Figure 13.11 Series mode operation

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Hybrid and Alternative Fuel VehiclesJames D. Halderman and Tony Martin

Figure 13.1 The Ford Escape hybrid looks very similar to a conventional Ford Escape except for the hybrid emblems and several other details.




Figure 13.2 The Mariner Hybrid SUV.The Ford/Mercury hybrids can be identified by the battery vent located in the left rear quarter window.




Figure 13.3 The dash display shows when the vehicle is being propelled using the electric motor alone, shown by the green area on the speedometer and labeled “EV.” The gauge on the left of the tachometer indicates whether the electrical system is being charged by the gasoline engine or regenerative braking and when the electric motor is being used to assist the gasoline engine during acceleration.




Figure 13.4 The Ford/Mercury hybrid SUV, showing the major components and where they are located.




Figure 13.5 The 2.3-liter four-cylinder all-aluminum ICE used in the Ford Escape and the Mercury Mariner hybrids uses a modified Atkinson cycle design to achieve maximum efficiency.




Figure 13.6 The Ford/Mercury 2.3-liter ICE is also equipped with an active engine mount that effectively dampens engine vibration during start/stop. The parts involved include a control solenoid, the active engine mount and a vacuum reservoir tank.




Figure 13.7 The Atkinson cycle delays the closing of the intake valve, which reduces the pumping losses on the compression stroke, yet results in a greater amount of expansion on the power stroke compared to a conventional (Otto cycle) gasoline engine design.




Figure 13.8 The cam lobe on the left is from a Ford/Mercury hybrid and shows the longer-duration intake cam lobe as compared to the intake cam lobe from a conventional gasoline engine on the right.




Figure 13.9 The air inlet to the ICE on the Ford/Mercury hybrid electric vehicle contains a charcoal filter that is used to trap and hold hydrocarbons and keep them from being released to the atmosphere.




Figure 13.10 A cutaway of a Ford Escape/Mercury Mariner hybrid transaxle, which includes the traction motor and the generator motor.




Figure 13.11 Series mode operation.




Figure 13.12 Positive split mode operation.




Figure 13.13 Ford Escape system chart showing the various sensors and components. The functions are distributed among engine, transaxle, and brake control modules. The VSC controls approximately 200 functions with about 600 signals between components.




Figure 13.14 The transaxle is used to blend the torque from the gasoline engine and the traction motor together. The generator motor controls sun gear rotation; therefore, the effective gear ratio can vary anywhere from reduction all the way to overdrive. Thus, the eCVT is a continuously variable automatic transmission.




Figure 13.15 The high-voltage (traction) battery pack is located under the cargo floor area.




Figure 13.16 The battery pack from a Ford/Mercury hybrid showing the cooling ducts at the bottom.




Figure 13.17 The traction battery cooling unit is located on the driver’s side of the cargo area and houses the battery zone A/C evaporator (labeled as “A”).




Figure 13.18 A button is located behind a cover on the driver’s side kick panel. By depressing this button, the 12-volt battery will charge the highvoltage batteries through the DC-DC converter.




Figure 13.19 The 12-volt auxiliary battery is located under the hood on the driver’s side, as shown.




Figure 13.20 The cooling system for the transaxle also cools the DC-DC converter.




Figure 13.21 The Ford/Mercury hybrid uses an electric power steering assembly.




Figure 13.22 The electric power steering assembly partially disassembled showing the DC motor and electrical connector for the torque sensor.




Figure 13.23 The electric power steering torque sensor housing with connector.




Figure 13.24 The buffer zone is an area that should be marked with cones to warn others to avoid the area because of a high-voltage danger.




Figure 13.25 To depower the HV system, start by rotating the service disconnect plug CCW to the UNLOCK position.




Figure 13.26 The service disconnect plug should be lifted and placed back in the SERVICE SHIPPING position before servicing the HV system.




Figure 13.27 This fiberglass pole/steel hook assembly is required equipment for Ford dealerships that service Ford/Mercury HEVs.




Figure 13.28 Using a pressure bleeder to bleed the brakes.




Figure 13.29 The battery zone air filter must be serviced regularly to prevent overheating of the high-voltage battery.

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Figure 13.11 Series mode operation