18

(G542741)

Service Training


Lesson 3 – Powertrain


Engine System - General Information

Injection system

2

4

3
1

8

7
6
5

11

10

9

E69809

1

High-pressure pipe


7

Fuel metering valve

2

Leak-off pipe

8

Fuel pressure sensor

3

Fuel injection line

9

Fuel temperature sensor

4

Injector

10 High-pressure pump

5

Pressure relief valve


11 Fuel return

6

Fuel injection supply manifold

Service Training (G542741)

19


Engine System - General Information

The introduction of the Transit 2006.5 (03/2006-) will
see the previously used Delphi common-rail system
replaced by the Denso common-rail system.
This has achieved an increase in engine power while at
the same time reducing fuel consumption.

Lesson 3 – Powertrain

The pressure relief valve opens at a fuel pressure of
approx. 2000 bar. It serves as a safeguard in the event
of a malfunction in the high-pressure system. This
prevents damage caused by excessive fuel pressure in
the high-pressure system.
Any triggering of the pressure relief valve is detected
by the PCM, which then sets an appropriate DTC
(Diagnostic Trouble Code- WDS) and the MIL
(Malfunction Indicator Lamp) is activated.


Fuel injection supply manifold

1
2

For installation and removal, refer to the instructions in
the current Service Literature.

High-pressure pump

3
E69911

1

Fuel pressure sensor

2

Pressure relief valve

3

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.


20

E68323

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

(G542741)

Service Training


Lesson 3 – Powertrain

Engine System - General Information

1
3

2

E68337

1

High-pressure pump coupling

2


Intake camshaft coupling

3

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.

Service Training (G542741)

21


Engine System - General Information

Lesson 3 – Powertrain

Fuel injectors

E64596

The fuel injectors are mounted by means of a bracket
with a central screw that fastens two nozzles at once.
It should be noted that if one of the two fuel injector
nozzles is removed, the second nozzle attached using
the common bracket must be resealed.


Identification number (injector correction
factor)
Illustration shows the fuel injector from above
1

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.

3
2
E69913

22

1

Electrical connection, solenoid valve

2

16-digit identification number

3


Connection, leak-off pipe

(G542741)

Service Training


Lesson 3 – Powertrain

To ensure optimum fuel metering, the PCM must be
informed when a new injector is installed.

Engine System - General Information

Valve train

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

E68320

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)

23