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
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 4
DIRECTIONS: View the Hybrid Brake Service
video, then use the video and service publications to
answer the questions below.
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 4
1.
A 2008 Escape Hybrid is brought to your facility
with a customer request for brake service.
According to service publications, what actions
can be taken to disable the intermittent brake pad
application?
 The
low-voltage battery negative cable
and fuses 9 and 18 from the battery
junction box (Section 206-03 Brake Pads
Hybrid in WSM)
Hybrid Vehicle Operation and Diagnosis Training
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 4
According to service publications, the rear brake
pads will wear at approximately what rate when
compared to the front brake pads?
 The rear brake pads will wear about twice as
fast as the front (Section 206-03 Brake Pads Hybrid in WSM)
2.
Hybrid Vehicle Operation and Diagnosis Training
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 4
When checking the brake fluid in the hybrid
master cylinder, what position must the ignition
switch be in?
 Ignition ON (Section 206-00 Brake System
Bleeding – Hybrid)
3.
Hybrid Vehicle Operation and Diagnosis Training
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 4
4.

What component has the function of giving the
driver the same feel as pushing on a regular
brake pedal, and where is this component found?
The component is the Brake Feel Emulator
and it is part of the Actuation Control Unit
(ACU) - (1:19 of video)
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 4
5.

At what speeds does the regenerative braking
slow the vehicle during normal application of
the brakes?
Between 70 and 5 mph - - (1:46 of video)
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 4
6.
When does the HECU cycle the brake pads?
A. When door is unlocked with remote
B. Key is turned on
C. Door is opened
D. All of the above
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 4
7.

According to the video, what method can be
taken to disable the intermittent brake pad
application?
Use of the IDS Brake Pad Replacement
selection - (3:34 of video)
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 4
8.

What step must be taken before hitting the tick
on the IDS for the brake air bleed check?
The brake pedal must be pressed - (4:15 of
video)
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 4
9.

What pressure is the Rotunda brake bleeder
initially set at when performing brake bleeding?
2 bar or 35 psi - (8:04 of video)
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 4
10.

After opening the right front bleeder screw, you
press the tick on the IDS. How many times must
you depress the brake pedal?
10 times - (8:25 of video)
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 4
11.

What does it indicate when the IDS presents a
code OB?
That the pedal needs to be pressed more
slowly - (12:56 of video)
Hybrid Vehicle Operation and Diagnosis Training
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 4
12.

What are the major inputs to the brake system?
APP sensor 1,2,3 - TP 1 & 2 - Longitudinal
Accelerometer - VSS – Brake Pedal Travel
Sensor - ACU (13:57 of video)
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 4
13.

What does a DTC C1524 indicate?
That the brake pedal position sensor has not
been calibrated or power to the brake pedal
travel sensor has been lost - (14:57 of video)
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 4
14.

What code indicates that the brake system
initialization is incomplete?
DTC C1525 - (16:24 of video)
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 5
DIRECTIONS: Go to the Fusion/Milan Hybrid
classroom vehicle. The customer says there is a “no
battery charging” message displayed in the instrument
panel. Diagnose this concern and answer the following
questions.
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 5
1.

Can you verify this concern. Are there any
messages being displayed in the message center?
YES – Check Charging System
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 5
2.

Does your visual inspection reveal any obvious
flaws?
NO
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 5
3.

Perform the KOEO self-test, then clear all
DTCs. Repeat the KOEO (ALL CMDTCs) selftest and list any CMDTCs found and list the
module in which the DTCS are stored?
P0AFA:13-AB - DC/DC, P0AFA:16-AB DC/DC and Possibly P0AFA:16-2A –
ACCM if A/C is on when codes were
pulled.
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 5
4.

Compare the service publication description for
each of the DTC’s listed. Do you find anything
in common in these descriptions?
All the DTCs are the result of a low voltage
condition
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 5
5.

Select the G_INV_V and M_INV_V PID from
the TCM Datalogger menu. Turn the ignition to
the ON position and pull out the Service
Disconnect Switch. What occurs and what does
this indicate?
The PIDs indicate the capacitor voltage and
show them discharging
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 5
6.

Select and perform the pinpoint test that you
think is most likely to find the fault? List the
pinpoint test and it’s results below, then notify
your instructor of your findings.
Students should end up at pinpoint test D for
DC/DC converter in Section 413-05 of WSM.
They should find the blown HV-LC fuse.
Have students complete questions 7-10 then
instruct them to remove fuse.
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 5
7.

What section of the Workshop Manual contains
directions for performing this service?
414-03
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 5
8.
At the beginning of the directions for replacing
this component, summarize the WARNING
about the service disconnect switch.
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 5
9.

Why must the high-voltage/low-current bus bar
be removed during this service procedure?
To prevent bending the High-voltage/lowcurrent circuit bus bar
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 5
10.


During installation of the component you are
directed to replace, what is torque specifications
for the high- voltage/high-current positive cable
nut and high-voltage/low-current fuse nuts?
High Voltage High Current Cable Nuts 15
Nm (133 lb-in)
High Voltage/Low Current Fuse Nuts 4 Nm
(35 lb-in)
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 6 (Part 1)
DIRECTIONS: Use IDS recording L1_WKS6 of
the 2010 Milan to answer the following questions.
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 6 (Part 1)
1. The three PIDS listed below are shown in this
recording. Write the IDS definition next to each PID.
PID
GENMODE
RPM TCM
VSS
PID Description
Generator Control Mode
Engine Revolutions Per Minute (as
measured by the TCM)
Vehicle Speed Sensor
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 6 (Part 1)
2. List the PID readings at approximately 8 seconds into
the recording.
PID
GENMODE
Speed
RPM TCM
1290 RPM
VSS
PID Description
6.83 mph
Hybrid Vehicle Operation and Diagnosis Training
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 6 (Part 1)
3. List the PID readings at approximately 28 seconds of
the recording.
PID
GENMODE
PID Description
Torque
RPM TCM
0 RPM
VSS
14 Kph
Hybrid Vehicle Operation and Diagnosis Training
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 6 (Part 1)
4.


Based upon your observations, what does the
GENMODE PID indicate when the gasoline
engine is running and what does it indicate when
the engine is off?
Engine running = Speed
Engine Off = Torque
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 6 (Part 1)
Review the entire recording. Based upon your
observations, what will the GENMODE PID
indicate when the gasoline engine is starting and
what will it indicate when the engine is shutting
down?
 Engine starting = Engine Start Normal
 Engine shut down = Engine Stop: Enhanced
Speed Control
5.
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 6 (Part 1)
How will viewing these three PIDs when
making Datalogger recordings help you during
diagnostics?
 It will enable the technician to identify the
vehicle operating mode (gas or electric), and
when the gasoline engine is starting or shutting
down
6.
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 6 (Part 2)
DIRECTIONS: A 2008 Escape Hybrid is brought to
you with a customer concern of “Hard Steering”.
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 6 (Part 2)
1.

What type of EPAS system does this vehicle
have?
Column Mounted
Hybrid Vehicle Operation and Diagnosis Training




Perform the diagnosis for the concern using the service publications and the
Data Sheet 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 SHEET ARE NOT USED IN THE
DIAGNOSIS AND ARE ONLY INCLUDED AS DISTRACTORS. Select
only the steps that are required.
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 6 (Part 2)
Diagnostic Step
Verify the Concern
Visual Inspection
Connect Scan Tool and
Retrieve DTCs
View DTC Charts and
Descriptions in PC/ED
View Master Diagnostic
Trouble Code (DTC)
Index in Workshop
Manual
View PSCM DTC Chart
Result
Concern exists as stated by the customer
All OK
DTC B2277 is present
Note Bxxxx
Go to Section 211-00 in WSM
Go to Pinpoint Test B
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstation 6 (Part 2)
Diagnostic Step
1.

Result
Pinpoint Test B1
DTC B2277 is present
Pinpoint Test B3
Voltage between circuit CBP35 (YE/GY)
and ground is 12.6V
Pinpoint Test B4
Voltage on circuit SBB01 is 12.4 V
Pinpoint Test B5
Resistance on Circuit GD116 is OL
What should be done to repair this concern?
Repair Circuit GD 116