New Product Introduction

Transit 2006.5 (04/2006-)

Service Information

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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
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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The previous 2.0L Duratorq TDCi engines have been replaced by a modified generation upgraded to a cubic capacity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

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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

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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................................................................................................................................................................................................... 16

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

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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

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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-)

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Internal designation: • Stability assist with active rollover protection
• V347 = Front wheel drive • Reinforced front axle (for vehicle versions with high
payload)
• V348 = Rear wheel drive

Chassis
• Improved drivability through fine-tuning of springs,
shock absorbers and steering
• Modified brake system (disc brakes on the rear axle)

Service Training (G542739) 5

At a glance Introduction

Powertrain • Power management

• Modified diesel engines with increased power and • Recharging function for the radio remote control
lower consumption, emission standard IV, • Modified locking system with configurable locking
second-generation common-rail technology functions
• Modified 2.3L Duratec-HE (MI4) engine with • Anti-theft alarm system in accordance with Thatcham
emission standard IV, LPG (Liquefied Petroleum CAT 1
Gas) (optional)
• Latest generation of audio units and Travel Pilot EX
• 2.4L Duratorq TDCi with 85 kW (115 PS) and 105 navigation system
kW (143 PS) in conjunction with 6-gear manual
• Hands-free kit with Bluetooth interface and voice
transmission (rear wheel drive)
control
• Gearshift lever in the instrument panel
Body
Electrical system
• Improved crash characteristics
• Central module configuration

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• side air bag modules
• New GEM (Generic Electronic Module) with
• New front end design
integrated PATS (Passive Anti-theft System)
• New instrument panel with numerous storage options
function
• Improved corrosion protection
• Completely newly developed vehicle electrical
system with MS-CAN (Controller Area Network) • Two new vehicle versions
and HS-CAN bus • New exterior colors
• New instrument cluster with dot matrix display • 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)

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1 GEM behind glove compartment, passenger side Hands-free kit/voice control module (beside
9
IFS (Inertia Fuel Shutoff) (vehicles with petrol instrument panel)
2
engine) PCM (Powertrain Control Module) in left-hand
10
3 Right-hand crash sensor (with side air bag only) side of engine compartment

Receiver for radio remote control (in center of ABS (Anti-lock Brake System) module, engine
4 11
headliner) compartment, underneath brake master cylinder

5 Booster heater (vehicle underbody, driver side) GPS (Global Positioning System) antenna (in
12
center of instrument panel)
6 Trailer module (under driver seat)
RCM (Restraints Control Module) (next to the
7 Left-hand crash sensor (with side air bag only) 13
GEM)
8 Instrument cluster

Service Training (G542739) 7

At a glance Introduction

IFS switch

The IFS switch is installed in the instrument panel

(passenger side).

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8 (G542739) Service Training

Lesson 2 – Chassis Suspension System

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

This requires a new procedure for installation and

removal. Instructions for this can be found in the
relevant Service literature.

Rear axle

In addition to modified suspension points at the rear

axle and a reinforced differential, modified final drive
ratios are also available.

Vehicles with front wheel drive feature a VXT75 manual

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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.

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

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A Front brake
B Rear brake
1 Brake pad wear indicator

the right-hand brake caliper piston, apply pressure to

Larger brake discs as well as modified brake calipers
the brake caliper piston while simultaneously turning it
are installed on the front axle depending on the engine.
clockwise.
Disc brakes are installed as standard on the rear axle
All vehicles feature a brake pad wear indicator at the
(except optional version).
disc brakes. The sensors for the brake pad wear indicator
The rear brake calipers are similar to those in the are installed at the inner brake pads and connected in
Mondeo 2001. The special tool 206-085 is needed to series.
reset the brake caliper piston.
If one of the sensors is interrupted, the instrument cluster
NOTE: To reset the left-hand brake caliper piston, registers a missing ground and activates a warning
apply pressure to the brake caliper piston while
indicator in the instrument cluster.
simultaneously turning it counter-clockwise. To reset

10 (G542740) Service Training

Lesson 2 – Chassis Brake System - General Information

ABS system overview

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1 HS-CAN data bus input/output signals 7 Pressure sensor (in the ABS/HCU)
2 Gateway (GEM) Yaw rate sensor and lateral acceleration sensor
8
3 ABS module (at the right-hand or left-hand foot controls)

4 ABS motor Steering wheel rotation sensor (behind the

9
steering wheel)
5 ABS/HCU (Hydraulic Control Unit).
10 Wheel speed sensors
6 Stoplamp switch
11 Stability assist switch

Service Training (G542740) 11

Brake System - General Information Lesson 2 – Chassis

HS-CAN input signals: 7. ABS module > GEM Gateway > Instrument cluster
> Stability assist warning indicator ESP
1. CKP (Crankshaft Position) sensor > GEM Gateway
> ABS module 8. Signals of all four wheel speed sensors > ABS
module > PCM
2. Engine idle speed (from PCM) > ABS module
3. Engine status (OFF, idling, stalling) (from PCM) > The following brake systems are available, depending
ABS module on the vehicle version:

4. Duration of driving cycle (from GEM) > Gateway – ABS (Bosch 8.0)
> ABS module – ABS/BTCS
5. Tire circumference > GEM Gateway > ABS module – ABS/BTCS, stability assist, electronic EBA
6. Ignition lock position > GEM Gateway > ABS (Emergency Brake Assist), active rollover protection
module
7. Torque (from PCM) > ABS module Bosch 8.0 ABS system

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8. APP (Accelerator Pedal Position) position > GEM
Gateway > ABS module The Bosch 8.0 ABS system is an enhancement of the
previously installed Bosch 5.3 system.
9. BPP (Brake Pedal Position) switch > PCM > ABS
module The hydraulic ABS unit and the rear brake calipers are
10. Parking brake switch > GEM Gateway > ABS service pre-filled. The front brake calipers and the
module cylinders of the rear drum brake are not pre-filled.

11. Outside air temperature sensor > GEM Gateway > The steering wheel rotation sensor is integrated together
ABS module with the clockspring in a housing and is located behind
the steering wheel.
12. Total mileage > GEM Gateway > ABS module
13. GEM Gateway > Instrument cluster > Data for The steering wheel rotation sensor works according to
central vehicle configuration the principle of magnetoresistance and permits absolute
sensing of the steering wheel position.
HS-CAN output signals:
NOTE: When replacing the sensor, make sure that the
1. Vehicle speed signal > ABS module > GEM
new sensor is installed centrally and is calibrated using
Gateway
WDS (Worldwide Diagnostic System). Instructions for
2. Intervention BTCS (Brake Traction Control System)
this can be found in the relevant Service literature.
> ABS module > PCM
The yaw rate/lateral acceleration sensor is
3. Torque adaptation request > ABS module > PCM
accommodated in a housing and is located on a separate
4. ABS module > GEM Gateway > Instrument cluster
bracket to the left of the foot controls (LHD and RHD
> ABS warning indicator
(Right-hand Drive)).
5. ABS module > GEM Gateway > Instrument cluster
Stability assist can be deactivated via a switch in the
> Brake system warning indicator
instrument panel.
6. ABS module > GEM Gateway > Instrument cluster
> ABS warning indicator

12 (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

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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

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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 (rear wheel drive)
following engine/transmission combinations: • 2.3L Duratec-HE (MI4) with MT-75 5-speed manual
• 2.2L Duratorq-TDCi (Puma) diesel with VXT-75 transmission (rear wheel drive)
5-speed manual transaxle (front wheel drive)
The engine range consists of the following power
• 2.4L Duratorq-TDCi (Puma) diesel with MT-75 versions:
(5-speed) and MT82 (6-speed) manual transmission

Cubic capacity (drive) Power output PS (kW) Torque (Nm)

2.2L (front wheel drive) 85 (63) 250

(previously 2.0L)

110 (81) 285

130 (96) 310

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2.4L (rear wheel drive) 100 (74) 285

115 (85) 320

140 (103) 375

2.3L (rear wheel drive) petrol 145 (107) 200

Service Training (G542741) 15

Engine System - General Information Lesson 3 – Powertrain

2.2L Duratorq-TDCi (Puma) diesel

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General • The engine features a modified valve train as well
as a modified accessory drive.
• The previously installed 2.0L TDCi engine will be
• The oil change interval is 25,000 km or one year.
replaced by a modified 2.2-liter version.
• The 63 kW version is the entry-level version for the
• The 2.2L Duratorq-TDCi (Puma) diesel is essentially
front wheel drive vehicles. A turbocharger with a
based on the previously installed 2.0-liter engine. It
wastegate is used.
is available in three different power output versions
of 63 kW, 81 kW and 96 kW.

16 (G542741) Service Training

Lesson 3 – Powertrain Engine System - General Information

• The 81 kW version additionally has oil spray nozzles Diagnosis

for cooling the piston crown.
• Diagnosis using WDS via the DLC (Data Link
• The 96 kW version has a turbocharger with
Connector).
electrically adjustable guide vane geometry as well
as fuel injector nozzles with an increased flow rate.
Engine data
Injection system
2.2L Duratorq-TDCi
Denso (Puma) diesel

• Fuel injectors Engine code P8FA (85 PS)

• High-pressure pump QVFA (110 PS)
• Fuel injection supply manifold QWFA (130 PS)

Cubic capacity 1,998 ccm

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Engine management Stroke 86 mm

• Visteon Bore 86 mm
• EOBD (European On-board Diagnostic) for the Compression ratio 19 : 1
monitoring of emissions-related components.
Firing order 1-3-4-2

Idle speed 900 rpm

Engine emission control
Max. power output, torque 63 kW (85 PS) at 3,500
• Meets emission standard IV
rpm, 250 Nm at 1,500 rpm
• Electrical EGR (Exhaust Gas Recirculation) valve 81 kW (110 PS) at 3,500
with water cooling rpm, 285 Nm at 1,750 rpm
96 kW (130 PS) at 3,500
rpm, 310 Nm at 1,600 rpm

Fuel Diesel

Service Training (G542741) 17

Engine System - General Information Lesson 3 – Powertrain

Power and torque curves

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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

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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 Lesson 3 – Powertrain

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
prevents damage caused by excessive fuel pressure in
This has achieved an increase in engine power while at
the high-pressure system.
the same time reducing fuel consumption.
Any triggering of the pressure relief valve is detected
by the PCM, which then sets an appropriate DTC
Fuel injection supply manifold
(Diagnostic Trouble Code- WDS) and the MIL
(Malfunction Indicator Lamp) is activated.

For installation and removal, refer to the instructions in

the current Service Literature.

High-pressure pump

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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 high-pressure pump is flanged onto the left of the
the valve can no longer be guaranteed.
cylinder head in the direction of travel and is driven by
the intake camshaft.

20 (G542741) Service Training

Lesson 3 – Powertrain Engine System - General Information

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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

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The fuel injectors are mounted by means of a bracket
with a central screw that fastens two nozzles at once. Identification number (injector correction
factor)
It should be noted that if one of the two fuel injector
nozzles is removed, the second nozzle attached using Illustration shows the fuel injector from above
the common bracket must be resealed.

The associated high-pressure lines must also be replaced.

Instructions for this can be found in the relevant Service
literature.

Further information on the Denso common-rail injection

system can be found in the Student Information "Diesel
Fuel Injection and Engine Management Systems –
Common-Rail Systems", CG 8180/S.

1 Electrical connection, solenoid valve

2 16-digit identification number
3 Connection, leak-off pipe

22 (G542741) Service Training

Lesson 3 – Powertrain Engine System - General Information

To ensure optimum fuel metering, the PCM must be Valve train

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.

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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

Engine System - General Information Lesson 3 – Powertrain

Accessory drive

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Accessory drive without A/C (Air Conditioning) 1 Tensioner
A
compressor 2 Tensioning rollers
B Accessory drive with A/C compressor

If air conditioning is installed, the accessory drive belt

of the A/C compressor is tensioned via a timing belt
tensioner. If there is no air conditioning installed, the
accessories are driven by two self-tensioning
multigroove belts.

24 (G542741) Service Training

Lesson 3 – Powertrain Engine System - General Information

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1 Power steering pump
2 Coolant pump

The pumps can be replaced separately during servicing.

The coolant pump is located on the front of the engine
Instructions for this can be found in the relevant Service
and is flanged on directly behind the power steering
literature.
pump. Both pumps are connected by means of a shaft
and driven via a pulley.

Service Training (G542741) 25

Engine System - General Information Lesson 3 – Powertrain

Cylinder head

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1 Oil baffle plate
2 Aluminum support

The mounting as well as the oil supply of the rocker

arms has been modified. The previously installed rocker
shafts have been discontinued. The rocker arms are now
mounted on a separate aluminum support.

26 (G542741) Service Training

Lesson 3 – Powertrain Engine System - General Information

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1 Hydraulic valve clearance compensation
2 Rocker arms

The components for hydraulic valve clearance

compensation are integrated in the rocker arms. The
changes to the procedure for assembly/disassembly of
the cylinder head are described in the relevant service
literature.

Service Training (G542741) 27

Engine System - General Information Lesson 3 – Powertrain

Cylinder block 2.4L Duratorq-TDCi (Puma) diesel

General

• The 2.4L Duratorq-TDCi (Puma) diesel engine is

essentially based on the previously installed 2.4-liter
engine. It is available in three different power output
versions of 74 kW, 85 kW and 103 kW.
• Like the 2.2-liter version, the engine features a
modified valve train as well as a modified accessory
drive.
• The introduction of the Transit 2006.5 (03/2006-)
will see the previously used Delphi common-rail
system replaced by the Denso common-rail system.

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– The fuel injection pump is still driven by the
timing chain of the valve train.
• The service interval is 25,000 km or one year for all
versions other than the 103 kW version.
• The service interval for the 103 kW version is 50,000
km or two years. A service interval indicator in the
instrument cluster alerts the driver when servicing
is required.
The cylinder block has been modified. One significant • The 74 kW version is the entry-level version for the
change in comparison with the 2.0L Duratorq-TDCi rear wheel drive vehicles.
(Puma) diesel engine is the omission of the bearings for
• The 85 kW version additionally has oil spray nozzles
the balance shafts.
for cooling the piston crown as well as fuel injector
This modifies the reference point for installation of the nozzles with an increased flow rate.
reinforcing frame between the engine block and oil pan. • The 103 kW version has an electrical actuator for
Please refer to the relevant Service literature for turbocharger guide vane adjustment, an oil
instructions on installing the reinforcing frame. level/temperature sensor and a centrifugal oil filter.

Injection System

Denso
• Fuel injectors
• High-pressure pump
• Fuel injection supply manifold

28 (G542741) Service Training

Lesson 3 – Powertrain Engine System - General Information

Engine management Engine data

• Visteon 2.4L Duratorq-TDCi

• EOBD for the monitoring of emissions-related (Puma) diesel
components.
Engine code PHFA (100 PS)
JXFA (115 PS)
Engine emission control H9FB (140 PS)

• Meets emission standard IV Cubic capacity 2,402 ccm

• Electrical EGR valve with water cooling Stroke 94.6 mm

Bore 89.9 mm
Diagnosis
Compression ratio 19:1
• Diagnosis using WDS via the DLC Firing order 1-3-4-2

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Idle speed 900 rpm

Max. power output, torque 74 kW (100 PS) at 3,500

rpm, 285 Nm at 1,600 rpm
85 kW (115 PS) at 3,500
rpm, 310 Nm at 1,750 rpm
103 kW (140 PS) at 3,500
rpm, 375 Nm at 2,000 rpm

Fuel Diesel

Service Training (G542741) 29

Engine System - General Information Lesson 3 – Powertrain

Power and torque curves

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A Torque (Nm) 3 Torque curve for 85 kW engine
B Engine speed (rpm) 4 Power curve for 85 kW engine
C Power output (kW) 5 Torque curve for 74 kW engine
1 Torque curve for 103 kW engine 6 Power curve for 74 kW engine
2 Power curve for 103 kW engine

30 (G542741) Service Training

Lesson 3 – Powertrain Engine System - General Information

Centrifugal oil filter (140 PS version only)

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1 Cover
2 Centrifuge (under the valve cover)
3 Oil pressure line to the centrifugal oil filter

The 103-kW version of the 2.4L Duratorq-TDCi (Puma) The oil pressure and the shape of the rotor cause this
diesel engine features a centrifugal oil filter. In pivot axis to turn, forcing the oil in the rotor outwards.
conjunction with a calculation algorithm in the PCM The centrifugal force presses the particles floating in
the oil (contamination particles) against the outer wall
and an additional oil level/temperature sensor, this
of the rotor, where they form a solid mass.
permits a service interval of up to 50,000 km.
The oil in the rotor is filtered in this manner and then
The centrifugal oil filter is located in the cylinder head
flows back into the oil circuit.
and comprises:
• a cover cap (in the valve cover) The centrifugal oil filter can even catch small particles
of dirt that cannot be filtered using normal oil filters.
• a replaceable rotor (centrifuge)
This increases the service life of the oil.
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.

Service Training (G542741) 31

Engine System - General Information Lesson 3 – Powertrain

Oil level/temperature sensor (103 kW version only)

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1 Oil level/temperature sensor
2 Openings
3 Oil dipstick

The oil temperature is simultaneously sensed via the

An oil level/temperature sensor located on the front of
integrated temperature sensor. The temperature is used
the engine directly beside the engine oil dipstick is
as a correction factor in the calculation.
provided for the service interval indicator.
The PCM calculates the next oil change on the basis of
The oil level is measured by means of a wire coil located
an integrated strategy (which also takes into account
inside the sensor. A continuous current is applied to this
the mileage and engine operating conditions) and
wire coil.
displays it in the instrument cluster.
The resistance and consequently the voltage drop at the
In addition, a separate indicator in conjunction with a
wire coil changes according to how deeply the sensor
corresponding message in the instrument cluster display
is immersed in the oil. The measured values are
warns the driver when the oil quantity falls below the
registered by the PCM.
minimum level.
The change in the voltage drop serves as an input
variable for calculation of the oil level.

32 (G542741) Service Training

Lesson 3 – Powertrain Engine System - General Information

Service instructions on all vehicles with a diesel engine.

Please refer to the relevant Service literature for a

The interval indicator must be reset after an oil change
description of this procedure.

2.3L Duratec-HE (MI4)

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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.

Service Training (G542741) 33

Engine System - General Information Lesson 3 – Powertrain

The main features of the engine are as follows: Engine data

• Longitudinally installed four-cylinder in-line engine
with two chain-driven overhead camshafts and 16 2.3L Duratec-HE (MI4)
valves Engine code GZFA (emission standard
• Aluminum cylinder block with lower crankcase IV)
• Mechanical bucket tappets GZFB (emission standard
• Intake manifold runner control with swirl flaps III)

• Ignition system with ignition coil-on-plug Cubic capacity 2,261 ccm

• Electronic throttle valve Stroke 94 mm
• Balance shafts
Bore 87.5 mm
Engine management
Compression ratio 9.7:1
• Visteon PCM
Firing order 1-3-4-2

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• Knock control with one KS (Knock Sensor)

Engine emission control Idle speed rpm

• Meets European emission standard IV Max. power output 107 kW (145 PS)
• EOBD for the monitoring of emissions-related at 5,250 rpm
components. Max. torque 210 Nm at 3,750 rpm
Diagnosis Fuel Premium 95 RON
• Diagnosis using WDS via the DLC

34 (G542741) Service Training

Lesson 3 – Powertrain Engine System - General Information

Power and torque curve (when using 95 RON fuel)

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A Torque (Nm)
B Engine speed (rpm)
C Power output (kW)

Service instructions Conversion of the engine to operation with alternative

fuel requires no modification to the engine as the valve
The valve clearance of the engine only needs to be seats are reinforced as standard. All that is required is
monitored if the engine is converted to operation using an adaptation of the fuel system.
alternative fuel (every 60,000 km).
The service interval is 20,000 km or one year.

Service Training (G542741) 35

Engine System - General Information Lesson 3 – Powertrain

Accessory drive

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A Accessory drive with A/C
B Accessory drive without A/C

For further information on the engine, please refer to

the following Student Information publications:
• New Product Information TN7002114S, Mondeo
2001, 1.8L and 2.0L Duratec-HE Petrol Engines,
CG 7870/S
• New Product Information TN7002142H, Focus
C-MAX 2003.75 (06/2003-), CG 8037/S
• New Product Information TN7002151H, Focus
2004.75 (07/2004-), CG 8144/S

36 (G542741) Service Training

Lesson 3 – Powertrain Engine System - General Information

Transmission

Shift mechanism

A new special tool 308-650 is available for adjusting

the gearshift mechanism on all transmissions.

Please refer to the relevant Service literature for

instructions on adjusting the gearshift mechanism.

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Clutch assembly

All rear wheel drive versions as well as the VXT75

manual transaxle in conjunction with the 96 kW
Duratorq TDCi engine are equipped with a dual mass
flywheel (LUK).

The gearshift lever is located on the instrument panel.

The reverse gear lock is overcome by lifting a
ring-shaped securing lever (previously knock-over
function).

A gearshift mechanism with control cable is used for

the first time for the rear wheel drive versions with
MT75 and MT82 manual transmissions.

Service Training (G542741) 37

Instrument Cluster Lesson 4 – Electrical

Overview

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1 HS-CAN data bus 5 Displays in the instrument cluster
2 MS-CAN data bus Multifunction switches ("set/reset" button, rotary
6
3 Gateway (GEM) switch)

4 Instrument cluster module 7 Digital tachograph

8 Brake pad wear indicator

38 (G542742) Service Training

Lesson 4 – Electrical Instrument Cluster

HS-CAN input signals: MS-CAN input signals:

1. CKP sensor > GEM Gateway > Instrument cluster 1. Ignition lock position > GEM Gateway > Instrument
> Tachometer cluster (power management)
2. Wheel speed sensor > ABS module > GEM Gateway 2. Reversing lamp switch > GEM Gateway >
> Instrument cluster > Vehicle speed display (VSS Instrument cluster
(Vehicle Speed Sensor)) 3. Time > GEM Gateway > Time display in instrument
3. ABS module > GEM Gateway > Instrument cluster cluster (with RDS 1500 or without radio)
> Brake system warning indicator 4. Alarm time > GEM Gateway > Instrument cluster
4. ABS module > GEM Gateway > Instrument cluster 5. Brake fluid level sensor GEM Gateway > Instrument
> ABS warning indicator cluster > Parking brake warning indicator
5. ABS module > GEM Gateway > Instrument cluster 6. Water-in-fuel sensor > GEM Gateway > Instrument
> Stability assist warning indicator ESP cluster > Warning LED (Light Emitting Diode)
6. PCM-controlled battery charge > Generator > GEM 7. Outside air temperature sensor > GEM Gateway >

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Gateway > Instrument cluster > Charging system Instrument cluster > Ice warning indicator or
warning indicator temperature gauge in the display in the message
7. PCM > GEM Gateway > Instrument cluster > Glow center
plug warning indicator (vehicles with diesel engine) 8. RCM > Instrument cluster > Air bag warning
8. ECT (Engine Coolant Temperature) sensor > PCM indicator or safety belt warning indicator
> GEM Gateway > Instrument cluster > Temperature 9. Headlamp switch > GEM Gateway > Instrument
display cluster > Lighting indicator or light-on warning tone
9. PCM > GEM Gateway > Instrument cluster > Speed 10. PATS transceiver > GEM Gateway > Instrument
control system warning indicator cluster > PATS indicator
10. PCM > GEM Gateway > Instrument cluster > MIL 11. Door contact/hood switch > GEM Gateway >
warning indicator Instrument cluster > Door warning indicator or door
11. PCM > GEM Gateway > Instrument cluster > status display in the message center
Powertrain warning indicator or display in the 12. GEM Gateway > Instrument cluster > Data for
message center central vehicle configuration
12. Oil pressure switch > PCM > GEM Gateway > 13. Fuel level sensor > GEM Gateway > Instrument
Instrument cluster > EOP (Engine Oil Pressure) cluster > Tank display or fuel reserve warning
warning indicator indicator
13. Oil level/temperature sensor > PCM > GEM MS-CAN output signals:
Gateway > Instrument cluster > Engine oil level
1. Instrument cluster > GEM Gateway > ABS module
warning indicator or oil change warning in message
> Mileage
center display
2. Instrument cluster > Audio unit > Vehicle speed
signal
3. Instrument cluster > Audio unit > Reverse gear signal

Service Training (G542742) 39

Instrument Cluster Lesson 4 – Electrical

4. Instrument cluster > Audio unit > Time display (not 5. Instrument cluster > DLC
with RDS 1500)

Operation

Shown: Low equipment level

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1 PATSLED Time setting button (not with high equipment
4
2 Brake pad wear warning indicator level)

Trip odometer reset button (not with high 5 Multi-function display

3
equipment level) 6 Service reminder indicator

The instrument cluster is available in two versions The instrument cluster is connected to the MS-CAN bus
depending on the vehicle equipment. The version with and forms the interface between the MS-CAN bus of
high equipment level has a full dot-matrix display as the audio system and the MS-CAN bus of the rest of
well as an info LED between the large analog displays. the module communications network. It contains three
120 Ohm terminating resistors; two for the audio
Messages are shown in the instrument cluster via the
network and one for the rest of the MS-CAN network.
display and the LED. The LED lights up yellow or red
according to the significance of the message.

40 (G542742) Service Training

Lesson 4 – Electrical Instrument Cluster

The instrument cluster is part of the central vehicle

configuration and saves the configuration data of all the
modules stored in the GEM. However, this data serves
only as a backup copy in the event that the GEM needs
to be replaced.

It is not possible to change and/or enter the mileage

following replacement. The original mileage will be
automatically read in and saved via the central vehicle
configuration.

Configuration of the message center (high

equipment level)

By pressing the "Set/Reset" buttons on the steering

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column control lever, a sub-menu can be selected or a
setting can be changed.

By operating the rotary switch on the steering column

lever, you can scroll through the displays within a
particular menu.

Diagnostics

The instrument cluster can be diagnosed using the WDS.

Observe the instructions on module configuration when

replacing the instrument cluster.

Service Training (G542742) 41

Tachograph Lesson 4 – Electrical

General The tachograph registers

• driving, working and rest times for the driver and
passenger,
• speed (24 hours in mass memory) and distance
driven,
• operation-specific parameters such as speed, other
work operations on the vehicle and events such as
information on calibration and/or periodic testing.

The data is stored:

• vehicle-specifically in an integrated mass memory
unit with capacity for recording the activities for
A digital tachograph (Siemens VDO, type DTCO 1381) approx. 365 days
is available for the Transit 2006.5. • driver-specifically on the personal driver card with

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This tachograph works with the aid of chip cards which capacity for approx. 28 days
store all the necessary information. These chip cards A separate VSS that transmits a digitally encrypted
are driver-specific and must be inserted in the card signal directly to the tachograph is installed at the
reader before departure. transmission during installation of the tachograph.
The data of two drivers can be registered in parallel The sensor is secured against tampering by a lead seal.
using two chip-card readers. Further instructions on
Installation and calibration of the system is carried out
operation can be found in the relevant Owner's
by authorized service partners.
Handbook.
The tachograph is supplied with separate operating
The tachograph in 1-DIN radio format is installed above
instructions (from Siemens).
the instrument panel and includes
• two chip-card readers, Diagnosis can only be carried out by authorized dealers.

• an integrated printer for creating logs for drivers and

inspectors, Note
• a display containing important information, e.g. on
The introduction of digital tachographs in commercial
the current driving and rest-period account,
vehicles with a permissible gross weight of more than
• a real-time clock, 3.5 tons and vehicles with more than nine seats came
• various controls. into force on August 5, 2005 (European Legislation
EEC No 3820/85 and 3821/85).

Digital tachographs have been permitted on new vehicles

since mid-2005. It must be noted here that digital
tachographs may only be diagnosed and/or repaired by
authorized Siemens dealers. Further instructions on this
can be found in TSB 59/2005.

Further information at "http://www.vdo.com"

42 (G542799) Service Training

Lesson 4 – Electrical Audio System

Overview

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1 MS-CAN data bus Hands-free system/Bluetooth/voice control
6
2 Gateway (instrument cluster) module

3 Audio/navigation unit 7 Audio remote control

4 Right-hand speaker GPS/GSM (Global System for Mobile

Communication)/AM (Amplitude
5 Left-hand speaker 8
Modulation)/FM (Frequency Modulation)
antenna

Service Training (G829488) 43

Audio System Lesson 4 – Electrical

MS-CAN input signals: General

1. Vehicle speed signal > Wheel speed sensor > ABS
module > GEM Gateway (MS-CAN) > Instrument All multimedia devices (audio units, navigation devices
cluster gateway > Audio unit and hands-free kit) are connected to each other via a
separate MS-CAN network (audio network).
2. Ignition lock > GEM Gateway > Instrument cluster
gateway > Audio unit The instrument cluster, which acts as a gateway between
3. Reversing lamp switch > GEM Gateway > the audio network and the rest of the MS-CAN network,
Instrument cluster gateway > Audio unit > Reverse enables the following functions:
gear signal • Time (from the GEM to the audio unit)
4. Microphone > Bluetooth/voice control module > • Setting time (from the audio unit to the GEM)
audio system • Vehicle speed information
MS-CAN output signals: • Reverse gear information
1. Instrument cluster gateway > Audio unit > Time • Diagnostics

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display/setting (not with RDS 1500) • Clear module
2. Audio unit > Bluetooth/voice control module • Central module configuration
3. Audio remote control > Audio unit > Bluetooth/voice The new generation of audio units is available in the
control module following versions for the Transit:
• 1500 RDS
• 6000 CD
• 6006 CDC

44 (G829488) Service Training

Lesson 4 – Electrical Audio System

1500 RDS

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

Service Training (G829488) 45

Audio System Lesson 4 – Electrical

6000 CD

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

46 (G829488) Service Training

Lesson 4 – Electrical Audio System

6006 CDC

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6006 CDC, as 6000 CD, with integrated 6-disc changer • REG function can be disabled

Radio remote control is available for certain equipment • No frequency display when the station name appears
levels (same as Focus/Focus C-MAX). One significant change to the 6000 CD and 6006 CDC
The time is shown in the display of all units with the in comparison with the units installed in the Focus and
exception of the 1500 RDS. The radio display serves Mondeo is the discontinuation of the program type code
exclusively to show and set the time. The actual clock (PTY) function. The PTY button has been replaced by
is located in the GEM. a new phone button bearing a handset symbol instead
of the inscription "PHONE".
For vehicles equipped with 1500 RDS or vehicles
without radio, the time is displayed in the instrument The phone button has been replaced by a button with
cluster. the inscription "CLOCK" for setting the time. This
makes it easier to set the time by means of direct access
It is not possible to display the RDS time in the audio
to the appropriate menu.
unit (deactivated in the radio software).
In addition, all audio units feature a modified anti-theft
Function changes compared with the devices installed
protection system. This system works on the basis of
in the Focus 2004.75 and Mondeo 2001 (does not apply
the VIN (Vehicle Identification Number) identification
to 1500 RDS):
rather than entry of a key code (see also central vehicle
• Separate CLOCK button configuration).
• No PTY function

Service Training (G829488) 47

Audio System Lesson 4 – Electrical

Instructions about the function and operation of the

audio units can be found in the Owner's Handbook
"Audio", CG3454 or 6S6J-19C104-HA 10/2005
20050920142621.

VIN locking function

A new type of anti-theft protection is being introduced

during production.

The VIN is, as was the case previously, transmitted to

the audio unit via the MS-CAN bus and saved in the
unit while still in the factory.

However, the keycode function is disabled, and instead

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the VIN of the audio unit is read in and checked every
time the ignition is switched on.

As soon as the audio unit is correctly identified when

the ignition is switched on (even when the battery has
been disconnected), it can be operated without any
further input.

If an audio unit whose VIN does not match that of the

vehicle is identified, the audio unit remains disabled.

It is not possible to manually enter or change the VIN.

Installing a previously configured unit (with saved VIN)

in another vehicle requires access to OASIS (On-line
Automotive Service Information System) in conjunction
with WDS.

48 (G829488) Service Training

Lesson 4 – Electrical Navigation System

Travel Pilot EX

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A factory-installed navigation system is available in the • Simulation mode can be activated/deactivated
Transit for the first time. The Travel Pilot EX directly from the Menu button
corresponds in function to the unit available in the Focus • The designation "RNS" has been dropped, no
2004.75 (11/2004-) and offers the following features: reference to the manufacturer
• 4 x 20 W output power NOTE: When installing a new navigation unit, the
• Large 4-inch monochrome display navigation unit must be configured by selecting the
• MP3-compatible CD drive routine "Install programmable modules" in WDS.

• Bluetooth-compatible Further information on operation is provided in the

• Turn-by-turn navigation (displays the street names Owner's Handbook CG 3474.
even if no route is calculated)
• Corridor function (additional area either side of the Service instructions
route. In this corridor, the system takes into account
the most up-to-date traffic information). The Travel Pilot EX can be diagnosed using two
different menus:
• Voice output without navigation CD-ROM (in
conjunction with corridor function) • Tuner test mode

• Navigation CD with detailed and additional data • Dealer service mode

Service Training (G829489) 49

Navigation System Lesson 4 – Electrical

Button combination Description

S1 + MENU Tuner test mode

S4 + MENU Dealer service mode

FM steps: This sets the size of the steps for the station search, usually 100 kHz, 50
kHz when cable connected in demo stand.
Version: Displays different versions (hardware, software, CD-ROM (Read Only
Memory))
Display test: Different patterns are shown on the display, enabling individual faulty
pixels to be detected
Faults: Stored diagnostic trouble codes are displayed here; this item cannot be
selected if no faults are stored
Navigation download: Loads the navigation software from the CD-ROM into the
unit's memory

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System download: Loads the system software from the CD-ROM into the unit's
memory
GPS information: Displays the latitude and longitude for the current position and
the number of satellites received
CD eject: Allows the CD eject button to be locked (e.g. for hire cars, demonstration
units, etc.)
System test: Different tests can be selected, the sensor test is important for service

All menus are exited when the unit is switched off or

the "ESC" (Escape) button is pressed when in the main
menu. The revised settings will then be stored.

Some of the information available in the dealer menu

can also be retrieved by pressing the NAV button and
then the preset button S5 or S6 (in the EXTRA display).

A diagnostic trouble code table is contained in FordEtis,

Group 419-07B.

50 (G829489) Service Training

Lesson 4 – Electrical Cellular Phone

General

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1 MS-CAN data bus input/output signals 5 Cellular phone
2 Gateway (instrument cluster) 6 GSM antenna
Hands-free system/Bluetooth/voice control 7 Handset holder
3
module 8 Microphone
4 Audio/navigation unit

Service Training (G829490) 51

Cellular Phone Lesson 4 – Electrical

A factory-installed hands-free kit is available in the

Transit for the first time.

Three types of system are available regardless of the

audio unit installed:
A. Hands-free kit with handset holder
B. Hands-free kit without handset holder, with
Bluetooth and voice control
C. Hands-free kit with handset holder, Bluetooth and
voice control

With all versions, voice output is via the vehicle

loudspeakers. The function of the system essentially
corresponds to that in the Mondeo 2001 (06/2003-),
Focus C-MAX 2003.75 (06/2003-) and Focus 2004.75

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(07/2004-). Further information is provided in the
training literature "Infotainment – Fundamentals"
TC4012031H, CG 8140/S and "Infotainment – Service
and Diagnosis" TC4012032H, CG8141/S and in the
Owner's Handbook CG3527.

MS-CAN input signals:

1. Audio remote control > Audio unit > Bluetooth/voice
control module
2. Station buttons > Audio unit > Bluetooth/voice
control module

MS-CAN output signals:

1. Microphone > Bluetooth/voice control module >
Audio unit
2. Microphone > Bluetooth/voice control module >
Navigation system

52 (G829490) Service Training

Lesson 4 – Electrical Exterior Lighting

General The low beam switch-off delay feature, when activated,

keeps the side lamps, the low beams and the
number-plate lamp on for approx. 30 seconds after the
last door is closed (this can be extended to max. 180
seconds through configuration).

If a vehicle door or the liftgate is opened, the switch-off

delay is increased to 180 seconds. After the last door
has been closed, the switch-off time is reset to 30
seconds.

The dipped beam switch-off delay function is

deactivated:
• when the ignition is switched on
• by pressing the high-beam lever again

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The autolamp feature works in the same way as on the
Mondeo 2001 (06/2003-), Focus C-MAX 2003.75
(06/2003-) and Focus 2004.75 (07/2003-).

All models with the exception of the flatback versions

feature a high mounted stoplamp. The design of the rear
lights has been modified through the use of a clear-glass
cover.

Also integrated is a one-touch turn signal function, i.e.

The mounting points of the headlamps have changed
briefly touching the direction indicator control triggers
on account of the redesign of the headlamps.
three short flashes of the turn signal.
In order to install new bulbs, the headlamp must be
removed. Please refer to the Service literature for
instructions.

In addition to the normal functions, the following

functions are also available:
• Low beam switch-off delay
• Autolamps (in conjunction with rain sensor)

The low beam switch-off delay feature is activated by

pressing the high-beam lever when the ignition key is
in position "0". Activation is confirmed by a short
audible signal.

Service Training (G542744) 53

Communications Network Lesson 4 – Electrical

Overview

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A MS-CAN data bus 7 Light/rain sensor
B ISO 9141 8 Radio remote control reception module
C Outgoing/incoming lines (RX/TX) 9 PATS transceiver unit
D LIN data bus Battery-buffered anti-theft alarm system horn
10
E HS-CAN data bus (BBS)

1 SRS (Supplemental Restraint System) module 11 Passenger compartment control sensor(s)

2 Phone / Bluetooth/voice control module 12 PCM

3 Instrument cluster 13 ABS module

4 Audio unit 14 Steering wheel rotation sensor

5 Parking aid module 15 Yaw rate/lateral acceleration sensor

6 GEM 16 DLC
17 Terminating resistors

54 (G542745) Service Training

Lesson 4 – Electrical Communications Network

Up to four data bus systems can be used in the Transit – Fuel fired booster heater
2006.5 depending on the model and equipment: – RCM
• HS-CAN bus – Parking aid module
• MS-CAN bus – Instrument cluster
• ISO 9141 protocol 2. MS-CAN for the audio system
• LIN (Local Interconnect Network) – Instrument cluster
All systems can be diagnosed via the DLC. – Audio system
The following modules are implemented as gateways: – Bluetooth/voice control module
– GEM Gateway between the HS-CAN and the central Here, the instrument cluster acts as a gateway to the
electrics MS-CAN MS-CAN network of the audio system. This gateway
– Instrument cluster gateway between the central provides the information required for the audio system
electrics MS-CAN and the audio system MS-CAN and the Bluetooth/voice control module (see the

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. description of the audio systems).

This eases the data transfer load on the remaining

HS-CAN MS-CAN network and reduces potential sources of
faults.
The following systems are connected to the HS-CAN
The two terminating resistors, each of 120 ohm, of the
bus:
MS-CAN data bus are integrated into the GEM and into
• ABS the instrument cluster. The total resistance of the central
– Steering wheel rotation sensor electrics MS-CAN amounts to 60 ohms, measured at
– Yaw rate/lateral acceleration sensor the DLC.
• PCM The two terminating resistors of the MS-CAN audio
• GEM (Gateway to the HS-CAN) system are installed together in the instrument cluster.
As this network is not connected to the DLC, the total
The two terminating resistors, 120 Ohm each, of the
resistance cannot be measured at the DLC.
HS-CAN data bus are integrated into the PCM and the
GEM.
ISO
Given the fact that both 120-ohm resistors are connected
in parallel, the total resistance is 60 ohms (measured at The following systems are connected using the
the DLC). When a control module is disconnected, 120 ISO-9141 protocol:
ohms must be measured at the DLC.
• Receiver for radio remote control
• PATS transceiver
MS-CAN
• Light/rain sensor
Two separate MS-CAN networks are used in the Transit:
1. MS-CAN for all systems apart from the audio
system:

Service Training (G542745) 55

Communications Network Lesson 4 – Electrical

LIN bus

The following systems are connected to the LIN bus

(only for vehicles with Thatcham CAT 1 alarm and
closed driver cab):
• Ultrasonic sensors
• Battery-buffered alarm horn

LIN is a standard specifically designed for cost-effective

communication between intelligent sensors and actuators
in vehicles. It is used wherever the bandwidth and
versatility of a CAN are not required.
Within a LIN bus the transfer rate can reach up to 20
kbit/s. On the Transit, the speed is approx. 9,600 baud

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(9.6 kbit/s).

A LIN network comprises a LIN master and one or more

LIN slaves. The LIN master, which is the GEM in the
case of the Transit, has information on the temporal
sequence of all the data to be transmitted.

This data is transmitted by the relevant LIN slaves (e.g.

ultrasonic sensors) when requested by the LIN master.

LIN is a single-wire bus, i.e. the data is transferred in

the cable via one wire. The same cable normally also
supplies the power.

The ground for the power supply voltage is also the

ground for data transfer.

No terminating resistors are used in the LIN network.

56 (G542745) Service Training

Lesson 4 – Electrical Module Configuration

Central module configuration

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A Previous configuration principle 2 GEM
B Central module configuration principle 3 WDS
1 Control modules 4 CAN

WDS now contains a new routine for replacing or

The modules in the vehicle were previously configured
retrospectively changing the configuration data. This
using WDS and the "Module Programming"
new routine is used to perform the central module
(inhale/exhale) function.
configuration.
In this case, the actual status of the relevant module is
In this case, however, the data is not read into WDS as
read into WDS and then stored on the new module.
previously, instead it is transferred by the GEM to the
The Transit 2006.5 uses a new method of module corresponding module. The WDS merely initiates and
configuration, so-called central module configuration. monitors the procedure.
Here, all the required configuration parameters are For safety reasons, all the configuration data which are
stored in the GEM at the factory, and from there they saved in the GEM are also backed up in the instrument
are transmitted via the CAN bus network to all the cluster. Then, if the GEM has to be replaced, this allows
individual modules. the necessary configuration data to be read out from the
instrument cluster with the aid of WDS and transferred
to the new GEM.

Service Training (G542746) 57

Module Configuration Lesson 4 – Electrical

The GEM checks the configuration data for consistency

and stores a DTC in the event of a fault. Operation of
the GEM may be restricted in the event of an error.

If the GEM is replaced, the keys for both the remote

control and for the PATS will need to be re-adapted.

The procedure for this is the same as for current

vehicles.

VIN identification

The VIN is saved in the individual modules at the

factory for the purpose of VIN identification.

As soon as a module is identified when the ignition is

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switched on (even when the battery is disconnected), it
can be operated without any further input.

If no VIN or an invalid VIN is read in by a module, it

is stored in a memory. Subsequent operation of the
module may be restricted depending on its purpose.

58 (G542746) Service Training

Lesson 4 – Electrical Module Controlled Functions

General

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Three different types of GEM are installed, depending
The GEM is located underneath the dashboard behind
on the equipment version. Only the fully equipped
the glove compartment. The glove compartment can be
version is available for service:
folded down by pressing together the two sides.
• Version A (low equipment level); Part No.:
6C1T-14A073-AX
GEM functions
• Version B (middle equipment level); Part No.:
The GEM is made up of a power distribution section 6C1T-14A073-BX
(including fuses and relays) and an electronics module, • Version C (high equipment level); Part No.:
which controls the operation of most of the electronic 6C1T-14A073-CX
convenience systems. • Version D (for Service department only, corresponds
to Version C); Part No.: 6C1T-14A073-DX

Function/system A B C/D

Communication

MS-CAN Gateway X X X

HS-CAN Gateway X X X

Service Training (G542749) 59

Module Controlled Functions Lesson 4 – Electrical

Function/system A B C/D

Number of digital inputs 29 49 50

Number of analog inputs 2 2 5

LIN (Local Interconnect Network) X

ISO K-line (light/rain sensor) X

ISO K-line for radio remote control X X

Interface for PATS transceiver X X X

Central vehicle configuration main module X X X

Network management X X X

Clock X X X

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Hardware

Number of fuses 20 20 20

Number of external relay slots 0 0 0

Number of integrated relays 4 8 11

Number of plugs/pins 79 119 139

Number of drivers (low side) 7 13 15

Number of drivers (high side) 2 3 4

Voltage supply

Ignition lock status X X X

Additional battery check X X X

Power management (e.g. shipping mode) X X X

Battery-saving function X X X

Exterior lighting

Side lamps X X X

High beams X X X

Low beams X X X

Rear fog lamp X X X

Turn signal lamps X X X

Headlamp switch input (light-on warning tone) X X X

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Lesson 4 – Electrical Module Controlled Functions

Function/system A B C/D

Reversing lamps X X X

Stoplamps X X X

Number-plate lamps X X X

Hazard flasher X X X

High mounted stoplamp (CHMSL) X X X

Hazard flasher off (in case of standing start) * X X X

Hazard flasher in case of accident * X X X

One-touch turn signal function X X X

Headlamp flasher X X X

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Low beam switch-off delay X X X

Fog lamps X X

Daytime running lamps X

Autolamps X

Interior lighting system

Interior lighting upon locking/unlocking X X X

Interior lighting, driver cab X X X

Interior lighting, loadspace X X X

Dimmer function X X

Fuel supply and fluid indicators

Fuel pump (petrol engines only) X

Fuel gauge X X X

Brake fluid level indicator X X X

Engine off in case of crash X X X

Heated windows

Heated windshield X X

Heated rear window(s) X X

Heated exterior mirrors X X

Wash/wipe system

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Module Controlled Functions Lesson 4 – Electrical

Function/system A B C/D

Wash/wipe function X X X

Windshield wipers X X X

Rear wiper (automatic when reverse gear is engaged) X X

Rain sensor X

Locking and anti-theft protection

PATS function (reading in of key) X X X

Door lock switch input X X X

VIN identification X X X

Alarm X X

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Radio remote control (with external receiver) X X

Central/double locking system X X

Partial unlocking X X

Automatic relocking X X

Individual door relocking X X

Automatic locking on start of journey X X

Locking/unlocking – visual/audible signal X X

Unlocking after failed locking (reverse cycling) X X

Individual door relocking (slam locking) X X

Configurable unlocking X

Thatchham CAT 1 alarm (BBS horn, interior monitoring and X

glass break sensors)

Other functions

Detection of APP X X X

Detection of CPP (Clutch Pedal Position) X X X

Parking brake status X X X

Diagnosis of brake pedal (in addition to ABS) X X X

Horn (for signaling central locking only) X X X

Trailer towing X X X

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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

The GEM is connected to the following modules via

All variants of the GEM contain a clock and an alarm
the MS-CAN:
function. The clock time is routed to other modules via
the CAN network. The clock time is adjusted via the • Instrument cluster
radio or the instrument cluster. • Parking aid module

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• RCM
Gateway The GEM is connected to the following modules via
serial interfaces:
The GEM is connected to the following modules via
• Remote control receiver
the HS-CAN:
• PATS transceiver (ring antenna)
• PCM
• Light/rain sensor
• ABS module

The GEM is connected to the following modules via

the MS-CAN:
Hazard warning lights for an accident

• Instrument cluster Accident detection is carried out by the RCM The signal
• Parking aid module is transmitted via the MS-CAN bus to the 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 and the HS-CAN. switched off via the hazard flasher switch.

The GEM is connected to the following modules via

the LIN bus: Service instructions
• Battery-buffered alarm horn (BBS = Battery Back-up
The GEM features a service mode, which enables
Sounder)
checking of the various input and output signals.
• Parking-aid module
Proceed as follows to activate the service mode:
• Interior scanning sensors
• Switch off the ignition
• Ensure that the alarm system is deactivated

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Module Controlled Functions Lesson 4 – Electrical

• Ensure that diagnostic mode or programming mode Both batteries are charged when the engine is running,
is not activated however a cutoff relay means that only one of the two
• Press one of the two front door lock switches 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
is always available for the engine start.
Entry into service mode is confirmed by an audible
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
soon as the engine reaches a set engine idle speed. This
The input signals can then be checked. Each input signal
decreases power consumption and increases the service
is indicated by an audible signal; the turn signals as well
life of the starter motor.
as the turn signal indicators on the instrument cluster
flash once.
Radio remote control
It is not possible to check the output signals during the
self-test. The radio remote control is integrated into the key. A

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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 seconds pass without anything being selected or battery which is integrated in the key (previously it was
operated. a non-rechargeable battery) is continuously recharged
while the ignition is switched on.
• The headlamp flasher is operated and the ignition is
switched OFF at the same time. The charge function of the accumulator is effected by
• Ignition lock position III (engine start) an induction circuit which has previously been used for
operation of the PATS transponder. Additional
• The voltage supply is too low (< 9 Volt).
components are therefore not required.
• The voltage supply is too high (> 16 Volt).
The charging process is initiated and executed by the
A signal tone sounds twice to indicate that the service
GEM via the ring antenna of the transceiver at the
mode has been exited. Further information on
ignition lock once the PATS key query has been
diagnostics can be found in the relevant service
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
and the receiver approx. 32 times.
The generator outputs 150 A as standard.
The remote control housing is additionally sealed and
A second battery (590 Ah) is installed as standard on
watertight. It is possible to identify the key by its blue
all rear wheel drive versions. This is available as an
housing. Replacement of the battery is not possible.
option on the front wheel drive versions.

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Lesson 4 – Electrical Module Controlled Functions

Power management The GEM automatically switches to normal mode once

shipping mode is deactivated.
Power management facilitates an effective supply of
Normal mode:
power appropriate to the respective requirements of the
individual modules by means of various modes. • Normal mode guarantees the full functionality of the
entire electrical systems.
The power management function is integrated into the
GEM. Crash mode:
• Crash mode is activated as soon as the RCM registers
One of four different vehicle modes is used depending
a vehicle impact of appropriate force.
on the operating status of the vehicle:
• Factory mode The following functions are carried out:

• Shipping mode • The vehicle will be centrally unlocked if it is locked

at the time of impact.
• Standard mode
• Activates the hazard warning lamps.
• Crash mode

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• The fuel-fired booster heater is deactivated.
Factory mode:
Crash mode is deactivated as soon as the ignition key
• Factory mode is activated during production of the
is turned to position "0" and then back to position "II"
vehicle. In this mode, relays are shut off to reduce
again. The hazard flashers are deactivated by pressing
the power supply to a minimum. When the vehicle
the hazard flasher switch.
leaves the factory, factory mode is deactivated and
shipping mode is activated.

Shipping mode:
PATS
• Shipping mode is activated en route from the factory The PATS functionality is integrated into the GEM.
to the dealer. The vehicle can be driven without Accordingly, the transceiver unit is directly connected
impairment of the driving safety systems. to the GEM (previously it was connected to the PCM).
• Individual modules and/or electrical systems (e.g.
After the key code is read in (in ignition lock position
anti-theft alarm system, clock and radio remote
II), the appropriate information is transmitted from the
control) are deactivated when the ignition is switched
GEM to the PCM via the HS-CAN data bus.
off.
Depending on this query and on the key status, starting
• This ensures that the battery has enough power when
is then enabled by the PCM.
the vehicle is handed over to the customer.
NOTE: When replacing the GEM, it is necessary to
If the engine is started while the system is in shipping
reprogram the PATS keys. Instructions for this can be
mode, the mode is interrupted only temporarily. It is
found in the relevant service literature.
resumed again as soon as the ignition is switched back
off. The key has a plastic transponder. Coded access is used
during programming of the key.
Shipping mode must be deactivated by the dealer.
This is done by pressing the brake pedal five times
and the hazard flasher switch twice within 10 seconds
when the ignition is switched off.

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Multifunction Electronic Modules Lesson 4 – Electrical

Overview

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66 (G542750) Service Training

Lesson 4 – Electrical Multifunction Electronic Modules

1 HS-CAN data bus 14 Fuel level sensor

2 MS-CAN data bus 15 APP sensor
3 Gateway (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, heated exterior mirrors 22 Hazard flasher switch
10 Heated windshield 23 Ambient air temperature sensor
11 Instrument cluster 24 Headlight switch

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12 Ignition lock 25 Brake fluid level switch
13 Stoplamp switch, BPP switch, CPP switch 26 Light/rain sensor (ISO 9141)

Not shown: – Oil change

• Parking brake switch – Glow plug indicator (vehicles with diesel engines)
• Trailer module – Engine coolant temperature ECT
• Door switches – PATS
• Battery cutoff relay – Charge indicator lamp
• Fuel pump (vehicles with petrol engine) – Speed control system
• Horn/alarm horn 6. PCM > Gateway > GEM (fuel pump ON/OFF
• Windshield washer pump request)
7. CKP sensor > GEM Gateway > Engine speed
HS-CAN input signals:
8. ABS module > GEM Gateway > Request for ABS
1. Vehicle speed signal: Wheel speed sensor > ABS
brake system warning indicator and stability assist
module > PCM > Gateway > GEM current
warning in instrument cluster
consumption for trip computer
HS-CAN output signals:
2. PCM controlled battery charging: Generator > PCM
> Gateway > GEM (control of heated windshield) 1. APP > GEM Gateway > PCM

3. Total mileage: Instrument cluster > Gateway > GEM 2. Status BPP/CPP switch > GEM Gateway > PCM

4. Water-in-fuel sensor > PCM > Gateway > GEM 3. Speed control system > GEM Gateway > PCM
(warning indicator request to instrument cluster) 4. Outside air temperature sensor > GEM Gateway >
5. PCM > Gateway > GEM warning indicator request: PCM

– MIL 5. Status PATS key: PATS transceiver > GEM Gateway

> PCM (start approval)
– Engine warning indicator
6. Ignition lock position status > GEM Gateway > PCM
– Low oil pressure warning indicator

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Multifunction Electronic Modules Lesson 4 – Electrical

7. Parking brake control status > GEM Gateway > ABS 9. Brake fluid level switch > GEM Gateway >
module/PCM Instrument cluster > Parking brake/brake system
8. Fuel level status > GEM Gateway > PCM warning indicator
10. Outside air temperature sensor > GEM Gateway >
MS-CAN input signals:
Instrument cluster > Outside air temperature display
1. Setting the time/alarm time: Instrument cluster >
11. Trailer module > GEM Gateway > Instrument cluster
GEM
> Trailer warning indicator display
2. Crash signal > RCM > GEM
ISO 9141 input/output signals:
MS-CAN output signals:
1. Windshield moisture status > Rain sensor > GEM
1. PCM > Gateway > GEM warning indicator request:
2. Ambient light status > Light sensor > GEM
– MIL
– Engine warning indicator
– Low oil pressure warning indicator

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– Oil change
– Glow plug indicator (vehicles with diesel engines)
– Engine Coolant Temperature ECT
– PATS
– Charge indicator lamp
– Speed control system
2. Headlamp switch > GEM Gateway > Instrument
cluster > Lighting indicator or light-on warning tone
3. Door contact/hood switch > GEM Gateway >
Instrument cluster > Door warning indicator or door
status display in the message center
4. GEM Gateway > Instrument cluster > Data for
central vehicle configuration
5. Fuel level sensor > GEM Gateway > Instrument
cluster > Tank display or fuel reserve warning
indicator
6. Headlamp switch > GEM Gateway > Instrument
cluster > Headlamp/front fog lamp/rear fog lamp
indicator
7. High-beam switch > GEM Gateway > Instrument
cluster > High-beam indicator
8. Turn signal lamp switch > GEM Gateway >
Instrument cluster > Turn signal indicator

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Lesson 5 – Body and Paint Body

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

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There are two steps in the lower area of the bumper.
The modification of the headlamps has permitted an
These provide easy access to the windshield and/or the
improvement in luminous efficiency. Visually, the
wiper blades.
headlamp design is characterized by a clear-glass cover
and a vertical arrangement. The side sections of the bumper are designed as separate
components as previously.
The hood contains the air intake vents for the blower
box as well as integrated washer jets. The radiator grille is fully integrated in the bumper and
contains large openings for the cooling air.
The front bumper in the area of the radiator grille is
optionally available in the vehicle color.

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Body Lesson 5 – Body and Paint

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

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Lesson 5 – Body and Paint Body

Interior

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The instrument panel has been completely redesigned.
It is available in a two-tone design and has two storage Anti-corrosion protection
compartments for bottles up to 2 liters and a removable
The Transit 2006.5 is available with a warranty against
glove compartment. The air outlet vents have also been
corrosion perforation of 10 years, depending on the
modified.
market. The number of zinc-coated sheet metal parts
Above the air bag is a storage compartment with lid, in has been increased and an innovative PVC (Polyvinyl
the center is a large A4-size storage compartment Chloride) underbody protection applied to this end.
(provided there is no tachograph installed).

The gearshift lever is mounted on the instrument panel, End of Life Vehicles Directive
thereby providing unimpeded passage between the driver
and passenger sides. The Transit 2006.5 conforms to the new End of Life
Vehicles Directive of the European Union. This includes
A four-spoke steering wheel is optionally available.
constructing vehicles in a recycle- and
processing-friendly manner as well as adhering to the
targets for the reuse, recycling and processing of
materials used in vehicles.

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Body Lesson 5 – Body and Paint

This means that manufacturers, importers and disposal 2006.

companies must together ensure that at least 85% of the These processing targets must be increased to 95%
average weight of an end of life vehicle is recycled and (processing) and 85% (material processing, reuse) as of
at least 80% of the materials processed or reused as of 2015.

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Lesson 5 – Body and Paint Body

Central door locking

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Body Lesson 5 – Body and Paint

1 HS-CAN data bus 9 Radio remote control

2 MS-CAN data bus 10 Ignition lock
3 Gateway (GEM) Passenger compartment monitoring sensors
11
4 GEM (LIN)

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

HS-CAN input signals:

Recharging function for the remote control
1. Vehicle speed signal > Wheel speed sensors > ABS

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module > PCM > GEM Gateway > Automatic A charging function for the radio remote control
locking batteries is available as an option. More detailed
MS-CAN output signals: information can be found in the description of the GEM.
1. Door ajar switch/liftgate latch switch/lid ajar switch
> GEM > Instrument cluster > Door ajar warning Individual door relocking
indicator or message in message center
If a door is opened during the locking operation, all
LIN input/output signals
other doors (with the exception of the sliding doors)
1. Interior scanning sensors will be locked once. If the open door is then closed, it
2. Battery-buffered alarm horn (with Thatcham CAT will also be locked once.
1 alarm only)
The double-locking mechanism will not work if there
Depending on the equipment version, the following is a door open.
central-locking functions are available:
Individual door relocking can be deactivated.
• Central locking with single locking
• Central locking with double locking
Configurable unlocking
• One-touch central unlocking
• Two-touch central unlocking Configurable unlocking enables different unlocking
options and sequences to be set. Six different
• Automatic locking upon setting off (as of 7 km/h)
configurations are available for this purpose.
• Automatic relocking (45 seconds after unlocking
without any other activity) The following tables provide an overview of the
configurations. The configuration can be changed using
• Individual door relocking
WDS.
• Configurable unlocking

The locking/unlocking status is indicated via an audible

and/or visual signal.

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Lesson 5 – Body and Paint Body

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

Driver door X X

Passenger door X

Sliding door on driver side X X X

Sliding door on passenger side X X

Rear door/liftgate X X

Configuration 2
To unlock the Press unlock Press unlock Press liftgate Press liftgate

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button 1 x button 2 x release 1 x release 1 x

Driver door X

Passenger door X X

Sliding door on driver side X X

Sliding door on passenger side X X X

Rear door/liftgate X X

Configuration 3
To unlock the Press unlock Press unlock Press liftgate Press liftgate
button 1 x button 2 x release 1 x release 1 x

Driver door X X

Passenger door X

Sliding door on driver side X X

Sliding door on passenger side X X

Rear door/liftgate X X X

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Body Lesson 5 – Body and Paint

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

Driver door X

Passenger door X X

Sliding door on driver side X X

Sliding door on passenger side X X

Rear door/liftgate X X X

Configuration 5
To unlock the Press unlock Press unlock Press liftgate Press liftgate

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button 1 x button 2 x release 1 x release 1 x

Driver door X X X

Passenger door X X X

Sliding door on driver side X X X

Sliding door on passenger side X X X

Rear door/liftgate X X

Configuration 6
To unlock the Press unlock Press unlock Press liftgate Press liftgate
button 1 x button 2 x release 1 x release 1 x

Driver door X X

Passenger door X

Sliding door on driver side X X X

Sliding door on passenger side X X

Rear door/liftgate X X X

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Lesson 5 – Body and Paint Body

SRS

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1 MS-CAN data bus Side air bag (driver side, passenger side with
7
2 Gateway (GEM) separate seat only)

3 ISO -9141 Seat belt tensioner (driver side, passenger side

8
with separate seat only)
4 RCM
Crash sensors (driver and passenger side, with
5 Driver air bag module 9
side air bags only)
6 Passenger air bag module

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Body Lesson 5 – Body and Paint

MS-CAN output signals:

1. RCM > Instrument cluster > Air bag indicator

The Transit 2006 (03/2006-) is equipped with a driver

air bag as standard. The volume of the passenger air bag
(optional) has been increased to 120 liters.

Side air curtains are available as an option for the front

seats in conjunction with belt tensioners (with separate
passenger seat only)

The RCM is installed under the instrument panel directly

next to the GEM. It is connected via the MS-CAN data
bus.

Diagnosis is performed via a separate ISO 9141 line.

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The RCM may be reused up to five times.

The crash sensors for the side air bags are installed in
the footwell near the B pillars and can be reused
following detonation.

The air bags/belt tensioners are triggered using direct

voltage.

ISOfix points are installed for the second seat row on

some models. These are marked by an indication
embroidered into the seat covering.

78 (G542751) Service Training

 List of Abbreviations

A/C Air Conditioning IFS Inertia Fuel Shutoff

ABS Anti-lock Brake System KS Knock Sensor

AM Amplitude Modulation LED Light Emitting Diode

APP Accelerator Pedal Position LHD Left-hand Drive

BPP Brake Pedal Position LPG Liquefied Petroleum Gas

BTCS Brake Traction Control System MIL Malfunction Indicator Lamp

CAN Controller Area Network OASIS On-line Automotive Service Information

System
CD Compact Disc
PATS Passive Anti-theft System
CKP Crankshaft Position

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PCM Powertrain Control Module
CPP Clutch Pedal Position
PVC Polyvinyl Chloride
DLC Data Link Connector
RCM Restraints Control Module
DTC Diagnostic Trouble Code
RHD Right-hand Drive
Diagnostic Trouble Code- WDS
ROM Read Only Memory
EBA Emergency Brake Assist
SRS Supplemental Restraint System
ECT Engine Coolant Temperature
VIN Vehicle Identification Number
EGR Exhaust Gas Recirculation
VSS Vehicle Speed Sensor
EOBD European On-board Diagnostic
WDS Worldwide Diagnostic System
EOP Engine Oil Pressure

FM Frequency Modulation

FPDM Fuel Pump Driver Module

GEM Generic Electronic Module

GPS Global Positioning System

GSM Global System For Mobile Communication

HCU Hydraulic Control Unit

Service Training 79