alternator FORD TRANSIT 2006 7.G Body And Equipment Mounting Section Manual

3.7Exhaust System..........................86
3.7.1Extensions and Optional Exhausts....
86
3.7.2Exhaust Pipes and Supports.............86
3.7.3Exhaust Heat Shields..........................86
3.8Fuel System.................................88
4 Electrical
4.1Communications Network..........90
4.1.1CAN-Bus System Description and
Interface................................................90
4.1.2Central Junction Box (CJB)................91
4.1.3Circuit Diagram....................................93
4.2Module Communications
Network—Specifications.............94
4.2.1Circit Diagram......................................94
4.3Charging System.........................95
4.3.1General Information and Specific
Warnings...............................................95
4.3.2Power Management Settings...........95
4.3.3Electrical Conversions........................95
4.3.4Fitting of Equipment Containing an
Electric Motor.......................................97
4.3.5Vehicle Electrical Capacity -
Alternator..............................................97
4.3.6Charge Balance Guidelines...............97
4.3.7Circuit Diagrams..................................97
4.4Battery and Cables.....................98
4.4.1Battery Information.............................98
4.4.2Generator and Alternator.................103
4.5Climate Control System.............106
4.6Instrument Cluster.....................107
4.7Horn...........................................108
4.8Tachograph................................109
4.8.1Legislation...........................................109
4.8.2Tachograph Mounting.......................110
4.9Information and Entertainment
System - General
Information—Specifications.......112
4.9.1Radio Connector................................112
4.9.2Possible Accessories.........................113
4.10Cellular Phone............................115
4.11Exterior Lighting.........................116
4.11.1Reversing Lamps...............................116
4.11.2Additional External Lamps................116
4.11.3Lamps – Hazard / Direction
Indication..............................................117
4.11.4Lamps – Front and Rear Fog Lights....
117
4.11.5Lamps for Wide Vehicles...................117
4.11.6Electrically operated Door Mirrors....
117
4.12Interior Lighting..........................118
4.12.1Additional Internal Lamps .................118
4.12.2Additional 'Theatre Lighting' for rear
of vehicle interior................................118
4.13Fuses and Relays.......................119
4.13.1Wiring Specification............................119
4.13.2Auxiliary Fuses, Fuse Box and Relays
(Fuses - Standard).............................119
4.13.3Customer Connection Points..........120
4.13.4Special Vehicle Option Auxiliary Fuse
Box........................................................121
4.13.5Additional Ignition, Instrument Panel
Illumination and Air Conditioning On
Signals.................................................124
4.13.6Relays and Switches.........................127
4.13.7Windscreen wipers...........................130
4.14Special Conversions..................131
4.14.1Vehicle Speed Output (Signal).........131
4.14.2Engine Run Signal (D+ Alternative)....
132
4.14.3Connectors.........................................133
4.14.4Installation and Routing Guides.......134
4.14.5Electrics for Tow bar.........................136
4.14.6Ground Points....................................140
4.14.7Special Vehicle Options (SVO) and
Aftermarket Kits.................................146
4.14.8Additional Vehicle Signals / Features..
147
4.14.9Engine RPM (Revs Per Minute) Speed
Controller.............................................157
4.14.10Adding Connectors, Terminals and
Wiring...................................................162
5 Body and Paint
5.1Body...........................................175
5.1.1Body Structures - General
Information..........................................175
5.1.2Back Panel Removal.........................177
5.1.3Integrated Bodies and Conversions...
177
5.1.4Chassis Cab........................................179
5.1.5Cab Van Floor.....................................185
5.1.6Hydraulic Lifting Equipment for Van,
Bus, Kombi and Chassis Cab..........186
5.1.7Partitions (Bulkhead) - Driver and
Front Passenger(s) Protection on Van,
Bus and Kombi..................................192
5.1.8Racking Systems...............................194
5.1.9Front End Integrity for Cooling, Crash,
Aerodynamics and Lighting.............198
5.1.10Tipper Bodies.....................................199
5.1.11Tank and Dry Bulk Carriers...............199
5.2Body System - General
Information—Specifications......200
5.2.1Van Floor - Load Compartment Tie
Downs for Van ,Bus and Kombi.....200
5.3Body Closures..........................203
5.3.1Load Compartment Interior Lining....
203
5.3.2Security, Anti Theft and Locking
System Security ...............................203
5.4Rear View Mirrors.....................208
5.4.1Mirrors for Wide Vehicles.................208
5.5Seats.........................................209
5.5.1Rear Seat Fixings Positions - Kombi...
209
5.5.2Heated Seats.....................................210
5.6Glass, Frames and Mechanisms...
211
5.6.1Rear Windows....................................211
Table of Contents
4

Dry Freight
Refer to: 1.14 (page 34).
Flat Bed /
Platform
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Refer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions, Hydraulic Lifting Equipment for Van, Bus, Kombi
and Chassis Cab).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 1.14 (page 34).
Float / Drop-
side
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Refer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions, Hydraulic Lifting Equipment for Van, Bus, Kombi
and Chassis Cab).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 4.4 Battery and Cables (page 98).
Tipper
(Also Generator and Alternator).
Refer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Chassis Cab & Tipper).
Refer to: 1.14 (page 34).
Box Van
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Refer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions, Hydraulic Lifting Equipment for Van, Bus, Kombi
and Chassis Cab).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 1.14 (page 34).
Curtain-side
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Refer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions, Hydraulic Lifting Equipment for Van, Bus, Kombi
and Chassis Cab).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 1.14 (page 34).
Pantechnicon
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Refer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions, Hydraulic Lifting Equipment for Van, Bus, Kombi
and Chassis Cab).
Refer to: 4.11 Exterior Lighting (page 116).
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
15

Dry Freight
Refer to: 1.14 (page 34).
Money
Carriers
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Refer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Roof Ventilation).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Refuse
Collection
Refer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Chassis Cab).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
DemountableRefer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Chassis Cab).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Vehicle Trans-
porters
Refer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Chassis Cab).
Refer to: 4.11 Exterior Lighting (page 116).
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
16

Passenger Carrying
Refer to: 5.1 Body (page 175).
(Hydraulic Lifting Equipment for Van, Bus, Kombi and Chassis Cab).
Mini Bus
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 4.12 Interior Lighting (page 118).
Refer to: 5.5 Seats (page 209).
Refer to: 5.6 Glass, Frames and Mechanisms (page 211).
Refer to: 5.7 Roof Opening Panel (page 214).
(Roof Ventilation).
Refer to: 5.8 Air Bag Supplemental Restraint System (SRS) (page 218).
Vocational Conversion
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Mobile Work-
shops
Refer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions, Hydraulic Lifting Equipment for Van, Bus, Kombi
and Chassis Cab, Racking System).
Refer to: 5.7 Roof Opening Panel (page 214).
(Roof Racks).
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Mobile Shops
/ Offices
Refer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions, Hydraulic Lifting Equipment for Van, Bus, Kombi
and Chassis Cab, Racking System).
Refer to: 5.7 Roof Opening Panel (page 214).
(Roof Racks).
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Glass
CarryingRefer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Racking System).
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Racking
ConversionsRefer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Racking System).
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Recovery
Vehicles
Refer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Chassis Cab).
Refer to: 5.11 Frame and Body Mounting (page 222).
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
18

Refrigerated Vehicles
Refer to: 1.8 End of Life Vehicle (ELV) Directive (page 26).
Van Conver-
sion
Refer to: 1.14 (page 34).
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Refer to: 4.5 Climate Control System (page 106).
Refer to: 4.13 Fuses and Relays (page 119).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions).
Refer to: 5.7 Roof Opening Panel (page 214).
(Roof Racks).
Refer to: 1.8 End of Life Vehicle (ELV) Directive (page 26).
Box Body
Conversion
Refer to: 1.14 (page 34).
Refer to: 4.4 Battery and Cables (page 98).
(Also generator and Alternator).
Refer to: 4.5 Climate Control System (page 106).
Refer to: 4.13 Fuses and Relays (page 119).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions).
Refer to: 5.7 Roof Opening Panel (page 214).
(Roof Racks).
Refer to: 3.3 Accessory Drive (page 77).Compressor
Installation
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
20

Emergency Services
Refer to: 1.14 (page 34).
Ambulance -
Front Line
Refer to: 3.2 Engine Cooling (page 75).
(Airflow Restrictions).
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 4.12 Interior Lighting (page 118).
Refer to: 4.13 Fuses and Relays (page 119).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions, Hydraulic Lifting Equipment for Van, Bus, Kombi
and Chassis Cab).
Refer to: 5.5 Seats (page 209).
Refer to: 5.8 Air Bag Supplemental Restraint System (SRS) (page 218).
Refer to: 1.14 (page 34).
Fire Brigade
Refer to: 3.2 Engine Cooling (page 75).
(Airflow Restrictions).
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 4.12 Interior Lighting (page 118).
Refer to: 4.13 Fuses and Relays (page 119).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions, Hydraulic Lifting Equipment for Van, Bus, Kombi
and Chassis Cab).
Refer to: 5.5 Seats (page 209).
Refer to: 5.8 Air Bag Supplemental Restraint System (SRS) (page 218).
Refer to: 1.14 (page 34).
Armed
Forces
Refer to: 3.2 Engine Cooling (page 75).
(Airflow Restrictions).
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 4.12 Interior Lighting (page 118).
Refer to: 4.13 Fuses and Relays (page 119).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions, Hydraulic Lifting Equipment for Van, Bus, Kombi
and Chassis Cab).
Refer to: 5.5 Seats (page 209).
Refer to: 5.8 Air Bag Supplemental Restraint System (SRS) (page 218).
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
21

Emergency Services
Refer to: 1.14 (page 34).
Police
Refer to: 3.2 Engine Cooling (page 75).
(Airflow Restrictions).
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 4.12 Interior Lighting (page 118).
Refer to: 4.13 Fuses and Relays (page 119).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions, Hydraulic Lifting Equipment for Van, Bus, Kombi
and Chassis Cab).
Refer to: 5.5 Seats (page 209).
Refer to: 5.8 Air Bag Supplemental Restraint System (SRS) (page 218).
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
22

Front End Accessory Drive Assembly on 2.4l Diesel Engine
Pulley and Belt Layout on 2.4l Diesel Engine
DescriptionItem
Power Steering Pump1
Fan2
Idler3
Vacuum Pump4
Coolant Pump5
Compressor (may be replace by ancillary unit)6
Crankshaft Pulley7
Alternator8
Auto Tensioner9
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
3 Powertrain
78123456789E74218

Front End accessory Drive Assembly on 2.3l Petrol Engine
Pulley and Belt Layout on 2.3l Petrol Engine
DescriptionItem
Alternator1
Idler2
Coolant Pump3
Power Steering Pump4
Compressor (may be replaced by ancillary unit)5
Crankshaft Pulley6
Auto Tensioner7
3.3.2 Front End Accessory Drive
2.2l Diesel
CAUTION: Do not fit an additional
front end accessory drive to a
vehicle already equipped with and
air-conditioning compressor.
When engineering and installing a new front end
accessory drive, i.e. belt drive of the crankshaft
pulley, the longitudinal alignment must be within
+/- 0.25mm and angular within +/- 0.33°.
The maximum power that is available for front
end accessory drive applications, in lieu of the
air conditioning compressor is 26Nm torque at
any engine speed up to a maximum of 6kW.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
3 Powertrain
79E742191234567

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