2006 FORD TRANSIT engine

Front End Accessory drive Assembly on 2.2l Diesel Engine
Pulley and Belt Layout on 2.2l Diesel Engine
DescriptionItem
Idler1
Idler2
Alternator3
Power Steering Pump4
Crankshaft Pulley5
Auto Tensioner6
Compressor7
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
3 Powertrain
807123456E74220

3.4 Electronic Engine Controls
CAUTION: Do not make any
additional connections to the
electrical circuits associated with
the engine management system
NOTE: It is not necessary to disconnect or
remove engine management modules.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
3 Powertrain
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3.5 Clutch
The manufacturer does not offer the option of a
reinforced clutch system. The axle ratio available
is dependent on the weight of the specified donor
vehicle.
It is necessary to select the appropriate drive,
engine, gear ratio, gross vehicle mass, gross train
mass, axle plates and payloads of the base
vehicle to match the customers order.
Where possible make sure that the base vehicle
is ordered with plant fit options
NOTE: For further information please contact
your local National Sales Company representative,
or Local Ford Dealer. If they are unable to help
you then please contact the Vehicle Converter
Advisory Service at [email protected].
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
3 Powertrain
82

3.6 Manual Transmission
The following manual transmissions are available
for diesel engines dependent on the drive.
•Front Wheel Drive vehicles
–VXT 75 transmission
•Rear Wheel Drive vehicles
–MT 82 transmission or
–MT 75 transmission
The following manual transmission is available
for gasoline engines .
•Rear Wheel Drive vehicles
–MT 75 transmission
WARNING: Do not reroute external
transmission gear shift cables

VXT 75 - 5 Speed Manual Front Wheel Drive Transmission
VXT75 Ratio of Single Gears
RatioGear
3.8001
2.1402
1.3503
0.9204
0.6705
3.750Reverse
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
3 Powertrain
83E76032

3.7 Exhaust System
3.7.1 Extensions and Optional
Exhausts
CAUTIONS:
Non-standard systems must be
tested for engine back pressure and
all legal compliance (noise and
emissions)
Make sure that for any pipes that
require bending, the radius of the
bend is minimum 2.5x tube diameter
Make sure that sufficient clearance
is maintained for all driving
conditions to all hot and moving
components.
NOTE: Where possible all pipe connections
should be designed so that the gas flows from
smaller to larger diameter pipes
For some territories a side exhaust is available as
a Special Vehicle Option on Chassis Cab.

Exhaust Pipe Design Principles
DescriptionItem
diameterd
radius = 2.5dr
3.7.2 Exhaust Pipes and Supports
CAUTIONS:
Maintain the original set-up and heat
shields
Do not position any plastic, rubber
or any other components closer to
the down pipe, catalytic converter
that the original Ford design (100mm
minimum).
3.7.3 Exhaust Heat Shields
Low Floor Exhaust Heat Shields
•Catalytic converters, in particular, operate at
high temperatures
•Ensure existing shields are maintained
•Add further shields over exhaust system as
necessary to avoid fire risk.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
3 Powertrain
86E74569rd

4.3 Charging System
4.3.1 General Information and
Specific Warnings
The Transit electrical system is a 12-Volt supply
with a negative earth return. The alternator and
battery equipment used as standard are
designed for normal operations with the type of
engine fitted. Higher capacity batteries are
available as standard production options and
special vehicle options. Before installing additional
electrical equipment check that the battery
capacity, harness load capability, and alternator
output are suitable for the extra load.
The battery capacity and charge available from
the alternator must be adequate to ensure
engine cranking in unfavorable climatic conditions
but excessive battery capacity could damage
the starter motor.
The Transit utilizes multiplexed vehicle electronics
- it is recommended that the appropriate Ford
proprietary accessory systems are used.
Inappropriate or incorrect connection of
additional equipment could cause mis-operation,
or damage to the vehicle, and so invalidate any
warranty.
Additional connection points are provided
specifically for customer use (except M1 and M2
Bus), and are located on the outside of the
driver's seat base.
Do not jump-start the vehicle directly from the
battery. Use designated jump-start points. Refer
to the owners literature.
4.3.2 Power Management
Settings
There are four Power Management Settings
available:
•Factory
•Transport
•Normal
•Crash
Factory and Transport modes are only active
with ignition off; with ignition on, the vehicle
operates with full functionality. When in Transport
mode, the interior lights, clocks, and power
locking and alarms (where fitted) do not work.
It is possible to switch from Transport Mode to
Normal Mode without the use of any ancillary
equipment, but not vice versa. To change mode,
the brake pedal must be depressed five times,
and the hazard warning switch operated twice
(in any combination) within 10 seconds.
WARNING: It is not possible to return
the transport setting without using
the vehicle's diagnostics.
At the end of production, the vehicle is
configured to the transport setting to minimize
power consumption. As part of the Pre Delivery
Inspection process at the Ford dealership, the
vehicle is reconfigured to normal operation.
4.3.3 Electrical Conversions
Operator requirements for additional and
specialised electrical equipment varies. The
vehicle converter/modifier must, therefore,
consider the following points when designing the
installation:
•Legality and regulatory conformity of the base
vehicle.
•Drive-ability and serviceability of the base
vehicle.
•The effect of regulations governing the
proposed conversion including National
Legislation in the country of sale.
•The method of integrating the circuit into the
base vehicle.
•No additional circuits are to be run alongside
the electrical circuits (shown in blue in the
figure below) associated with the
Management System (shown in green in the
figure below), due to the possible Electro
Motive Force (EMF) effect on the circuits.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
4 Electrical
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Electrical circuits associated with Management System
•The base vehicle will be equipped with a single
or dual battery system (with battery disconnect
switch). Additional batteries can be fitted in
conjunction with a battery disconnect switch
(cut-off relay), described in the section Battery
and Cables.
•When auxiliary electrical systems are added
to the vehicle, it is recommended that the
additional circuits are designed to be used with
the Special Vehicle Option Auxiliary Fuse Box
and / or the Link Harnesses, to maintain the
integrity of the electrical system.
Refer to: 4.13 Fuses and Relays (page 119).
•The materials and installation must meet the
quality standards described in this section.
•Any additional equipment or components must
be designed such that they have no Electro
Motive Force effect on the vehicle.
•The alternator and Engine Management
System [EMS, also referred to as Powertrain
Control Module (PCM)] are interdependent.
•The alternator should not be used as a source
for a conventional D+ signal.
Refer to: 4.14 Special Conversions (page 131).
•Take special care with the routing of existing
electrical looms within the vehicle to avoid
damage when fitting additional equipment.
WARNING: The fitting of voltage
boosters or other devices to
enhance alternator output are not
allowed. The fitting of such devices
will not only invalidate vehicle
warranties, but could damage either,
or both, the alternator and Engine
Management System or Powertrain
Control Module (PCM), and possibly
affect vehicle legal compliance.
Check local legislation.
Please see below the note concerning installation
of equipment containing an electric motor.
Where vehicles are equipped with twin battery
system, no additional connections should be
made to the terminal posts of the start relevant
battery. Further connections should only be made
via the customer connection point.
When an additional battery is fitted, this must be
connected to the appropriate battery.
Refer to: 4.4 Battery and Cables (page 98).
Disconnect all batteries, including earth, and the
alternator multi-plug prior to using welding or
cutting equipment and before working on any
electrical installations.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
4 Electrical
96E84706

•Before disconnecting the battery, check
availability of radio key code.
•Fuses – when auxiliary electrical systems are
to be added to the vehicle it is mandatory that
the additional circuit design includes the
necessary fuses.
•The Special Vehicle Option auxiliary fuse box
is recommended.
Refer to: 4.13 Fuses and Relays (page 119).
4.3.4 Fitting of Equipment
Containing an Electric Motor
WARNINGS:
When equipment containing an
electrical motor is connected, it
must be connected via a blocking
diode or relay to prevent “back
Electro Motive Force (EMF)” being
applied to the auxiliary terminal.
When electric motors are to be
fitted, account must be taken of the
potentially high currents that a
motor can draw.
CAUTION: The following must be
observed:
•All motors must be driven via relays with
contacts rated at least 3 times the maximum
rated current of the motor.
•All motor supply circuits must be individually
fused with the proper fuse rating for the
motor.
•All power wiring must be rated for at least 3
times the rating of the motor and installed as
far away as possible from any existing vehicle
wiring.
•All motors fitted should be fully suppressed to
ensure electrical interference does not affect
the vehicle systems.
•Add EMC emissions statement to CE
approval.
4.3.5 Vehicle Electrical Capacity
- Alternator
WARNING: Do not cut into the
alternator wires or use the
alternator as a source to obtain a
'D+ Signal'
An engine run signal is available from the Central
Junction Box by installing a T-piece jumper
harness (Ford Part Number 6C1V-14A411-F_).
Refer to: 4.14 Special Conversions (page 131).
4.3.6 Charge Balance Guidelines
The base vehicle is fitted with a 150A alternator.
It is recommended to conduct a charge balance
calculation in case the conversion comprises a
high number of electrical consumers or high
electrical consumption is expected.
4.3.7 Circuit Diagrams
For circuit diagrams for Auxiliary Fuse Box
Connections and Standard Ford relays.
Refer to: 4.13 Fuses and Relays (page 119).
Full vehicle wiring and circuit diagrams are in the
Ford Workshop Manual.
NOTE: For further information please contact
your local National Sales Company
representative, or Local Ford Dealer. If they are
unable to help you then please contact the
Vehicle Converter Advisory Service at
[email protected].
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
4 Electrical
97