Hybrid Vehicle Operation and Diagnosis Training Demonstration Interactive Diagnostics Interactive...

Hybrid Vehicle Operation and Diagnosis TrainingHybrid Vehicle Operation and Diagnosis Training

Demonstration

• Interactive DiagnosticsInteractive Diagnostics• Engine Running/Cranking Diagnosis ModeEngine Running/Cranking Diagnosis Mode


Lesson TwoDemonstration

1.1. What requirements must be met for the IDS to What requirements must be met for the IDS to be utilized for Interactive Diagnostics? be utilized for Interactive Diagnostics?

The IDS must be web-enabled via a LAN or The IDS must be web-enabled via a LAN or wireless connectionwireless connection



2.2. Once connected to the PTS website, how do you Once connected to the PTS website, how do you begin the diagnostic process? begin the diagnostic process?

Either the Quick Start selection or by going to Either the Quick Start selection or by going to the workshop manualthe workshop manual



3.3. Once in the Workshop Manual, what section was Once in the Workshop Manual, what section was selected, and what topic was selected?selected, and what topic was selected?

Section 211-02B, Diagnostic SelectionSection 211-02B, Diagnostic Selection



4.4. On this page, what is unique about the left hand On this page, what is unique about the left hand menu of the Workshop Manual?menu of the Workshop Manual?

The Pinpoint Tests are grayed out indicating The Pinpoint Tests are grayed out indicating they are lockedthey are locked



5.5. In order to continue the diagnosis, what must be In order to continue the diagnosis, what must be selected on this page?selected on this page?

Known Vehicle ConcernsKnown Vehicle Concerns



6.6. What does the IDS automatically perform when What does the IDS automatically perform when this page is selected? this page is selected?

Retrieves DTCs for the system being Retrieves DTCs for the system being diagnosed (EPAS)diagnosed (EPAS)



7.7. What is the next selection that must be made in What is the next selection that must be made in order to continue the diagnosis? order to continue the diagnosis?

OASIS must be viewedOASIS must be viewed



8.8. From this page, what must be done to continue?From this page, what must be done to continue? The OASIS page must be closedThe OASIS page must be closed



9.9. What question is now asked by the IDS, and What question is now asked by the IDS, and what will result based upon the answer to the what will result based upon the answer to the question?question?

IDS will ask if a DTC was present, if so it IDS will ask if a DTC was present, if so it directs you to the DTC Chart, if not it directs directs you to the DTC Chart, if not it directs you to the Symptom Chartyou to the Symptom Chart



10.10. Once you are directed to the page based upon Once you are directed to the page based upon your answer to the question, what is shown on your answer to the question, what is shown on that page?that page?

Possible cause of the fault and links to the Possible cause of the fault and links to the Pinpoint Tests for the faultPinpoint Tests for the fault



11.11. What has happened to the left menu on this What has happened to the left menu on this page? page?

All the Pinpoint Tests are now unlockedAll the Pinpoint Tests are now unlocked



12.12. If a VMM is connected to the vehicle, what If a VMM is connected to the vehicle, what action will the IDS automatically perform during action will the IDS automatically perform during your diagnosis? your diagnosis?

It will archive the resultsIt will archive the results



13.13. What additional aid does Interactive Diagnostics What additional aid does Interactive Diagnostics offer if you require assistance from the Technical offer if you require assistance from the Technical Hotline? Hotline?

The Technical Hotline can see the steps The Technical Hotline can see the steps you’ve taken and their results in real time via you’ve taken and their results in real time via the netthe net


Engine Cranking/Engine Running Diagnostic Mode

The purpose of these modes is to enable the The purpose of these modes is to enable the service technician to perform engine service technician to perform engine cranking or to maintain a running gasoline cranking or to maintain a running gasoline engine for diagnostic purposes.engine for diagnostic purposes.


Lesson TwoWorkstations 1 - 3

Workstation 1Workstation 1 IDS Hybrid Diagnosis IDS Hybrid Diagnosis

Workstation 2Workstation 2Hands On – Fusion/MilanHands On – Fusion/Milan

DiagnosisDiagnosis

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

THE BEC COVER IS REMOVEDTHE BEC COVER IS REMOVED

Workstation 3Workstation 3Hybrid Diagnostic ProceduresHybrid Diagnostic Procedures

Use CMT Active Student Program

shortcut to launch the service information.


Lesson TwoWorkstation 1 (Part 1)

SCENARIO/DIRECTIONS: A 2010 Fusion Hybrid SCENARIO/DIRECTIONS: A 2010 Fusion Hybrid is brought to you from the body shop that has is brought to you from the body shop that has been in a flood. The vehicle is a no-start and the been in a flood. The vehicle is a no-start and the red triangle warning light is illuminated. red triangle warning light is illuminated. P0AA6:00 is present in the BCM memory? Using P0AA6:00 is present in the BCM memory? Using the IDS open recording L2_WKS1 and service the IDS open recording L2_WKS1 and service publications, answer the following questions publications, answer the following questions about this concern.about this concern.



1.1. What service publication and section of that What service publication and section of that publication describes this DTC?publication describes this DTC?

WSM 414-03WSM 414-03



2.2. What is the DTC Chart description of this DTC?What is the DTC Chart description of this DTC? Hybrid Battery Voltage System Isolation Hybrid Battery Voltage System Isolation

FaultFault



3.3. Which pinpoint test are you directed to for Which pinpoint test are you directed to for diagnostic procedures?diagnostic procedures?

Pinpoint Test JPinpoint Test J



4.4. According to the pinpoint test introduction, what According to the pinpoint test introduction, what does the BECM monitor that could cause this does the BECM monitor that could cause this DTC?DTC?

The electrical isolation between the high The electrical isolation between the high voltage system and the chassisvoltage system and the chassis



5.5. In step 1 of this pinpoint test, you are directed to In step 1 of this pinpoint test, you are directed to view specific PIDs. Go to IDS recording and view specific PIDs. Go to IDS recording and view these PIDs. List each PID and record the view these PIDs. List each PID and record the value shown on the IDS.value shown on the IDS.

BECM PID LEAKRESPOS - 1.63 MohmsBECM PID LEAKRESPOS - 1.63 Mohms BECM PID LEAKRESNET - 1.63 MohmsBECM PID LEAKRESNET - 1.63 Mohms BECM PID LEAKRESALL - 1.63 MohmsBECM PID LEAKRESALL - 1.63 Mohms



6.6. What resistance value is considered a failure on What resistance value is considered a failure on this system?this system?

147,000 ohms147,000 ohms



7.7. If these readings were/are out of specifications, If these readings were/are out of specifications, what might be the cause of the concern based on what might be the cause of the concern based on the vehicle history and description of the the vehicle history and description of the pinpoint test?pinpoint test?

That water or moisture may have gotten into That water or moisture may have gotten into the HV electrical connectorsthe HV electrical connectors



8.8. This vehicle is going to be repainted. Your This vehicle is going to be repainted. Your facility uses a paint booth for paint drying. Is facility uses a paint booth for paint drying. Is there any special information that you must there any special information that you must provide the body shop manager to prevent provide the body shop manager to prevent vehicle component damage?vehicle component damage?


The paint booth temperature must The paint booth temperature must be set at or below 60°C (140°F) be set at or below 60°C (140°F) with a bake time of 45 minutes with a bake time of 45 minutes or lessor less



•SCENARIO/DIRECTIONS: A 2010 Fusion Hybrid is brought to you from SCENARIO/DIRECTIONS: A 2010 Fusion Hybrid is brought to you from the vehicle prep department: the vehicle prep department: • The vehicle now seems to run normally, but the prep technician said The vehicle now seems to run normally, but the prep technician said that when he first attempted to start the vehicle it would not start and the that when he first attempted to start the vehicle it would not start and the red triangle light was illuminated. red triangle light was illuminated. • The next day, when the service manager tried to start it, the vehicle The next day, when the service manager tried to start it, the vehicle started normally. However, the service manager wants you to check the started normally. However, the service manager wants you to check the vehicle out. vehicle out. • After visual inspecting the vehicle, you find no obvious faults. Then you After visual inspecting the vehicle, you find no obvious faults. Then you retrieve DTCs and find CMDTC of P0A7D00 stored in the BECM memory. retrieve DTCs and find CMDTC of P0A7D00 stored in the BECM memory. Use IDS recording L2_WKS2 and service publications to answer the Use IDS recording L2_WKS2 and service publications to answer the following questions about this concern.following questions about this concern.



1.1. What service publication and section of that What service publication and section of that publication describes this DTC?publication describes this DTC?

WSM 414-03WSM 414-03



2.2. What is the DTC Chart description of this DTC?What is the DTC Chart description of this DTC? Hybrid Battery Pack State of Charge LowHybrid Battery Pack State of Charge Low



3.3. Which pinpoint test are you directed to for Which pinpoint test are you directed to for diagnostic procedures?diagnostic procedures?

Pinpoint Test BPinpoint Test B



4.4. According to the pinpoint test introduction, what According to the pinpoint test introduction, what does the BECM monitor that could cause this does the BECM monitor that could cause this DTC?DTC?

Low state of charge of HVBPLow state of charge of HVBP



5.5. In step 2 of this pinpoint test, you are directed to In step 2 of this pinpoint test, you are directed to view specific PIDs. Go to IDS recording and view specific PIDs. Go to IDS recording and view these PIDs. List each PID and record the view these PIDs. List each PID and record the value shown on the IDS.value shown on the IDS.

BECM PID HEVMINVOLT = HYBRID BECM PID HEVMINVOLT = HYBRID MINIMUM BATTERY VOLTAGE = 10.30 MINIMUM BATTERY VOLTAGE = 10.30 voltsvolts

BECM PID BATTPACKVOLT = HYBRID BECM PID BATTPACKVOLT = HYBRID BATTERY PACK VOLTAGE = 269 voltsBATTERY PACK VOLTAGE = 269 volts



6.6. According to the pinpoint test, what actions According to the pinpoint test, what actions should you take?should you take?

Clear DTCs and retest the vehicleClear DTCs and retest the vehicle



7.7. On a 2010 Fusion Hybrid, what action will the On a 2010 Fusion Hybrid, what action will the ABS module take if there is a vacuum pump ABS module take if there is a vacuum pump motor concern?motor concern?

The ABS module will store a DTC and the The ABS module will store a DTC and the gasoline engine will continue to run to gasoline engine will continue to run to provide brake system vacuum (WSM 206-09 - provide brake system vacuum (WSM 206-09 - Anti-Lock Control - Hybrid)Anti-Lock Control - Hybrid)



8.8. On a 2010 Fusion Hybrid, what is the flow On a 2010 Fusion Hybrid, what is the flow direction in the M/E cooling system (from direction in the M/E cooling system (from component to component)?component to component)?

Coolant flow in the M/E cooling system is Coolant flow in the M/E cooling system is from the DC/DC converter, then to the eCVT, from the DC/DC converter, then to the eCVT, then through the MECs cooler from the LH then through the MECs cooler from the LH to RH side, then back to the DC/DC converter to RH side, then back to the DC/DC converter (WSM 307-01C)(WSM 307-01C)



9.9. On a 2010 Fusion Hybrid, what action must be On a 2010 Fusion Hybrid, what action must be taken before welding on the vehicle?taken before welding on the vehicle?

The HVBP must be removed (WSM 501-35)The HVBP must be removed (WSM 501-35)



10.10. On a 2009 Escape Hybrid, what type of On a 2009 Escape Hybrid, what type of conventional brake system is used?conventional brake system is used?

It uses the SBA systemIt uses the SBA system



11.11. On a 2009 Escape Hybrid, what pinpoint test are On a 2009 Escape Hybrid, what pinpoint test are you directed to for a DTC P2612?you directed to for a DTC P2612?

Pinpoint Test E in Section 412-00B in the Pinpoint Test E in Section 412-00B in the WSMWSM



12.12. On a 2009 Escape Hybrid, how many lift points On a 2009 Escape Hybrid, how many lift points are used to remove the HV battery pack?are used to remove the HV battery pack?

Three (WSM 414-03)Three (WSM 414-03)


Lesson TwoWorkstation 2

SCENARIO/DIRECTIONS: A 2010 Fusion Hybrid is towed to your facility with a customer concern of no start and the red hazard triangle is illuminated. Diagnose the cause of this concern listing the steps you perform and answering the questions below.



1.1. Can you verify the customer concern?Can you verify the customer concern? YESYES



2.2. Your visual inspection revealed nothing out of Your visual inspection revealed nothing out of the ordinary so you retrieve DTCs. List any the ordinary so you retrieve DTCs. List any DTCs found below.DTCs found below.

P0AD9:00P0AD9:00



3.3. Which service publication contains the Master Which service publication contains the Master DTC chart for this vehicle?DTC chart for this vehicle?

Workshop ManualWorkshop Manual



4.4. What is the description of this DTC?What is the description of this DTC? Hybrid Battery Positive Contactor Control Hybrid Battery Positive Contactor Control

Circuit/OpenCircuit/Open



5.5. What pinpoint test are you directed to?What pinpoint test are you directed to? Pinpoint Test PPinpoint Test P



6.6. Summarize the WARNING in the first step of Summarize the WARNING in the first step of the pinpoint test to which you are directed.the pinpoint test to which you are directed.



Pinpoint Test P1Pinpoint Test P1 Yes, all resistances are within Yes, all resistances are within specificationsspecifications

Pinpoint Test P2Pinpoint Test P2 Yes, resistance is between 6 and 10 ohmsYes, resistance is between 6 and 10 ohms

Pinpoint Test P3Pinpoint Test P3 Yes, resistance is less than 5 ohmsYes, resistance is less than 5 ohms

Pinpoint Test P4Pinpoint Test P4 Open found between C4236D-4 and Open found between C4236D-4 and C4237B-61 on circuit J1-A61C4237B-61 on circuit J1-A61

Diagnostic StepDiagnostic Step ResultResult

7.7. List the Pinpoint Test Steps you are directed to List the Pinpoint Test Steps you are directed to perform and their results in the table below.perform and their results in the table below.



8.8. What action are you directed to take to correct What action are you directed to take to correct this concern?this concern?

Replace the HVBP and wiringReplace the HVBP and wiring



SCENARIO/DIRECTIONS: Open the IDS software on the classroom PC and load the Escape/Mariner L2 WKS 3 file. Use the Datalogger files and service publications to answer the following questions.



1.1. What size and type of gasoline engine is installed What size and type of gasoline engine is installed in this vehicle?in this vehicle?



2.2. At what vehicle speed does the gasoline engine At what vehicle speed does the gasoline engine start for the first time on this recording?start for the first time on this recording?



3.3. When the gasoline engine starts for the first When the gasoline engine starts for the first time, what is the MECT_V reading?time, what is the MECT_V reading?



4.4. Go to Pinpoint Test DN in the PC/ED manual Go to Pinpoint Test DN in the PC/ED manual for this vehicle. Using the information in the for this vehicle. Using the information in the introduction of this pinpoint test, what is the introduction of this pinpoint test, what is the approximate operating temperature of the ME approximate operating temperature of the ME coolant?coolant?

About 20 About 20 °° C (68 C (68°°F)F)



5.5. Based upon the information in questions 3 & 4, Based upon the information in questions 3 & 4, approximately what should the resistance be for approximately what should the resistance be for the MECT sensor if you measured it with a ohm the MECT sensor if you measured it with a ohm meter?meter?

About 38 K ohms About 38 K ohms



6.6. At about what time in the recording does the At about what time in the recording does the HPUMP# PID indicate ON for the first time?HPUMP# PID indicate ON for the first time?

About 3 secondsAbout 3 seconds



7.7. If you were unsure of heater pump operation, If you were unsure of heater pump operation, what can you do using the IDS to determine if it what can you do using the IDS to determine if it operates?operates?

It can be commanded on. This is indicated by It can be commanded on. This is indicated by the # sign next to the PIDthe # sign next to the PID



Directions: Directions: A 2010 Fusion is brought to your A 2010 Fusion is brought to your facility with a no start/no crank condition. facility with a no start/no crank condition. Perform the diagnosis for this concern using Perform the diagnosis for this concern using the service publications and the Data Table the service publications and the Data Table provided by comparing the service provided by comparing the service publication pinpoint test steps to the publication pinpoint test steps to the pinpoint test steps listed.pinpoint test steps listed.



Verify the ConcernVerify the Concern Vehicle does not start High Voltage Vehicle does not start High Voltage Telltale light is illuminatedTelltale light is illuminated

Visual InspectionVisual Inspection All OKAll OK

Connect Scan Tool and Connect Scan Tool and Retrieve DTCsRetrieve DTCs

DTC P0A0A:00 is presentDTC P0A0A:00 is present

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

Refer to Workshop ManualRefer to Workshop Manual

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

ManualManual

Go to Section 414-03Go to Section 414-03

View HVBP DTC ChartView HVBP DTC Chart Go to Pinpoint Test A1Go to Pinpoint Test A1





Pinpoint Test A2Pinpoint Test A2

Voltage between C4237-B Pin 44 and 47 Voltage between C4237-B Pin 44 and 47 is 5.0is 5.0

Pinpoint Test A3Pinpoint Test A3 Resistance is 0.2 ohms on all listed circuitsResistance is 0.2 ohms on all listed circuits

Pinpoint Test A4Pinpoint Test A4Resistance is between 0.2 and 0.8 ohms Resistance is between 0.2 and 0.8 ohms on all listed circuitson all listed circuits

Pinpoint Test A5Pinpoint Test A5 Resistance is OLResistance is OL

Pinpoint Test A1Pinpoint Test A1 PID VOLTINTINP does not read closedPID VOLTINTINP does not read closed

2.2. What component should be replaced to correct this fault?What component should be replaced to correct this fault? Replace DC/DC converter. Clear DTCs and retest to Replace DC/DC converter. Clear DTCs and retest to

verify repair.verify repair.


Post Test

On-VehicleOn-VehiclePost Test Hands-On WorksheetPost Test Hands-On Worksheet

At SeatAt SeatWritten Post TestWritten Post Test

DiagnosisDiagnosis

Hybrid Vehicle Operation and Diagnosis Training Demonstration Interactive Diagnostics Interactive...

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