Hybrid Vehicle Operation and Diagnosis Course Code 30N10T1

1
Hybrid Vehicle Operation and Diagnosis Course
Code 30N10T1
Instructor Information PowerPoint
2
Instructor Information PowerPoint

• Purpose
• This PowerPoint presentation has been prepared to
  help Ford Service Training Instructors (STIs)
  prepare for the presentation of the New Hybrid
  Vehicle Operation and Diagnosis Classroom Course.
• Any additional questions about the presentation
  of this training course should be directed to
  Paul Garcia, TSO Project Manager at
  pgarci13_at_ford.com.

3
Course Requirements

• This is a two-day course.
• Instructors must take the prerequisite web based
  training course, 30N26W1 Hybrid Vehicle
  Components and Operation.
• The course content is almost completely new in
  comparison to the old hybrid classroom course.

4
PowerPoint Contents

• This PowerPoint is divided into 3 Sections.
• Bug Setup
• Workstation Setup
• Post Test

5
Supplemental Material

• This presentation is designed to be used with the
  Instructor Information Section of the Instructor
  Guide (IGK) for 30N10T1 Hybrid Vehicle Operation
  and Diagnosis.
• During this presentation you will be referred to
  setup information within the IGK.

6
Pre-Class Setup

• PG. Inst 2 of the IGK lists pre-class setup
  steps for this course.
• Before performing the pre-class setup, view the
  Bug Setup section of this presentation.

7
WARNINGS

• This PowerPoint Presentation is designed
  specifically for STIs that have previously
  taught the Hybrid Classroom New Model Course
  (2005 version).
• All service publication WARNINGS must be followed
  when preparing the classroom vehicle.
• Failure to do so could result in injury or death.

8
BUG SETUP
9
Bug Setup

• There are two on-vehicle bugs for this course.
• There is also a component location activity
  requiring the vehicle be tagged.
• Tags must be attached to the components listed on
  the Lesson One Workstation 2 worksheet and the
  vehicle must be on a hoist.

10
Remove the Rear Seat Cushion

• Begin classroom vehicle preparation by removing
  the rear seat cushion.
• Removal of the seat requires that the two rear
  seat cushion latches are fully disengaged or
  latch damage will result.
• View the next page for photos of this procedure.

11
Remove the Rear Seat Cushion
Seat Latch
Push Latch in this Direction

• Release the rear of the seat cushion in the
  following sequence.
• Push the cushion assembly back as far as
  possible.
• Press both seat latches in the direction shown in
  the photo until the front of the seat is
  released.
• Lift up at the rear outboard ends of the cushion
  assembly, disengaging the wires in the cushion
  from the wire retainer hooks of the seat cushion.
• Pull the cushion assembly forward and remove.

12
Remove the Rear Seat Cushion

• Refer to 2010 Fusion/Milan WSM Section 510-10
  Removal and Installation for additional
  information as needed.

13
Lower the Rear Seat Backs
Open the trunk and remove the cover over the HVBP
cooling fan.
14
Lower the Rear Seat Backs
Position of Latches to release rear seat
backs (location to insert screwdriver tip)

• There are two releases for the rear seat. These
  are difficult to see. See the photos on the
  following pages.

15
Lower the Rear Seat Backs

• Place the tip of the screwdriver against these
  two releases and pry outward, towards the outside
  of the vehicle.
• The seat backs are spring-loaded and will pop
  down.

16
Lower the Rear Seat Backs

• Refer to 2010 Fusion/Milan WSM Section 510-10
  Removal and Installation for additional
  information as needed.

17
Remove the Service Disconnect Switch

• Remove the Service Disconnect Switch Before
  Proceeding

18
Remove Passenger Side Rear Seat Bolster

• Next, remove the passenger side rear seat
  bolster.
• Begin by removing the 10mm retaining bolt from
  the bottom of the bolster.

19
Remove Passenger Side Rear Seat Bolster
Bolster Latch

• You must now release the bolster retaining latch,
  which is the same design as those used for the
  seat cushion.
• To do this, slide a flat-blade screwdriver behind
  the bolster to push the latch release toward the
  RH side of the vehicle and release the side
  bolster

20
Remove Passenger Side Rear Seat Bolster

• Refer to 2010 Fusion/Milan WSM Section 510-10
  Removal and Installation for additional
  information as needed.

21
Remove the BEC/BECM/BPSM Cover
10 mm Nuts
10 mm Nut
T-35 Torx

• Now, remove the BEC/BECM/BPSM Cover.
• This is done by removing the four 10 mm retaining
  nuts, and the two 35 Torx retaining nuts shown
  here.

22
Remove the BEC/BECM/BPSM Cover

• Then remove the BEC/BECM/BPSM Cover.

23
Remove the BEC/BECM/BPSM Cover
Re-Install Ground Strap and Nut

• Re-install ground strap and nut.

24
Remove the BEC/BECM/BPSM Cover

• Refer to 2010 Fusion Milan WSM Section 414-03
  Removal and Installation for additional
  information as needed.

25
Installing the Permanent Bug for Lesson Two
Worksheet 2

• This bug opens the circuit to the Hybrid Battery
  Positive Contactor and sets DTC P0AD900 in the
  BECM memory.
• This is accomplished by inserting a micro-switch
  in circuit J1A61 (GY) at pin 4 of C4236D
• The following pages detail this process.
• Additional information is available on pages
  INST-37 INST 39 in the IGK.

26
Installing the Permanent Bug for Lesson Two
Worksheet 2
Wiring Harness

• WARNING MAKE SURE THE SERVICE DISCONNECT SWITCH
  IS REMOVED FROM THE VEHICLE
• To provide room to access the wiring harness,
  disconnect the three connectors for the black
  wiring harness running to the BEC (See next page
  for additional details).

27
Installing the Permanent Bug for Lesson Two
Worksheet 2
C4236D Female Connector
C4236D Male Connector

• Connectors removed from BEC for black wiring
  harness.

28
Installing the Permanent Bug for Lesson Two
Worksheet 2
Good retainer end (spread carefully)
Not so Good retainer end (spread a bit too far)

• Carefully remove the red pin retainer from the
  center of C4236D by spreading the outside ends of
  the retainer (Dont spread them too far or they
  will break. Bet you cant guess how we know this!)

29
Installing the Permanent Bug for Lesson Two
Worksheet 2

• Carefully remove pin 4 of C4236D (GY) from the
  connector using a thin pick.

30
Installing the Permanent Bug for Lesson Two
Worksheet 2
Pin 4 in Wiring Diagram Connector view
31
Installing the Permanent Bug for Lesson Two
Worksheet 2

• Get the micro-switch and pigtails from the course
  setup package

32
Installing the Permanent Bug for Lesson Two
Worksheet 2
Male pigtail of bug
Pin 4 of C4236D
Female pigtail (GY) of bug inserted into Pin 4
slot of C4236D

• Open the convolute as required and pull pin 4
  out.
• Insert the male pin pigtail into pin 4.
• Insert the female pin pigtail into the connector
  in the slot for pin 4.

33
Installing the Permanent Bug for Lesson Two
Worksheet 2
Micro-switch

• Reassemble the connector and use black electrical
  tape to close the convolute.
• Ensure that the wires are high enough on the
  harness to allow it to be tucked up under the
  rear window deck so that it can not be seen when
  the harness is reattached to the BEC.

34
Bug for Lesson Two Workstation 2

• IMPORTANT NOTES FOR THIS WORKSTATION
• While diagnosing this bug make sure the students
  use these DVOM adapters
• Set 300-08040 .060 Female Flex Probes for DVOM
  leads
• Set 300-08045 .064 Male Flex Probes for DVOM
  leads
• Failure to use these adapters will result in
  damage to the connector pins, which may require
  replacement of the wiring harness.
• THIS HARNESS CAN ONLY BE ORDERED WITH A BATTERY
  PACK! SO BE CAREFUL.
• INSTRUCTOR WARNING
• AFTER SETTING THE BUG, PLACE THE BEC COVER BACK
  OVER THE BEC AND BPSM TO PREVENT ACCIDENTAL
  CONTACT WITH A HV COMPONENT WITH THE SERVICE
  DISCONNECT INSTALLED. USE ONLY 1 FASTENER TO
  RETAIN THE COVER AND ALLOW EASY ACCESS TO THE
  STUDENTS.

35
Lesson One Workstation 2 Tag Components

• This is a component location and function
  activity (Easter egg hunt).
• Tag components listed on worksheet before
  beginning class on Day One.

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Tag Components for Lesson One Workstation 2

• IMPORTANT NOTES FOR THIS WORKSTATION
• This activity will require that the vehicle be
  placed on a hoist.
• Remove the Beauty cover from the engine.
• Remove the aeroshield from the bottom of the
  engine.
• The Electric A/C compressor, eCVT, vacuum pump,
  M/E cooling pump, and heater helper pump are all
  tagged from the bottom of the vehicle.
• Students may have difficulty identifying the M/E
  cooling pump and the heater helper pump since
  they both look the same. The one that is higher
  up in the engine compartment is the helper pump.
• Students may have difficulty identifying the
  Electric A/C Compressor and the Vacuum Pump due
  to limited space in engine compartment.
• After tagging, raise the vehicle seat backs so
  the students will have to use the screwdriver to
  release the seats.
• See the next page for a list of components to be
  tagged.

37
Tag Components for Lesson One Workstation 2

• This activity requires that the students locate
  the components listed on the worksheet and
  identify the component function.
• The 18 components listed below are tagged with
  either numbers or letters
• HVPB
• Electrical A/C Compressor
• Brake Booster
• Electric Coolant Pump
• DC/DC Converter
• Vacuum Pump
• Service Disconnect Switch
• RCM (Tag on outside of
• BEC
• DC/AC Inverter
• 110 Volt Plug
• BPSM
• EPAS
• BECM
• ME Coolant Pump
• HVBP Cooling Fan
• eCVT

38
Bug for Lesson One Workstation 5

• This activity requires that the students diagnose
  and replace the High-Voltage Low-Current fuse on
  a 2010 Fusion/Milan.
• Before beginning class on Day One, install the
  blown High-Voltage Low-Current (HVLC) fuse in the
  BEC.
• Refer to INST 21 in the IGK
• Refer to Section 414-03 in the WS manual.
• View photos on following pages for more details.

39
Bug for Lesson One Workstation 5
8 mm screw
13 mm Nut
8 mm nuts

• WARNING MAKE SURE THE SERVICE DISCONNECT SWITCH
  IS REMOVED FROM THE VEHICLE
• After accessing the BEC, remove the two 8mm and
  one 13mm nut and one 8mm screw shown here.

40
Bug for Lesson One Workstation 5
8 mm Screw
HV Bus Bar
8 mm nuts
13 mm Nut
HVLC Fuse
HVLC Bus Bar

• Remove the HVLC Bus Bar from the BEC, then remove
  the fuse.
• This is not reassembled the same way for the
  class. See next page.

41
Bug for Lesson One Workstation 5
13 mm Nut
8 mm nuts
HVLC Bus Bar
HVLC Fuse

• During reassembly, install the HV bus bar 1st,
  and retain it using the 8 mm screw.
• Then install the HVLC bus bar over the HV bus bar
  end.
• This will require that the students only remove
  the parts shown here to replace the fuse.

42
Bug for Lesson One Workstation 5

• IMPORTANT NOTES FOR THIS WORKSTATION
• Have the students use a lb-in torque wrench and
  torque nuts and bolts to ½ WSM torque
  specifications.
• There is a question on the worksheet to make them
  look up the correct torque specifications.
• Make sure that the students remove the HV bus bar
  and HVLC bus bar and do not bend it.
• Have the first two workgroups re-install the
  blown fuse into the BEC.
• Give the last workgroup the good fuse to install
  and verify the vehicle will start.
• INSTRUCTOR WARNING
• AFTER SETTING THE BUG, PLACE THE BEC COVER BACK
  OVER THE BEC AND BPSM TO PREVENT ACCIDENTAL
  CONTACT WITH A HV COMPONENT WITH THE SERVICE
  DISCONNECT INSTALLED. USE ONLY 1 FASTENER TO
  RETAIN THE COVER AND ALLOW EASY ACCESS TO THE
  STUDENTS.

43
Bug for Post Test

• The post test fault is to simply remove the
  Service Disconnect switch.
• Remove the Service Disconnect Switch, lower the
  handle and reinsert it into its socket to help
  disguise that it is not connected.
• Raise both seat backs until they latch. This will
  help disguise the bug and require that the
  student demonstrate their ability to release the
  latches with the long flat tipped screwdriver.
• This will create a no-start condition and the
  student must read the DTCs and identify the
  fault.

44
Workstation Setup

• Supplemental information for preparing these
  workstations can be found in the IGK Instructor
  Information Section.

45
Lesson One Workstation 1Escape/Mariner Component
Location and Function

• Instructor Strategy
• In this activity, students will look up data and
  procedures in the PC/ED manual and Wiring
  Diagrams manual, and answer related questions on
  the worksheet.
• Remind students that some publications change
  from year to year and model to model. Always
  consult the Service Publications for the correct
  model year and vehicle being serviced.
• Instruct the students to NOT open any other files
  loaded on this computer at this time.
• Activity/Bug Setup
• Before class starts, install the following on the
  workstation PC
• - Training Service Publications DVD
• - Zip folder IDS_SessionArchive1.zip
• - Zip folder L2 WKS 3. zip
• - IDS Version 60 or newer

46
Lesson One Workstation 1Escape/Mariner Component
Location and Function

• Required Equipment
• l PC on table
• l Training Service Publications DVD
• l Student Guide - Lesson One - Workstation 1
  Worksheet

47
Lesson One Workstation 2FUSION/MILAN COMPONENT
LOCATION AND FUNCTION

• Instructor Strategy
• In this activity, students will locate specific
  hybrid vehicle components, identify the function
  of those components and list the tag number that
  is attached to that component on the vehicle.
• This activity will require tags that are visible
  only by raising the vehicle on a hoist.
• Activity/Bug Setup
• There are no bugs for this activity.
• Tag the components listed on the worksheet and
  note the tag numbers in your instructor guide.
  These numbers may be added to your PowerPoint
  presentation for convenience.
• Remove the HV safety switch

48
Lesson One Workstation 2FUSION/MILAN COMPONENT
LOCATION AND FUNCTION

• See the Bug Setup section of this PowerPoint for
  more information.
• Tag components listed on worksheet before
  beginning class on Day One.
• Refer to the Bug Setup section of this PowerPoint
  for more details about this workstation.

49
Lesson One Workstation 2FUSION/MILAN COMPONENT
LOCATION AND FUNCTION

• Required Equipment
• QTY ITEM
• 1 Vehicle on hoist
• 18 Tags
• 2 Fender covers
• 1 Long flat tipped screwdriver for releasing the
  rear seat
• 1 Personal Computer with Training Service
  Publications DVD
• 2 Wheel chocks
• 1 Student Guide - Lesson One - Workstation 2
  Worksheet

50
Lesson One Workstation 3High Voltage Safety Quiz

• Instructor Strategy
• In this activity, students will look up safety
  procedures as described in the student guide and
  service publications, and then answer related
  questions on the worksheet.
• Students must enter their name at the top of the
  worksheet as this document demonstrates they
  received safety training.
• Activity/Bug Setup
• Before class starts, install the following on the
  workstation PC
• - Training Service Publications DVD
• - Student Guide Lesson One Workstation 3
  Worksheet

51
Lesson One Workstation 3High Voltage Safety Quiz

• Required Equipment
• PC on table
• Training Service Publications DVD
• Student Guide - Lesson One - Workstation 3
  Worksheet

52
Lesson One Workstation 4Escape/Mariner Hybrid
Brake Service

• Instructor Strategy
• For this workstations the students will use the
  PC to play the Escape Brake Service video
  found on the instructor CD for this course .
  Additionally, service publications will also have
  to be referenced.
• The purpose of this activity is to allow students
  to view Escape Hybrid brake service procedures on
  the hotline produced video. This will teach them
  the unique aspects of Escape Hybrid brake
  service.
• Instruct the students to NOT open any other files
  loaded on this computer at this time.
• Activity/Bug Setup
• Load the Escape Brake Service video on to the
  PC.

53
Lesson One Workstation 4Escape/Mariner Hybrid
Brake Service

• Required Equipment
• PC on table with speakers
• Training Service Publications DVD
• Student Guide - Lesson One - Workstation 4
  Worksheet

54
Lesson One Workstation 5Fusion/Milan High
Voltage Service

• Instructor Strategy
• Using the IDS and the service publications,
  students will diagnose and repair a No Charging
  concern on a 2010 Fusion/Milan Hybrid. This is
  caused by a blown High-Voltage Low-Current
  (HV-LC) fuse. DTC P0AFA16 will be diagnosed.
• This activity is designed to provide the students
  with hands-on practice diagnosing and servicing
  the HV system.
• Activity/Bug Setup
• For this activity the install the damaged HV-LC
  fuse.
• This will require that the students to remove and
  replace the fuse to correct the source of the
  fault.
• See Bug Setup section of this PowerPoint for
  additional information.

55
Lesson One Workstation 5Fusion/Milan High
Voltage Service
T-35 Torx
10 mm Nuts
D
E
C
B
F
G
A
H
10 mm Nut

• Required Equipment
• QTY ITEM
• 1 105-00R57 Digital Multi-Meter (A)
• 1 Blown High-Voltage Low- Current Fuse (B)
• 1 1/4 Rachet with extension (C)
• 1 13 mm socket (D)
• 1 10 mm socket (E)
• 1 T35 Torx socket (F)
• 1 1/4 Lb.- In. torque wrench (G)
• 1 Long flat tip screwdriver (H)

56
Lesson One Workstation 6Hybrid Diagnostic
Procedures

• Instructor Strategy
• This is a 2 part activity. In part 1 of this
  activity the students will view the IDS recording
  and interpret the Datalogger readings to answer a
  series of questions. In part 2 of this activity,
  students will look up data and procedures in the
  service publications, and answer related
  questions on the worksheet.
• Remind students that some publications change
  from year to year and model to model. Always
  consult the Service Publications for the correct
  model year and vehicle being serviced.
• Instruct the students to NOT open any other files
  loaded on this computer at this time.
• Activity/Bug Setup
• Before class starts, install the following on the
  workstation PC
• Training Service Publications DVD
• Zip folder IDS_SessionArchive1.zip
• Zip folder L2 WKS 3. zip
• IDS Version 60 or newer

57
Lesson One Workstation 6Hybrid Diagnostic
Procedures

• Required Equipment
• PC on table
• Training Service Publications DVD
• Student Guide - Lesson One - Workstation 6
  Worksheet

58
Lesson Two DemonstrationHybrid Vehicle
Diagnostics

• Instructor Strategy
• This demonstration teaches the students
• Interactive Diagnostics
• Engine Running/Cranking Diagnosis Mode
• To perform the interactive diagnostic portion of
  the demonstration
• Connect a web-enabled Instructor PC to the
  overhead projector. Go to the PTS website. Under
  the training tab select the Steering Systems
  Theory and Operation Web Course 33S12W1.

59
Lesson Two DemonstrationHybrid Vehicle
Diagnostics

• Instructor Strategy (continued)
• Select the Electronic Power Steering (EPAS)
  lesson. Then select the EPAS Interactive
  Diagnostics subtopic.
• Then, review the web course addressing the
  questions on the Student Worksheet.
• For more details on the operation of Interactive
  Diagnostics refer to the Steering Systems Theory
  and Operation Web Course 33S12W1 and the service
  publications.
• If web access is not available at your location,
  an alternative method of presenting the
  interactive diagnostics demonstration is to show
  the PowerPoint review of the student worksheet
  while reviewing the answers with the students as
  a class.
• To perform the Engine Running/Cranking Diagnosis
  Mode
• Gather the students at the classroom vehicle and
  use the directions on the student worksheet to
  place the vehicle in the Engine Running/Cranking
  Diagnosis Modes.

60
Lesson Two DemonstrationHybrid Vehicle
Diagnostics

• Instructor Strategy (continued)
• Activity/Bug Setup
• None
• Required Equipment
• Fusion/Milan Hybrid classroom vehicle
• Computer with connection to PTS website.
• Lesson Two - Demonstration Worksheet
• Instructor Action Upon Completion of
  Demonstration
• Give the students a break, and then set up Lesson
  Two - Workstation 2 by placing the micro-switch
  for the bug into the open position.

61
Lesson Two Workstation 1IDS Hybrid Diagnosis

• Instructor Strategy
• This is a 2 part activity. In part 1 of this
  activity the students will view the IDS recording
  and interpret the Datalogger readings to answer a
  series of questions about voltage leakage. In
  part 2 of this activity the students will view
  the IDS recording and interpret the Datalogger
  readings to answer a series of questions about
  HVBP voltage. In both parts students will look up
  data and procedures in the service publications,
  and answer related questions on the worksheet.
• Remind students that some publications change
  from year to year and model to model. Always
  consult the Service Publications for the correct
  model year and vehicle being serviced.
• Activity/Bug Setup
• Before class starts, install the following on the
  workstation PC
• Training Service Publications DVD
• Zip folder IDS_SessionArchive1.zip
• Zip folder L2 WKS 3. zip
• IDS Version 60 or newer

62
Lesson Two Workstation 1IDS Hybrid Diagnosis

• Required Equipment
• PC on table
• Training Service Publications DVD
• Student Guide Lesson Two - Workstation 2
  Worksheet

63
Lesson Two Workstation 2High Voltage System
Diagnosis

• Instructor Strategy
• The purpose of this activity is for students to
  become familiar with performing high voltage
  diagnostic and service procedures on hybrid
  vehicles.
• Activity/Bug Setup
• After completion of the Demonstration, have the
  students take a break out of the classroom.
• Flip the previously installed micro-switch to
  open circuit J1-A61

64
Lesson Two Workstation 2High Voltage System
Diagnosis
B
A
C
E

• Required Equipment
• QTY ITEM
• 1 105-00R57 Digital Multi-Meter (A)
• 1 IDS (B)
• 1 Long flat tip screwdriver (C)
• 1 Set 300-08040 .060 Female Flex Probes for DVOM
  leads (D)
• 1 Set 300-08045 .064 Male Flex Probes for DVOM
  leads (E)

D
65
Lesson Two Workstation 3Hybrid Diagnostic
Procedures

• Instructor Strategy
• This is a 2 part activity. In part 1 of this
  activity the students will view the IDS recording
  and interpret the Datalogger readings to answer a
  series of questions. In part 2 of this activity,
  students will look up data and procedures in the
  service publications, and answer related
  questions on the worksheet.
• Remind students that some publications change
  from year to year and model to model. Always
  consult the Service Publications for the correct
  model year and vehicle being serviced.
• Instruct the students to NOT open any other files
  loaded on this computer at this time.
• Activity/Bug Setup
• Before class starts, install the following on the
  workstation PC
• Training Service Publications DVD
• Zip folder IDS_SessionArchive1.zip
• Zip folder L2 WKS 3. zip
• IDS Version 60 or newer

66
Lesson Two Workstation 3Hybrid Diagnostic
Procedures

• Required Equipment
• PC on table
• Training Service Publications DVD
• Student Guide Lesson Two - Workstation 2
  Worksheet

67
Post Test
68
Post Test

• Instructor Strategy
• The purpose of this activity is for students to
  prove out their understanding of hybrid vehicle
  operation and demonstrate their ability to
  diagnose a hybrid vehicle concern. The exam is
  performed at two workstations at their seats and
  on the classroom vehicle.
• Activity/Bug Setup
• Prior to class
• Make one copy of the HANDS-ON POST TEST worksheet
  for each student from the Replication section
  of this Instructor Guide.
• Make one copy of the WRITTEN POST TEST ANSWER
  SHEET for each student from the Replication
  section of this Instructor Guide.
• Make the following copies of the WRITTEN POST
  TEST from the Replication section of this
  Instructor Guide
• Written Post-Test A for approximately one-third
  of the class
• Written Post-Test B for approximately one-third
  of the class
• Written Post-Test C for approximately one-third
  of the class
• AFTER DAY TWO WORKSTATIONS (DURING LUNCH OF DAY
  2)
• Remove HV service connector from vehicle
• Close rear seat of classroom vehicle over HVBP
• Clear DTCs and perform a KOEO test. Verify
  P0B3700 now appears.