STUDENT WORKSHEETS ESCAPE/MARINER HYBRID NEW MODEL CLASSROOM TRAINING FCS-13994-WKS FCS-13994-WKS February 2005 COURSE CODE: 30N10T0 WORKSTATIONS DAY WORKSTATION 1A BRAKE BLEED QUESTIONS DIRECTIONS There are two activities involved in this workstation, 1A and 1B The activities can be done in any order One student at a time should go to the workstation near the classroom vehicle The student should then use the provided service information and tools to perform a partial Service Bleed procedure and then answer the following questions NOTE: DO NOT open up the brake system components physically or by using the diagnostic tool When does the pressure bleeder need to be used? What does a Code 03 mean while performing a brake bleed? How will it affect how you perform the procedure? What additional Caution has been added to the Workshop Manual concerning brake fluid? At what pressure should the pressure regulator be set? How is it locked in place? Escape/Mariner Hybrid Classroom February, 2005 Day – DAY WORKSTATION 1B COMPONENT IDENTIFICATION Go to the classroom vehicle Locate the components that perform the functions listed in the right hand column List the name of the components, the function letter and the letter on the tag attached to each component in the left column Answers will vary based on component tags numbers/letters used Tag Number Component Function Supplies the power to the high voltage components Manages torque between the traction motor, engine and generator A pedal feel emulator is located internal to this component When the driver requests cabin heating and the engine is not running, this component is commanded on Vacuum operated component that reduces NVH at idle Converts high voltage (330 volt battery power) to low voltage Allows the customer to charge the high voltage battery from a 12-volt donor source Keeps the HV battery from overheating Prior to performing any service procedures this component must be removed Cuts off the fuel in an emergency situation Allows power steering to be delivered under all operating conditions Has an interlock circuit that shuts off all high voltage power when disconnected Cuts off power to the high voltage contactors in an emergency situation Escape/Mariner Hybrid Classroom February, 2005 Day – DAY WORKSTATION 2A STEERING DIFFICULT WORKSHEET DIRECTIONS A customer says that the steering wheel on their Escape/Mariner Hybrid has become very difficult to turn Perform the diagnosis for this concern using the service publications and the Data Table provided by comparing the service publication pinpoint test steps to the pinpoint test steps listed • 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 • Continue doing this until you have identified the cause of the concern and verified the repair NOTE: SOME STEPS IN THE DATA TABLE ARE NOT USED IN THE DIAGNOSIS AND ARE ONLY INCLUDED AS DISTRACTORS Select only the steps that are required Diagnostic Step Escape/Mariner Hybrid Classroom February, 2005 Day 1– DAY WORKSTATION NO START, HAZARD TELLTALE What component(s) or circuit(s) failed? Which code told you which component(s) or circuit(s) were involved? Where did you find the diagnostic path? Escape/Mariner Hybrid Classroom February, 2005 Day – 37 DAY WORKSTATION 6A DIM LIGHTS DIRECTIONS A customer complains that all of the lights on their Escape/Mariner Hybrid appear to be dim Perform the diagnosis for this concern using the service publications and the Data Table provided by comparing the service publication pinpoint test steps to the pinpoint test steps listed • 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 • Continue doing this until you have identified the cause of the concern and verified the repair NOTE: SOME STEPS IN THE DATA TABLE ARE NOT USED IN THE DIAGNOSIS AND ARE ONLY INCLUDED AS DISTRACTORS Select only the steps that are required Diagnostic Step Escape/Mariner Hybrid Classroom February, 2005 Day – 39 DAY WORKSTATION 6A DIM LIGHTS DATA TABLE Diagnostic Step Pinpoint Test QT2: Perform PCM and TCM Self Tests Symptom Chart: The DC/DC Converter does not operate correctly Pinpoint Test C2:Check the integrity of the 12 volt battery Pinpoint Test C6: Check the negative 12-volt cable No Go to Pinpoint Test C Yes Yes Pinpoint Test C3 – Check for current drains No Pinpoint Test R4 12.4 volts Pinpoint Test C5: Check the positive 12-volt cable Yes Visual Inspection All OK Pinpoint Test H2 Pin to Ground = OL Pin to Ground = OL Pinpoint Test KR4 volts Step No DTCs Present Symptom Chart Index Symptom is not listed, refer to applicable Workshop Manual Repair the circuit in question Clear the DTCs C1778 Verify the concern Concern exists as stated by the customer Pinpoint Test C7: Check for correct DC/DC converter operation Yes, Install new DC/DC converter Section 414-05 High Voltage Inverter/Converter Go to Symptom Chart Pinpoint Test QT1:Perform Data Link Diagnostics Test Verify the Concern is Resolved: Clear the DTCs and Repeat the Self Test Pinpoint Test C4: Check the voltage to the 12 volt battery System Pass Pinpoint Test KR1 No Pinpoint Test H2 11.6 volts Pinpoint Test C1: Check the PCM for DTCs No Escape/Mariner Hybrid Classroom February, 2005 System Pass No Day – 41 DAY WORKSTATION 6A DIM LIGHTS What pinpoint test was used and where did you find it? What component(s) or circuit(s) failed? Name any special steps needed for repairing the failed component or circuit Escape/Mariner Hybrid Classroom February, 2005 Day – 43 DAY WORKSTATION 6B YELLOW WRENCH DIRECTIONS A customer says that the yellow wrench indicator is on Perform the diagnosis for this concern using the service publications and the Data Table provided by comparing the service publication pinpoint test steps to the pinpoint test steps listed • 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 • Continue doing this until you have identified the cause of the concern and verified the repair NOTE: SOME STEPS IN THE DATA TABLE ARE NOT USED IN THE DIAGNOSIS AND ARE ONLY INCLUDED AS DISTRACTORS Select only the steps that are required Diagnostic Step Escape/Mariner Hybrid Classroom February, 2005 Day – 45 DAY WORKSTATION 6B YELLOW WRENCH DATA TABLE Diagnostic Step Go to Diagnostic Trouble Code Charts Bxxxx, See Note Pinpoint Test C2 Yes Traction Battery Control Module DTC Index B1239, Go to Pinpoint Test A Pinpoint Test A1: Check circuit 699 for an open or a short to ground 0.7 ohms and OL Pinpoint Test R4 12.4 volts Pinpoint Test C4 3.6 volts Pinpoint Test A3: Check circuit 1128 for an open or a short to ground 0.7 ohms and OL Note Refer to the applicable Workshop Manual section Pinpoint Test KR4 volts Pinpoint Test QT2: Perform PCM and TCM Self Tests PCM Self Test: B1239 Air Flow Blend Door Driver Circuit Failure Verify the concern Concern exists as stated by the customer Section 412-00B Climate Control System – Escape Hybrid Refer to Diagnosis and Testing Pinpoint Test KR5 OL Pinpoint Test QT1:Perform Data Link Diagnostics Test System Pass Visual Inspection All OK Pinpoint Test A2: Check circuit 698 for an open or a short to ground Verify the Concern is Resolved: Clear the DTCs and Repeat the Self Test 0.7 ohms and OL System Pass Pinpoint Test H2 11.6 volts Pinpoint Test A4: Check circuit 1129 for an open or a short to ground OL and OL, Repair the circuit in question Escape/Mariner Hybrid Classroom February, 2005 Day – 47 DAY WORKSTATION 6B YELLOW WRENCH What pinpoint test was used and where did you find it? What component(s) or circuit(s) failed? Name any special steps needed for repairing the failed component or circuit Escape/Mariner Hybrid Classroom February, 2005 Day – 49 ... step on the classroom vehicle)? Escape/ Mariner Hybrid Classroom February, 2005 Day – 21 DAY WORKSTATION 4A ROUGH IDLE WORKSHEET DIRECTIONS A customer says that their Escape/ Mariner Hybrid runs... circuit Escape/ Mariner Hybrid Classroom February, 2005 Day 1– 11 DAY WORKSTATION 2B YELLOW WRENCH WORKSHEET DIRECTIONS A customer says that the braking is very difficult on their Escape/ Mariner Hybrid. .. situation Escape/ Mariner Hybrid Classroom February, 2005 Day – DAY WORKSTATION 2A STEERING DIFFICULT WORKSHEET DIRECTIONS A customer says that the steering wheel on their Escape/ Mariner Hybrid has