Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstations 4 - 6 Workstation 4 Escape/Mariner Brake Service Procedures Escape/Mariner Brake

Hybrid Vehicle Operation and Diagnosis TrainingHybrid Vehicle Operation and Diagnosis Training

Lesson OneWorkstations 4 - 6

Workstation 4Workstation 4 Escape/Mariner Brake Service Procedures Escape/Mariner Brake Service Procedures

Workstation 5Workstation 5Hands On – Fusion/MilanHands On – Fusion/Milan

High Voltages Service High Voltages Service

WARNING: THESERVICE DISCONNECT SWITCH WARNING: THESERVICE DISCONNECT SWITCH MUST BE REMOVED WHENEVER THE BEC MUST BE REMOVED WHENEVER THE BEC

COVER IS REMOVEDCOVER IS REMOVED

Workstation 6Workstation 6Diagnosis and Service ProceduresDiagnosis and Service Procedures

Use CMT Active Student Program

shortcut to launch the service information.


Lesson OneWorkstation 4

DIRECTIONS: View the Hybrid Brake Service View the Hybrid Brake Service video, then use the video and service publications to video, then use the video and service publications to answer the questions below.answer the questions below.



1.1. A 2008 Escape Hybrid is brought to your facility A 2008 Escape Hybrid is brought to your facility with a customer request for brake service. with a customer request for brake service. According to service publications, what actions According to service publications, what actions can be taken to disable the intermittent brake can be taken to disable the intermittent brake pad application?pad application?

The low-voltage battery negative cable The low-voltage battery negative cable and fuses 9 and 18 from the battery and fuses 9 and 18 from the battery junction box (Section 206-03 Brake junction box (Section 206-03 Brake Pads Hybrid in WSM) Pads Hybrid in WSM)




2.2. According to service publications, the rear brake According to service publications, the rear brake pads will wear at approximately what rate when pads will wear at approximately what rate when compared to the front brake pads? compared to the front brake pads?

The rear brake pads will wear about twice as The rear brake pads will wear about twice as fast as the front (Section 206-03 Brake Pads - fast as the front (Section 206-03 Brake Pads - Hybrid in WSM)Hybrid in WSM)




3.3. When checking the brake fluid in the hybrid When checking the brake fluid in the hybrid master cylinder, what position must the ignition master cylinder, what position must the ignition switch be in? switch be in?

Ignition ON (Section 206-00 Brake System Ignition ON (Section 206-00 Brake System Bleeding – Hybrid)Bleeding – Hybrid)




4.4. What component has the function of giving the What component has the function of giving the driver the same feel as pushing on a regular driver the same feel as pushing on a regular brake pedal, and where is this component found?brake pedal, and where is this component found?

The component is the Brake Feel Emulator The component is the Brake Feel Emulator and it is part of the Actuation Control Unit and it is part of the Actuation Control Unit (ACU) - (1:19 of video)(ACU) - (1:19 of video)



5.5. At what speeds does the regenerative braking At what speeds does the regenerative braking slow the vehicle during normal application of slow the vehicle during normal application of the brakes?the brakes?

Between 70 and 5 mph - - (1:46 of video)Between 70 and 5 mph - - (1:46 of video)



6.6. When does the HECU cycle the brake pads?When does the HECU cycle the brake pads?

A.A. When door is unlocked with remoteWhen door is unlocked with remote

B.B. Key is turned onKey is turned on

C.C. Door is openedDoor is opened

D.D. All of the aboveAll of the above



7.7. According to the video, what method can be According to the video, what method can be taken to disable the intermittent brake pad taken to disable the intermittent brake pad application?application?

Use of the IDS Brake Pad Replacement Use of the IDS Brake Pad Replacement selection - (3:34 of video)selection - (3:34 of video)



8.8. What step must be taken before hitting the tick What step must be taken before hitting the tick on the IDS for the brake air bleed check? on the IDS for the brake air bleed check?

The brake pedal must be pressed - (4:15 of The brake pedal must be pressed - (4:15 of video)video)



9.9. What pressure is the Rotunda brake bleeder What pressure is the Rotunda brake bleeder initially set at when performing brake bleeding?initially set at when performing brake bleeding?

2 bar or 35 psi - (8:04 of video)2 bar or 35 psi - (8:04 of video)



10.10. After opening the right front bleeder screw, you After opening the right front bleeder screw, you press the tick on the IDS. How many times must press the tick on the IDS. How many times must you depress the brake pedal?you depress the brake pedal?

10 times - (8:25 of video)10 times - (8:25 of video)



11.11. What does it indicate when the IDS presents a What does it indicate when the IDS presents a code OB?code OB?

That the pedal needs to be pressed more That the pedal needs to be pressed more slowly - (12:56 of video)slowly - (12:56 of video)




12.12. What are the major inputs to the brake system? What are the major inputs to the brake system? APP sensor 1,2,3 - TP 1 & 2 - Longitudinal APP sensor 1,2,3 - TP 1 & 2 - Longitudinal

Accelerometer - VSS – Brake Pedal Travel Accelerometer - VSS – Brake Pedal Travel Sensor - ACU (13:57 of video)Sensor - ACU (13:57 of video)



13.13. What does a DTC C1524 indicate? What does a DTC C1524 indicate? That the brake pedal position sensor has not That the brake pedal position sensor has not

been calibrated or power to the brake pedal been calibrated or power to the brake pedal travel sensor has been lost - (14:57 of video)travel sensor has been lost - (14:57 of video)



14.14. What code indicates that the brake system What code indicates that the brake system initialization is incomplete? initialization is incomplete?

DTC C1525 - (16:24 of video)DTC C1525 - (16:24 of video)



DIRECTIONS: Go to the Fusion/Milan Hybrid Go to the Fusion/Milan Hybrid classroom vehicle. The customer says there is a “no classroom vehicle. The customer says there is a “no battery charging” message displayed in the instrument battery charging” message displayed in the instrument panel. Diagnose this concern and answer the following panel. Diagnose this concern and answer the following questions.questions.



1.1. Can you verify this concern. Are there any Can you verify this concern. Are there any messages being displayed in the message center?messages being displayed in the message center?

YES – Check Charging SystemYES – Check Charging System



2.2. Does your visual inspection reveal any obvious Does your visual inspection reveal any obvious flaws?flaws?

NONO



3.3. Perform the KOEO self-test, then clear all Perform the KOEO self-test, then clear all DTCs. Repeat the KOEO (ALL CMDTCs) self-DTCs. Repeat the KOEO (ALL CMDTCs) self-test and list any CMDTCs found and list the test and list any CMDTCs found and list the module in which the DTCS are stored?module in which the DTCS are stored?

P0AFA:13-AB - DC/DC, P0AFA:16-AB - P0AFA:13-AB - DC/DC, P0AFA:16-AB -

DC/DC and Possibly DC/DC and Possibly P0AFA:16-2A – P0AFA:16-2A – ACCM if A/C is on when codes were ACCM if A/C is on when codes were pulled.pulled.



4.4. Compare the service publication description for Compare the service publication description for each of the DTC’s listed. Do you find anything each of the DTC’s listed. Do you find anything in common in these descriptions?in common in these descriptions?

All the DTCs are the result of a low voltage All the DTCs are the result of a low voltage conditioncondition



5.5. Select the G_INV_V and M_INV_V PID from Select the G_INV_V and M_INV_V PID from the TCM Datalogger menu. Turn the ignition to the TCM Datalogger menu. Turn the ignition to the ON position and pull out the Service the ON position and pull out the Service Disconnect Switch. What occurs and what does Disconnect Switch. What occurs and what does this indicate?this indicate?

The PIDs indicate the capacitor voltage and The PIDs indicate the capacitor voltage and show them dischargingshow them discharging



6.6. Select and perform the pinpoint test that you Select and perform the pinpoint test that you think is most likely to find the fault? List the think is most likely to find the fault? List the pinpoint test and it’s results below, then notify pinpoint test and it’s results below, then notify your instructor of your findings.your instructor of your findings.

Students should end up at pinpoint test D for Students should end up at pinpoint test D for DC/DC converter in Section 413-05 of WSM. DC/DC converter in Section 413-05 of WSM. They should find the blown HV-LC fuse. They should find the blown HV-LC fuse. Have students complete questions 7-10 then Have students complete questions 7-10 then instruct them to remove fuse. instruct them to remove fuse.



7.7. What section of the Workshop Manual contains What section of the Workshop Manual contains directions for performing this service?directions for performing this service?

414-03414-03



8.8. At the beginning of the directions for replacing At the beginning of the directions for replacing this component, summarize the WARNING this component, summarize the WARNING about the service disconnect switch.about the service disconnect switch.



9.9. Why must the high-voltage/low-current bus bar Why must the high-voltage/low-current bus bar be removed during this service procedure?be removed during this service procedure?

To prevent bending the High-voltage/low-To prevent bending the High-voltage/low-current circuit bus barcurrent circuit bus bar



10.10. During installation of the component you are During installation of the component you are directed to replace, what is torque specifications directed to replace, what is torque specifications for the high- voltage/high-current positive cable for the high- voltage/high-current positive cable nut and high-voltage/low-current fuse nuts?nut and high-voltage/low-current fuse nuts?

High Voltage High Current Cable Nuts 15 High Voltage High Current Cable Nuts 15 Nm (133 lb-in)Nm (133 lb-in)

High Voltage/Low Current Fuse Nuts 4 Nm High Voltage/Low Current Fuse Nuts 4 Nm (35 lb-in)(35 lb-in)


Lesson OneWorkstation 6 (Part 1)

DIRECTIONS: Use IDS recording L1_WKS6 of Use IDS recording L1_WKS6 of the 2010 Milan to answer the following questions. the 2010 Milan to answer the following questions.



GENMODEGENMODE Generator Control ModeGenerator Control Mode

RPM TCMRPM TCM Engine Revolutions Per Minute (as Engine Revolutions Per Minute (as measured by the TCM)measured by the TCM)

VSSVSS Vehicle Speed SensorVehicle Speed Sensor

PIDPID PID DescriptionPID Description

1.1. The three PIDS listed below are shown in this The three PIDS listed below are shown in this recording. Write the IDS definition next to each PID.recording. Write the IDS definition next to each PID.



GENMODEGENMODE SpeedSpeed

RPM TCMRPM TCM 1290 RPM1290 RPM

VSSVSS 6.83 mph 6.83 mph


2.2. List the PID readings at approximately 8 seconds into List the PID readings at approximately 8 seconds into the recording.the recording.




GENMODEGENMODE TorqueTorque

RPM TCMRPM TCM 0 RPM0 RPM

VSSVSS 14 Kph 14 Kph


3.3. List the PID readings at approximately 28 seconds of List the PID readings at approximately 28 seconds of the recording.the recording.




4.4. Based upon your observations, what does the Based upon your observations, what does the GENMODE PID indicate when the gasoline GENMODE PID indicate when the gasoline engine is running and what does it indicate when engine is running and what does it indicate when the engine is off?the engine is off?

Engine running = SpeedEngine running = Speed Engine Off = TorqueEngine Off = Torque



5.5. Review the entire recording. Based upon your Review the entire recording. Based upon your observations, what will the GENMODE PID observations, what will the GENMODE PID indicate when the gasoline engine is starting and indicate when the gasoline engine is starting and what will it indicate when the engine is shutting what will it indicate when the engine is shutting down?down?

Engine starting = Engine Start NormalEngine starting = Engine Start Normal Engine shut down = Engine Stop: Enhanced Engine shut down = Engine Stop: Enhanced

Speed ControlSpeed Control



6.6. How will viewing these three PIDs when How will viewing these three PIDs when making Datalogger recordings help you during making Datalogger recordings help you during diagnostics?diagnostics?

It will enable the technician to identify the It will enable the technician to identify the vehicle operating mode (gas or electric), and vehicle operating mode (gas or electric), and when the gasoline engine is starting or when the gasoline engine is starting or shutting downshutting down



DIRECTIONS: A 2008 Escape Hybrid is brought to you with a customer concern of “Hard Steering”.



1.1. What type of EPAS system does this vehicle What type of EPAS system does this vehicle have?have?

Column MountedColumn Mounted


Perform the diagnosis for the concern using the service publications and the Perform the diagnosis for the concern using the service publications and the Data Sheet provided by comparing the service publication pinpoint test steps Data Sheet provided by comparing the service publication pinpoint test steps to the pinpoint test steps listed.to the pinpoint test steps listed.

The RESULTS COLUMN of the table lists the results of the tests performed, The RESULTS COLUMN of the table lists the results of the tests performed, use these results to select the next step that must be performed.use these results to select the next step that must be performed.

Continue doing this until you have identified the cause of the concern and Continue doing this until you have identified the cause of the concern and verified the repair.verified the repair.

NOTE: SOME STEPS IN THE DATA SHEET ARE NOT USED IN THE NOTE: SOME STEPS IN THE DATA SHEET ARE NOT USED IN THE DIAGNOSIS AND ARE ONLY INCLUDED AS DISTRACTORS. Select DIAGNOSIS AND ARE ONLY INCLUDED AS DISTRACTORS. Select only the steps that are required.only the steps that are required.



Verify the ConcernVerify the Concern Concern exists as stated by the customerConcern exists as stated by the customer

Visual InspectionVisual Inspection All OKAll OK

Connect Scan Tool and Connect Scan Tool and Retrieve DTCsRetrieve DTCs

DTC B2277 is presentDTC B2277 is present

View DTC Charts and View DTC Charts and Descriptions in PC/EDDescriptions in PC/ED

Note BxxxxNote Bxxxx

View Master Diagnostic View Master Diagnostic Trouble Code (DTC) Trouble Code (DTC) Index in Workshop Index in Workshop

ManualManual

Go to Section 211-00 in WSMGo to Section 211-00 in WSM

View PSCM DTC ChartView PSCM DTC Chart Go to Pinpoint Test BGo to Pinpoint Test B

Diagnostic StepDiagnostic Step ResultResult



Diagnostic StepDiagnostic Step ResultResult

Pinpoint Test B3Pinpoint Test B3 Voltage between circuit CBP35 (YE/GY) Voltage between circuit CBP35 (YE/GY) and ground is 12.6Vand ground is 12.6V

Pinpoint Test B4Pinpoint Test B4 Voltage on circuit SBB01 is 12.4 VVoltage on circuit SBB01 is 12.4 V

Pinpoint Test B1Pinpoint Test B1 DTC B2277 is presentDTC B2277 is present

Pinpoint Test B5Pinpoint Test B5 Resistance on Circuit GD116 is OLResistance on Circuit GD116 is OL

1.1. What should be done to repair this concern?What should be done to repair this concern? Repair Circuit GD 116Repair Circuit GD 116

Documents

Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstations 4 - 6 Workstation 4 Escape/Mariner Brake Service Procedures Escape/Mariner Brake