Download 2005 Escape Hybrid

Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstations 1 - 3
Workstation 1
Written– Escape/Mariner
Component Location and Operation
Workstation 2
Hands On – Fusion/Milan
Component Location and Operation
Use CMT Active
Student Program
shortcut to launch the
service information.
Workstation 3
Written
High Voltage Safety Quiz
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 1
DIRECTIONS: Use the 2008 Escape Hybrid service
publications to answer the following questions.
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 1
1. List the PSCM connector number that contains
the connector pin for circuit CBP35, and where
is the connector located?

C 2231A is located at the lower left of the
instrument panel
Hybrid Vehicle Operation and Diagnosis Training
Hybrid Vehicle Operation and Diagnosis Training
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 1
2. List all of the connectors that run to the DC/DC
converter. Also list the location of the converter,
and specify which connector contains the HV
interlock circuits.
 C 1457a, C 1457b, C 1457c, C 1457d. It is
located in the right front engine compartment
behind coolant reservoir. Interlock circuits
are located in C 1457d
Hybrid Vehicle Operation and Diagnosis Training
Hybrid Vehicle Operation and Diagnosis Training
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 1
3. What cell in the Wiring Diagrams contains the
safety warnings for the high voltage system?
 In the Introduction Cell 3-6
Hybrid Vehicle Operation and Diagnosis Training
Hybrid Vehicle Operation and Diagnosis Training
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 1
4. Where is the TCM located, and which TCM
connector contains the Hybrid Transaxle
Generator Shutdown circuit? Also list the pin,
circuit number, and color of the wire for the
circuit.
 The TCM is located on the left side of the
engine compartment near the battery
junction box (inside eCVT). The connector
that contains the circuit is C1458b, it is pin 10
of the connector, the circuit # is CYT07 (VT)
Hybrid Vehicle Operation and Diagnosis Training
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 1
5. A 2008 Escape Hybrid is brought to you with a
no start condition. You believe there is an open
circuit between the TBCM and the High Voltage
Cutoff Switch. What circuit, should be tested
between which connectors to verify your
diagnosis?
 Circuit CYB15 (GN) between C4227A and
C4229
Hybrid Vehicle Operation and Diagnosis Training
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 1
6. What is the function of the Engine Cranking
Diagnostic Mode?
 The engine cranking diagnostic mode is a
powertrain control module (PCM) strategy
which is separate from the normal operating
strategy. It allows the engine to crank in a
similar fashion as a conventional vehicle with
the fuel disabled.
Hybrid Vehicle Operation and Diagnosis Training
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 1
7. What indicates that the vehicle is in the Engine
Cranking Diagnostic Mode?
 The Hazard Indicator (Red Triangle) flashes
once per second when the gear selector is
shifted to the Park position.
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 1
8. What indicates that the vehicle is in the Engine
Running Diagnostic Mode?
 The Powertrain Malfunction Indicator
(Wrench) flashes once per second when the
gear selector is shifted to the Park position.
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 2
DIRECTIONS: Go to the classroom vehicle. Locate
the components that perform the functions listed in the
right hand column. List the name of the component in
the center column, and the tag letter/number that is
attached to the component on the vehicle in the left
column.
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 2
Component Name
HVBP
Tag
???
Component Function
Stores high voltage energy
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 2
Component Name
Component Function
Electrical A/C Compressor A high voltage low-amperage pump for
passenger comfort
Tag
???
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 2
Component Name
Brake Booster
Tag
???
Component Function
Contains vacuum solenoids
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 2
Component Name
Electric Coolant Pump
Tag
???
Component Function
When the driver requests cabin heating
and the engine is not running, this
component is commanded on.
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 2
Component Name
DC/DC Converter
Tag
???
Component Function
Converts high voltage to low voltage
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 2
Component Name
Vacuum Pump
Tag
???
Component Function
Provides vacuum when the gasoline
engine is not running
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 2
Component Name
Component Function
Service Disconnect Switch Prior to performing any HV service
procedures this component must be
removed.
Tag
???
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 2
Component Name
RCM
Tag
???
Component Function
Cuts off high voltage and fuel in an
emergency situation
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 2
Component Name
BEC
Tag
???
Component Function
Contains a serviceable high-voltage lowcurrent fuse
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 2
Component Name
DC/AC Inverter
Tag
???
Component Function
Converts DC voltage to AC Voltage
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 2
Component Name
110 volt plug
Tag
???
Component Function
Provides a 110 volt AC power source
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 2
Component Name
BPSM
Tag
???
Component Function
HV current is always present at this
component, even with the service
disconnect switch removed
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 2
Component Name
EPAS
Tag
???
Component Function
Provides steering assist
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 2
Component Name
BECM
Tag
???
Component Function
Contains most strategies for the high
voltage system
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 2
Component Name
ME Coolant Pump
Tag
???
Component Function
Provides coolant flow to various electronic
components
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 2
Component Name
HVBP Cooling Fan
Tag
???
Component Function
Provides airflow to cool the HVBP
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 2
Component Name
eCVT
Tag
???
Component Function
Splits power for Traction Motor and
Gasoline Engine
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 2
Component Name
Brake Pedal Simulator
Tag
???
Component Function
Simulates Pedal Feel to the driver
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 2
2. List the steps required to depower the HVBP?
 The ignition must be turned off
 The service disconnect switch must be removed
then wait for 5 minute
 Store service disconnect switch where it cannot
be accidently reinstalled
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 3 – Safety Quiz
Objective: To describe the emergency instructions
provided in this section.
DIRECTIONS: Using the High Voltage Safety
information and the Emergency Response Guide in
the Appendix, find the correct answers for the
questions below.
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Safety Quiz
1.
What color are high voltage cables on
hybrid vehicles?
ORANGE
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Safety Quiz
2.
When performing diagnostic or service on
the high voltage system of a hybrid
vehicle, what personal items must you
remove?
Rings, Watches, Jewelry, other metallic
items (coins)
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Safety Quiz
3.
What clothing material is recommended
for working around high voltage?
Cotton
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Safety Quiz
4.
A.
B.
C.
D.
Identify the hazard that is associated with
high voltage.
Electric shock
Blast
Arcing
All of the above
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Safety Quiz
5.
A.
B.
C.
D.
Choose the cause that usually leads to
electrical accidents.
Unsafe acts by workers
Unsafe work areas
Unsafe equipment or installation
All of the above
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Safety Quiz
Match the classes of fire with the
descriptions shown on the right.
3 Class A
1. Chemical fire
1 Class B
2. Electrical fire
2 Class C
3. Typical fire
6.
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Safety Quiz
7.
Review the accident prevention steps in
this student guide. List what you feel are
the three most important steps of those
presented.
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Safety Quiz
8.
A.
B.
C.
D.
Which of the following types of fire
extinguisher should never be used on an
electrical fire?
Regular dry chemical
Multi-purpose dry chemical
Carbon dioxide
Water
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Safety Quiz
9.
A.
B.
If a person is in contact with an electrical
current, you should break the electrical
connection as quickly as possible without
exposing yourself to the current.
True
False
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Safety Quiz
10.

What is the first thing you should do if
you see someone that has been disabled by
an electric shock?
Call for help
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Safety Quiz
11.

What should you use to move a person
that is in unconscious and in contact with
a high voltage wire?
A fiberglass reach pole
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Safety Quiz
12.
An emergency responder calls and wants
to know how to determine by a VIN if a
vehicle is a hybrid. What VIN
letters/numbers will provide that
information?

VIN positions 5,6, and 7 will provide that
information (POL = Fusion Hybrid, MOL=
Milan Hybrid).
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Safety Quiz
13.

At what temperature will the high-voltage
battery be disabled when the key is in the
ON position?
600 C (1400 F)
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Safety Quiz
14.
If a hybrid vehicle is submerged
underwater, how can you tell when the
battery has been fully discharged?

The battery will be fully discharged
when the fizzing or bubbling from the
battery pack has stopped
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Safety Quiz
15.
If a hybrid vehicle is on fire, what type of
vapors might be released from the battery
pack?

Hydrogen
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstations 4 - 6
Workstation 5
Hands On – Fusion/Milan
High Voltages Service
Workstation 4
Escape/Mariner Brake Service Procedures
WARNING: THESERVICE DISCONNECT SWITCH
MUST BE REMOVED WHENEVER THE BEC
COVER IS REMOVED
Use CMT Active
Student Program
shortcut to launch the
service information.
Workstation 6
Diagnosis and Service Procedures