Vehicle Operation and Diagnosis Student Guide fcs-21020-REF FCS-21020-REF Course Code: 30N10T1 August, 2009 Ford Customer Service Division Technical Training Blank IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles, as well as the personal safety of the individual doing the work This manual provides general directions for accomplishing service and repair work with tested, effective techniques Following them will help assure reliability There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual doing the work This manual cannot possibly anticipate all such variations and provide advice or cautions as to each Accordingly, anyone who departs from instructions provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS Each one is there for a specific purpose NOTES give you added information that will help you to complete a particular procedure CAUTIONS are given to prevent you from making an error that could damage the vehicle WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury The following list contains some general WARNINGS that you should follow when you work on a vehicle Always wear safety glasses for eye protection Use safety stands whenever a procedure requires you to be under the vehicle Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure Set the parking brake when working on the vehicle If you have an automatic transmission, set it in PARK unless instructed otherwise for a specific service operation If you have a manual transmission it should be in REVERSE (engine OFF) or NEUTRAL (engine ON) unless instructed otherwise for a specific service operation Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide Keep yourself and your clothing away from moving parts when the engine is running, especially the fan and belts To help prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler Do not smoke while working on the vehicle To help avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle Tie long hair securely behind your head Keep hands and other objects clear of the radiator fan blades Electric cooling fans can start to operate at any time by an increase in underhood temperatures, even though the ignition is in the OFF position Therefore, care should be taken to ensure that the electric cooling fan is completely disconnected when working under the hood The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership parts and/or service department operations These recommendations and suggestions not supersede or override the provisions of the Warranty and Policy Manual, and in any cases where there may be a conflict, the provisions of the Warranty and Policy Manual shall govern The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was approved for printing Ford Motor Company reserves the right to discontinue models at any time, or change specifications, design, or testing procedures without notice and without incurring obligation Any reference to brand names in this manual is intended merely as an example of the types of tools, lubricants, materials, etc recommended for use Equivalents, if available, may be used The right is reserved to make changes at any time without notice DANGER: Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs Exposure to excessive amounts of dust may be a potential cancer and lung disease hazard Exposure may also cause irritation to skin, eyes, and respiratory tract, may cause allergic reactions, and/or may lead to other chronic health effects Do not breathe dust Do not use compressed air to blow dust from storage containers or friction components A high-efficiency (HEPA) vacuum cleaner should be used carefully to remove dust Adherent dust should be removed with a damp rag If inhaled, remove to fresh air If irritation persists, seek medical attention or advice If dust gets in eyes, irrigate under eyelids with water for 15 minutes and seek medical attention Copyright © 2009 Ford Motor Company Produced and Coodinated by Technical Support Operations Ford Customer Service Division Augustl, 2009 M CUSTOMER EXPECTATIONS Customer Expectations: Service Make it convenient to have my vehicle serviced at your dealership The Service Advisor should demonstrate a genuine concern for my service needs Fix it right the first time, on time Complete servicing my vehicle in a timely and professional manner Provide me with a clear and thorough explanation of the service performed Call me within a reasonable amount of time after my service visit to ensure that I'm completely satisfied Be responsive to questions or concerns that I bring to your attention Expectation #3 “Fix It Right the First Time, on Time.” Both service advisors and technicians are important players when it comes to Expectation #3 Why Customers tell us “Fixing It Right the First Time, on Time” is one of the reasons they would decide to return to a dealer to buy a vehicle and get their vehicles serviced Technician Training It is our goal to help the technician acquire all of the skills and knowledge necessary to “Fix it Right the First Time, on Time.” We refer to this as “competency.” Technician’s Role Acquire the skills and knowledge for competency in your specialty via: STST New Model — Web-Based — Web-Based — Instructor Led — Instructor Led The Benefits The successful implementation of expectations means: — Satisfied customers — Repeat vehicle sales — Repeat service sales — Recognition that Ford and Lincoln/Mercury technicians are “the Best in the Business” HYBRID VEHICLE OPERATION AND DIAGNOSIS TABLE OF CONTENTS Contents STUDENT INTRODUCTION Course Description Intro - Worksheets Intro - Course Requirements Intro - Course Objectives Intro - Course Agenda Intro - Electric Vehicle Background Intro - LESSON ONE Prerequisite Review - High Voltage Safety - Battery System Warnings - High Voltage Hazards - 10 Electrical Accidents - 11 Driver Response to Accident - 11 Accident Prevention - 12 First Aid Procedures - 17 Fire Prevention - 18 Emergency Responder Guides - 21 Workstation Escape/Mariner Hybrid Component Location and Function - 24 Workstation Fusion/Milan Hybrid Component Location and Functionn - 25 Workstation High Voltage Safety Quiz - 26 Workstation Escape/Mariner Hybrid Brake Service - 30 Workstation Fusion/Milan Hybrid High Voltage Service - 32 Workstation Hybrid Diagnostic Procedures (Part 1) - 34 Workstation Hybrid Diagnostic Procedures (Part 2) - 36 LESSON TWO Demonstration Hybrid Vehicle Diagnostics - Workstation IDS Hybrid Diagnosis (Part 1)) - Workstation Hybrid Diagnostic Procedures (Part 2) - Workstation Fusion/Milan Diagnostic Procedures - Workstation Hybrid Diagnostic Procedures (Part 1) - 10 Workstation Hybrid Diagnostic Procedures (Part 2) - 12 Hybrid Acronyms and Terms Acornym - Appendix: 2010 Fusion/Milan Emergency Response Guide Append - Hybrid Vehicle Operation and Diagnosis TOC - i August, 2009 HYBRID VEHICLE OPERATION AND DIAGNOSIS Hybrid Vehicle Operation and Diagnosis TOC - ii TABLE OF CONTENTS August, 2009 HYBRID VEHICLE OPERATION AND DIAGNOSIS INTRODUCTION INTRODUCTION August, 2009 Intro - Hybrid Vehicle Operation and Diagnosis HYBRID VEHICLE OPERATION AND DIAGNOSIS INTRODUCTION FORD HYBRID VEHICLE OPERATION AND DIAGNOSIS Course Description Escape/Mariner and Fusion/Milan Hybrids This is the only instructor-led course in the Hybrid Vehicle curriculum It is a two-day course facilitated by an instructor This course is designed to provide hands-on opportunities for technicians to learn and improve their skills using tools and equipment, and to apply knowledge learned in the 30N26W1 Hybrid Vehicle Components and Operation web-based training course Each day, you will have multiple opportunities to practice selected skills The results of your work are recorded on worksheets Worksheets All classroom and hands-on activities are guided by worksheets When you are assigned to a workstation, you will be given an appropriate amount of time to complete the tasks and questions required by the worksheet for that workstation Upon completion of the workstation, you will move to another workstation and complete another worksheet until all worksheets for the activity are complete Hybrid Vehicle Operation and Diagnosis Intro - August, 2009 HYBRID VEHICLE OPERATION AND DIAGNOSIS INTRODUCTION Course Requirements Each technician attending this course will be required to pass a combination of hands-on and written evaluations These will be administered on the afternoon of the 2nd day z The hands-on evaluation is a pass/fail type It will be conducted with exercises in hybrid vehicle performance diagnosis, and will cover: – hybrid performance system diagnosis – service publication navigation – selected special tool usage In order to pass the course, you must demonstrate mastery of the skills covered at the evaluated hands-on exercise AND you must answer at least 80% of the written post-test questions correctly Course Objectives Upon successful completion of this course, you will be able to: z Describe Ford and Lincoln-Mercury Hybrid Vehicle Components and Operation z Describe unique hybrid vehicle safety procedures z Perform visual inspections and selected tests on various hybrid vehicle components z Diagnose hybrid vehicle performance concerns z Perform tests to verify hybrid vehicle concerns and identify causes of these concerns z Perform hybrid vehicle service procedures Course Agenda LESSON ONE: Introductions, Safety Briefing, Prerequisite Review, Lesson Workstations LESSON TWO Lesson Workstation Reviews, Lesson Workstations, Final Review, Post-Test August, 2009 Intro - Hybrid Vehicle Operation and Diagnosis HYBRID VEHICLE OPERATION AND DIAGNOSIS INTRODUCTION ELECTRIC VEHICLE BACKGROUND The concept of an electric vehicle is not new In fact, Henry Ford’s wife Clara used a 1914 Detroit Electric Model 47 Brougham to travel around Dearborn, visiting her friend, Mrs Mina Ives and sister, Mrs Eva Brubaker This car resided at the Ford’s Fair Lane Estate from 1916 until the 1930’s Early automotive pioneers began developing electric vehicles during the Nineteenth Century However, it soon became apparent that electrical energy storage on a vehicle would be difficult Batteries are heavy and require a great deal of room Because of this, and the promise of the internal combustion engine, early automakers soon abandoned electric power But petroleum fuels have a drawback, they generate exhaust emissions While this was not a concern for early automakers, it has become a major concern for auto manufacturers today Ford Motor Company began its electric vehicle (EV) development in 1982 with the introduction of the ETX 1, a converted Lynx LN7 This experimental vehicle was powered by a lead-acid battery and a 50-horsepower AC motor The ETX was followed by the ETX 2, a converted Aerostar using a refined 70horsepower motor The ETX tested various battery types In 1993, Ford began a demonstration program to help potential customers gain real-world experience in the use of electric-powered vehicles With the participation of utility companies and other commercial organizations, this program is now nearing the 1-million mile mark in vehicle miles driven The vehicle platform for this demonstration was the Ecostar , a two-passenger electric vehicle based on the European Ford Escort Van In 1998 the introduction of the electrically powered Ranger introduced the next generation of electric vehicles The Ford EV demonstration program served as a test bed for electric powered vehicles However, battery technology again handicapped the development of the pure electric vehicle The limited range, and weight of the batteries required to achieve that range was too great, and in 2001 production of the EV Ranger was discontinued But Ford did not stop developing electric technology, it was only redirected towards a system that would combine the internal combustion engine and the electric motor to provide out customers with improved fuel economy and range, while dramatically lowering vehicle emissions This effort resulted in the introduction of the 2005 Escape/Mariner Hybrid, the first SUV to feature an gasolineelectric powertrain For 2010 Ford is introducing the Fusion/Milan Hybrid This next generation hybrid utilizes the latest technology to create a practical vehicle with the comfort, range, lower emissions, fuel economy and durability Ford and LincolnMercury customers have come to expect Both the Escape/Mariner and Fusion/Milan Hybrids represent the highest standards in technology and quality, but be assured that Ford will continue the research and development needed to create high-quality, fuel-efficient hybrid and electric vehicles to meet the transportation needs of our customers today, and in the future! Hybrid Vehicle Operation and Diagnosis Intro - August, 2009 HYBRID VEHICLE OPERATION AND DIAGNOSIS Hybrid Vehicle Operation and Diagnosis HYBRID ACRONYMS AND TERMS Acronym - August, 2009 Appendix 2010 FUSION HYBRID MILAN HYBRID EMERGENCY RESPONSE GUIDE FCS-14265-10 2010 Fusion Hybrid, Milan Hybrid Emergency Response Guide, 02/2009 FOREWORD The emergency response procedures for the Fusion Hybrid and Milan Hybrid vehicles are similar to those for traditional gasoline-powered vehicles with the addition of special considerations for the high-voltage electric system components The Fusion Hybrid or Milan Hybrid vehicles use a conventional gasoline engine in addition to an electric motor to power the vehicle The energy used to power the vehicle comes from gasoline (used by the internal combustion engine) and electricity (used by the electric motor) • Gasoline is stored in a traditional fuel tank • Electricity is stored in a high-voltage battery pack The combination of a gasoline engine and electric motor provides for improved performance (V6 performance with a 4-cylinder engine and electric motor), reduced emissions and improved fuel economy The high-voltage system is self contained, never needing to be plugged into an electrical outlet for recharging The system incorporates a generator that recharges the high-voltage batteries during cruising and braking from the engine The information in this guide will allow response to emergencies involving Fusion Hybrid or Milan Hybrid vehicles to be as safe as with conventional vehicles The Fusion Hybrid and Milan Hybrid vehicles have been designed with many safety features for your protection These features help provide safe access to the vehicle under various conditions However, when approaching a high-voltage vehicle in a fire, rescue or recovery situation, always follow one industry standard rule: ALWAYS ASSUME THE VEHICLE’S HIGH-VOLTAGE SYSTEM IS POWERED UP ! FCS-14265-10 2010 Fusion Hybrid, Milan Hybrid Emergency Response Guide, 02/2009 FUSION HYBRID AND MILAN HYBRID VEHICLE IDENTIFICATION • The Fusion Hybrid and Milan Hybrid vehicles can be easily identified by the Ford “green leaf highway” badges located on the left and right front doors There is a “Hybrid” nameplate on the trunk lid that also includes the “green leaf highway” icon Hybrid Nameplate with “Green Leaf Highway” Badge on Front Door Unique Hybrid Specific Wheels FCS-14265-10 2010 Fusion Hybrid, Milan Hybrid Emergency Response Guide, 02/2009 • The Fusion Hybrid and Milan Hybrid vehicles have a unique engine appearance cover with a raised “green leaf highway” icon and HYBRID lettering Unique Hybrid Engine Appearance Cover with “Green Leaf Highway” Icon • The 5th, 6th and 7th digits of the Vehicle Identification Number (VIN) identify the Hybrid vehicle line VIN POSITIONS 5, and VEHICLE P0L Fusion Hybrid — Front Wheel Drive (FWD) M0L Milan Hybrid — Front Wheel Drive (FWD) SAMPLE VIN 3FAD P0L30AR100001 Fusion Hybrid FWD FCS-14265-10 2010 Fusion Hybrid, Milan Hybrid Emergency Response Guide, 02/2009 HIGH-VOLTAGE ELECTRICAL DISCONNECT FEATURES The following list describes certain features that have been incorporated into the Hybrid vehicles that allow for either simple or automatic shutoff of the high-voltage electrical systems • High-Voltage Fuse — In the event of a high-current short circuit, the high-voltage fuse will open, disabling the high-voltage system • High-Voltage Interlock Circuit — Whenever a high-voltage connector is disconnected, the high-voltage interlock circuit opens and disables the high-voltage system • Ignition Key in OFF Position — Any time the ignition lock cylinder is in the OFF position, the high-voltage system is disabled • High-Voltage Service Disconnect — Whenever the high-voltage service disconnect (located behind the rear seat) is removed, the high-voltage system is disabled For additional information, refer to Page in this manual • Thermal Sensors — In the event the ignition key is left in the ON position and the high-voltage battery temperature exceeds 60°C (140°F), thermal sensors located near the high-voltage battery will automatically disable the high-voltage battery FCS-14265-10 2010 Fusion Hybrid, Milan Hybrid Emergency Response Guide, 02/2009 HIGH-VOLTAGE WARNING DECALS 2U5A-14B218-CA • Warning decals, as shown here, will be located on components included in the high-voltage system FCS-14265-10 2010 Fusion Hybrid, Milan Hybrid Emergency Response Guide, 02/2009 HYBRID COMPONENT LOCATION AND IDENTIFICATION This chart provides the location, description and basic function of the hybrid system components Refer to the hybrid component description on the following page NOTE: All high-voltage wires and harnesses are wrapped in orange-colored insulation FCS-14265-10 2010 Fusion Hybrid, Milan Hybrid Emergency Response Guide, 02/2009 COMPONENT LOCATION / DESCRIPTION High-Voltage Service Disconnect High-Voltage Battery • Located behind the rear 275 Volts seatback FUNCTION • Orange rectangle with a molded Provides means to disconnect plastic handle, about 100 mm high-voltage battery for safely (4 in) in length servicing vehicle Provides high-voltage storage (275 V) for vehicle propulsion requirements • Sealed nickel-metal hydride High-Voltage Wiring • Runs along the vehicle’s Provides physical path for floorpan from the high-voltage high-voltage circuitry battery to the Electronically Controlled Continuously Variable Transaxle (eCVT), to DC-to-DC converter, then the electric A/C unit • All high-voltage wiring has orange-colored insulation 12-Volt Battery • Located under the hood on driver side of the vehicle Provides 12-volt power for vehicle accessories • Typical automotive 6-cell lead/acid design Electronically Controlled Continuously Variable Transaxle (eCVT) • Transverse-mounted design similar to the non-Hybrid Fusion/Milan vehicles DC/DC Converter • Located under the hood on the passenger side forward of the strut tower Electric A/C Compressor • Located in the front of the engine • Contains the traction motor, generator motor and hybrid electronics Provides delivery of power to wheels for vehicle propulsion, generates electricity to recharge the batteries during operation and contains certain hybrid electronics Provides 12 volts of power to charge the 12-volt battery and run vehicle accessories Provides electric A/C operation Replaces the belt driven A/C compressor FCS-14265-10 2010 Fusion Hybrid, Milan Hybrid Emergency Response Guide, 02/2009 HIGH-VOLTAGE SERVICE DISCONNECT To gain access to the high-voltage service disconnect, the rear seat must be lowered The rear seat is released from the trunk area • Locate the seat backrest latch release levers (2) between the high-voltage battery and the body sheet metal • Push the release lever toward the outboard side of the vehicle FCS-14265-10 2010 Fusion Hybrid, Milan Hybrid Emergency Response Guide, 02/2009 HIGH-VOLTAGE BATTERY PACK WARNING • Removing the high-voltage service disconnect will disconnect the high-voltage from the vehicle • The individual cells inside the battery pack will still be charged • Do not cut, weld or screw into the high-voltage battery case or penetrate the batteries in any way The high-voltage battery pack is located behind the rear seatback • The total voltage of the battery pack is approximately 275 volts DC • The battery case is designed to be water resistant • The battery cells contain a base electrolyte (consisting of potassium hydroxide as the dominant active ingredient) that is absorbed in a special paper The electrolyte will not leak from the battery under most conditions, however, if the battery is crushed, it is possible for a small amount (drops) of electrolyte to leak These warnings must be observed when working with a damaged battery: NOTE: If possible, remove the high-voltage service disconnect 10 FCS-14265-10 2010 Fusion Hybrid, Milan Hybrid Emergency Response Guide, 02/2009 Exposure to electrolyte could cause skin/eye irritation and/or burns If exposed, rinse with large amounts of water until the soapy feel is gone Personal Protective Equipment (PPE) such as splash shield or safety goggles, gloves (latex, rubber or Nitrile), an apron or overcoat suitable to protect against alkaline and rubber boots are required when handling damaged batteries Fold-down helmet shields are not acceptable for acid or alkaline spills If the battery is exposed to intense heat, it is possible that hydrogen could be released from the battery Appropriate precautions should be taken to make sure the area is properly ventilated, such as, opening the vehicle windows or doors APPROACHING A DAMAGED HIGH-VOLTAGE VEHICLE FOLLOW EXISTING TRAINING AND INCIDENT COMMANDER DIRECTION • This guide provides only supplemental information as it pertains to the Fusion Hybrid and Milan Hybrid vehicles The same rules apply when approaching any potential high-voltage situation Always follow your high-voltage safety training Some precautions to be taken in any high-voltage situation include: — Remove all jewelry (watches, necklaces and earrings) Metal objects are conductors of electricity — Wear the necessary PPEs (high-voltage rubber gloves, face shield, insulated boots, protective raincoat or apron) — Bring the following equipment: • Class ABC powder-type fire extinguisher • A non-conductive object – about 1.5 m (5 ft) long – used to safely push someone away from the vehicle if they accidentally come in contact with high-voltage APPROACHING A DAMAGED VEHICLE • Disable the high-voltage electrical system using as many of the following steps as possible: — Secure the vehicle — place the shift lever into the PARK position Remove the ignition key Block the wheels, if necessary Removing the ignition key or turning the key to the OFF position will disconnect the high-voltage system — Disconnect the negative cable from the 12-volt battery – this will also disable the high-voltage system — If possible, remove the high-voltage service disconnect (See Page 9) 11 FCS-14265-10 2010 Fusion Hybrid, Milan Hybrid Emergency Response Guide, 02/2009 SPECIAL NOTES • If the vehicle is on fire, use a Class ABC powder-type extinguisher to contain and smother the flames If water is being used, large amounts of water will be required (e.g., from a fire hydrant) to extinguish the flames • If the vehicle has any exposed cables, make sure to wear high-voltage rubber gloves and other protective clothing Do not touch any broken or damaged high-voltage orange cables Treat severed cables as if they contain high voltage • If the vehicle is submerged in water, not touch any high-voltage components or orange cables while extricating the occupant(s) Do not remove the vehicle until you are sure the high-voltage battery is completely discharged A submerged high-voltage battery may produce a fizzing or bubbling reaction The high-voltage battery will be discharged when the fizzing or bubbling has completely stopped IF THE HIGH-VOLTAGE BATTERY CASE HAS BEEN RUPTURED • Just like any other battery, hose the area down with large amounts of water MOVING DAMAGED VEHICLES — WRECKER DRIVERS • Turn the vehicle ignition key to the ACCESSORY position to release the locking steering wheel • If possible, remove the high-voltage service disconnect • Follow the guidelines in the Wrecker Towing Manual — Front Tow: Wheel Lift (FWD) — Rear Tow: Wheel Lift with Dolly (FWD) — Flat bed: Front and Rear SPECIAL NOTE TO SALVAGE YARDS • If a vehicle with a high-voltage battery is to be scrapped, the high-voltage battery must be disposed of following all local, state/provincial and federal guidelines 12 FCS-14265-10 2010 Fusion Hybrid, Milan Hybrid Emergency Response Guide, 02/2009 ... Append - Hybrid Vehicle Operation and Diagnosis TOC - i August, 2009 HYBRID VEHICLE OPERATION AND DIAGNOSIS Hybrid Vehicle Operation and Diagnosis TOC - ii TABLE OF CONTENTS August, 2009 HYBRID VEHICLE. .. DIAGNOSIS INTRODUCTION INTRODUCTION August, 2009 Intro - Hybrid Vehicle Operation and Diagnosis HYBRID VEHICLE OPERATION AND DIAGNOSIS INTRODUCTION FORD HYBRID VEHICLE OPERATION AND DIAGNOSIS Course... Lincoln-Mercury Hybrid Vehicle Components and Operation z Describe unique hybrid vehicle safety procedures z Perform visual inspections and selected tests on various hybrid vehicle components z Diagnose hybrid