tài liệu về xe ô tô Ford transit 2006

A second batterystandard on all rear wheel drive versions as well as a function for charging the radio remote control represent amarked improvement in terms of the power supply.. Transit

2006.50 Transit

Service Information

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)

Model year 2006.5 will see the introduction of a modified front end as well as a range of new functions and equipmentoptions for the Transit Also available will be two new body versions; one with a higher payload as well as a vanwith 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, anavigation system, a hands-free kit, a Bluetooth interface and voice control for the phone and audio functions exworks

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The previous 2.0L Duratorq TDCi engines have been replaced by a modified generation upgraded to a cubic capacity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 beenreduced All engines meet emission standard IV

The vehicle electrical system has undergone significant modification; in addition to providing an instrument clusterwith 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 amarked 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 aninnovative Controller Area Network

The body has again been modified with regard to its crash characteristics In addition, side air bags and ISOfixmounting 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 beable 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'snew systems and components

Please remember that our training literature has been prepared for FORD TRAINING PURPOSES only Repairsand adjustments MUST always be carried out according to the instructions and specifications in the workshopliterature Please make full use of the training offered by Ford Technical Training Courses to gain extensiveknowledge of both theory and practice

1 Preface

5

At a glance

7 Position of electrical components

Lesson 1 – General Information

Lesson 2 – Chassis

9 Suspension System

9 Front axle

10 Brake System - General Information

10 General

11 ABS system overview

12 Bosch 8.0 ABS system

13 Active rollover protection

Lesson 3 – Powertrain

14 Engine System - General Information

16 2.2L Duratorq-TDCi (Puma) diesel

17 General

17 Engine data

19 Injection system

20 High-pressure pump

22 Fuel injectors

23 Valve train

24 Accessory drive

26 Cylinder head

28 Cylinder block

28 2.4L Duratorq-TDCi (Puma) diesel

28 General

29 Engine data

31 Centrifugal oil filter (140 PS version only)

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

33 2.3L Duratec-HE (MI4)

34 Engine data

37 Transmission

37 Shift mechanism

37 Clutch assembly

Lesson 4 – Electrical

38 Instrument Cluster

38 Overview

40 Operation

41 Configuration of the message center (high equipment level)

41 Diagnostics

42 Tachograph

42 General

43 Audio System

43 Overview

44 General

49 Navigation System

49 Travel Pilot EX

51 Cellular Phone

51 General

53 Exterior Lighting

53 General

54 Communications Network

54 Overview

57 Module Configuration

57 Central module configuration

59 Module Controlled Functions

59 General

63 Service instructions

64 Power supply

65 PATS

66 Multifunction Electronic Modules

66 Overview

Lesson 5 – Body and Paint

69 Body

69 General

71 Interior

71 Anti-corrosion protection

71 End of Life Vehicles Directive

73 Central door locking

77 SRS

79 List of Abbreviations

Transit 2006.5 (03/2006-)

E73654

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 highpayload)

• 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 lockingfunctions

• Anti-theft alarm system in accordance with ThatchamCAT 1

• Latest generation of audio units and Travel Pilot EXnavigation system

• Hands-free kit with Bluetooth interface and voicecontrol

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

Position of electrical components

Shown: LHD (Left-hand Drive)

9 10

10ABS (Anti-lock Brake System) module, enginecompartment, underneath brake master cylinder11

GPS (Global Positioning System) antenna (incenter of instrument panel)

12RCM (Restraints Control Module) (next to theGEM)

13

IFS switch

E74568

The IFS switch is installed in the instrument panel

(passenger side)

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

E64599

2 1

Press-fit ball joint (standard front axle)

This requires a new procedure for installation andremoval Instructions for this can be found in therelevant Service literature

Rear axle

In addition to modified suspension points at the rearaxle and a reinforced differential, modified final driveratios are also available

Vehicles with front wheel drive feature a VXT75 manualtransaxle 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 MT82manual transmissions

E64590

A

B 1

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

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 thedisc brakes The sensors for the brake pad wear indicatorare installed at the inner brake pads and connected inseries

If one of the sensors is interrupted, the instrument clusterregisters a missing ground and activates a warningindicator in the instrument cluster

ABS system overview

Steering wheel rotation sensor (behind thesteering wheel)

9

Wheel speed sensors

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

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 > ABSmodule > 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 thepreviously installed Bosch 5.3 system

The hydraulic ABS unit and the rear brake calipers areservice pre-filled The front brake calipers and thecylinders of the rear drum brake are not pre-filled.The steering wheel rotation sensor is integrated togetherwith the clockspring in a housing and is located behindthe steering wheel

The steering wheel rotation sensor works according tothe principle of magnetoresistance and permits absolutesensing of the steering wheel position

NOTE: When replacing the sensor, make sure that the

new sensor is installed centrally and is calibrated usingWDS (Worldwide Diagnostic System) Instructions forthis can be found in the relevant Service literature.The yaw rate/lateral acceleration sensor is

accommodated in a housing and is located on a separatebracket to the left of the foot controls (LHD and RHD(Right-hand Drive))

Stability assist can be deactivated via a switch in theinstrument panel

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

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

(rear wheel drive)

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

The engine range consists of the following powerversions:

Torque (Nm) Power output PS (kW)

Cubic capacity (drive)

250

85 (63)2.2L (front wheel drive)

2.2L Duratorq-TDCi (Puma) diesel

E64592

• 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

• 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

• EOBD (European On-board Diagnostic) for the

monitoring of emissions-related components

Engine emission control

• Meets emission standard IV

• Electrical EGR (Exhaust Gas Recirculation) valvewith water cooling

P8FA (85 PS)QVFA (110 PS)QWFA (130 PS)Engine code

1,998 ccmCubic capacity

86 mmStroke

86 mmBore

19 : 1Compression ratio

1-3-4-2Firing order

900 rpmIdle speed

63 kW (85 PS) at 3,500rpm, 250 Nm at 1,500 rpm

81 kW (110 PS) at 3,500rpm, 285 Nm at 1,750 rpm

96 kW (130 PS) at 3,500rpm, 310 Nm at 1,600 rpmMax power output, torque

DieselFuel

Power and torque curves

120 140 160 180 200 220 240 260 280 300 320

0 10 20 30 40 50 60 70 80 90 100

7 8

9 10

Fuel return11

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

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 pressure relief valve opens at a fuel pressure ofapprox 2000 bar It serves as a safeguard in the event

of a malfunction in the high-pressure system Thisprevents damage caused by excessive fuel pressure inthe 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 inthe current Service Literature

High-pressure pump

E68323The high-pressure pump is flanged onto the left of thecylinder head in the direction of travel and is driven bythe intake camshaft

2

3 1

High-pressure pump coupling

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

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

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 –

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

E68320The valve train has been adapted to the new position ofthe high-pressure pump The timing chain now onlydrives the two camshafts Consequently, the housing aswell as the routing of the timing chain have beenmodified

Tensioning rollers2

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

The coolant pump is located on the front of the engine

and is flanged on directly behind the power steering

pump Both pumps are connected by means of a shaft

and driven via a pulley

The pumps can be replaced separately during servicing.Instructions for this can be found in the relevant Serviceliterature

Cylinder head

E68321

2 1

Oil baffle plate

1

Aluminum support

2

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

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

Cylinder block

E64595

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

2.4L Duratorq-TDCi (Puma) diesel

General

• The 2.4L Duratorq-TDCi (Puma) diesel engine isessentially based on the previously installed 2.4-literengine It is available in three different power outputversions of 74 kW, 85 kW and 103 kW

• Like the 2.2-liter version, the engine features amodified valve train as well as a modified accessorydrive

• The introduction of the Transit 2006.5 (03/2006-)will see the previously used Delphi common-railsystem replaced by the Denso common-rail system.– The fuel injection pump is still driven by thetiming chain of the valve train

• The service interval is 25,000 km or one year for allversions 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 theinstrument cluster alerts the driver when servicing

• The 103 kW version has an electrical actuator forturbocharger guide vane adjustment, an oillevel/temperature sensor and a centrifugal oil filter

Engine management

• Visteon

• EOBD for the monitoring of emissions-related

components

Engine emission control

• Meets emission standard IV

• Electrical EGR valve with water cooling

Diagnosis

• Diagnosis using WDS via the DLC

Engine data

2.4L Duratorq-TDCi (Puma) diesel

PHFA (100 PS)JXFA (115 PS)H9FB (140 PS)Engine code

2,402 ccmCubic capacity

94.6 mmStroke

89.9 mmBore

19:1Compression ratio

1-3-4-2Firing order

900 rpmIdle speed

74 kW (100 PS) at 3,500rpm, 285 Nm at 1,600 rpm

85 kW (115 PS) at 3,500rpm, 310 Nm at 1,750 rpm

103 kW (140 PS) at 3,500rpm, 375 Nm at 2,000 rpmMax power output, torque

DieselFuel

Power and torque curves

120 140 160 180 200 220 240 260 280 300 320

0 10 20 30 40 50 60 70 80 90 100

Centrifugal oil filter (140 PS version only)

E68324

1

2 3

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

The oil pressure and the shape of the rotor cause thispivot axis to turn, forcing the oil in the rotor outwards.The centrifugal force presses the particles floating inthe 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 thenflows 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

Oil level/temperature sensor (103 kW version only)

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

The oil temperature is simultaneously sensed via theintegrated 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 accountthe mileage and engine operating conditions) anddisplays it in the instrument cluster

In addition, a separate indicator in conjunction with acorresponding message in the instrument cluster displaywarns the driver when the oil quantity falls below theminimum level

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 adescription of this procedure

2.3L Duratec-HE (MI4)

E64753

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

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

Engine code

2,261 ccmCubic capacity

94 mmStroke

87.5 mmBore

9.7:1Compression ratio

1-3-4-2Firing order

rpmIdle speed

107 kW (145 PS)

at 5,250 rpmMax power output

210 Nm at 3,750 rpmMax torque

Premium 95 RONFuel

Power and torque curve (when using 95 RON fuel)

The valve clearance of the engine only needs to be

monitored if the engine is converted to operation using

alternative fuel (every 60,000 km)

Conversion of the engine to operation with alternativefuel requires no modification to the engine as the valveseats 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

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,

Shift mechanism

E68391

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

Brake pad wear indicator8