1. Lesson One Workstations 4 - 6
Escape/Mariner Brake Service Procedures
Workstation 5
Hands On – Fusion/Milan
High Voltages Service
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: Summary:
4 Escape/Mariner Brake Service (video-written)
5 High Voltage Service (hands-on)
6 Hybrid Diagnostic Procedures (written)
Workstation 6
Diagnosis and Service Procedures

2. Lesson One Workstation 4
DIRECTIONS: View the Hybrid Brake Service video, then use the video and service publications to answer the questions below.
Review worksheet instructions

3. Lesson One Workstation 4
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 Brake Pads Hybrid in WSM)
Use the PowerPoint slide to explain how to manually shut down the brake system for service.

4. Use the PowerPoint slide to explain how to manually shut down the brake system for service.

5. 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 Brake Pads - Hybrid in WSM)
Use the PowerPoint slide to explain the unique life span of the brake pads.

6. Use the PowerPoint slide to explain the unique life span of the brake pads.

7. 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 Brake System Bleeding – Hybrid)
Use the PowerPoint slides to show the students where the brake fluid checking procedure is described. Also point out the brake bleeding video link.

8. Use the PowerPoint slides to show the students where the brake fluid checking procedure is described. Also point out the brake bleeding video link.

9. Lesson One Workstation 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)
Review answer as needed.

10. Lesson One Workstation 4
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)
Review answer as needed.

11. Lesson One Workstation 4
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
Review answer as needed.

12. Lesson One Workstation 4
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)
Explain that this is an IDS exclusive feature and that aftermarket technicians must use the method described in the WSM.

13. Lesson One Workstation 4
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)
Emphasize the importance of following the brake bleed procedure as described in the video or the brake system will not operate correctly and will likely set a DTC.

14. Lesson One Workstation 4
What pressure is the Rotunda brake bleeder initially set at when performing brake bleeding?
2 bar or 35 psi - (8:04 of video)
Emphasize the need to use the brake bleeder for correct bleeding of hybrid brakes.

15. Lesson One Workstation 4
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)
Explain the need to follow the pedal pumping procedures to correctly bleed the brakes.

16. Lesson One Workstation 4
What does it indicate when the IDS presents a code OB?
That the pedal needs to be pressed more slowly - (12:56 of video)
Use the PowerPoint slide to discuss the codes that indicate brake bleeding issues.
Go to next slide.

17. Use the PowerPoint slide to discuss the codes that indicate brake bleeding issues.

18. Lesson One Workstation 4
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)
Discuss brake system inputs as needed.

19. Lesson One Workstation 4
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)
Discuss the cause of the DTC.

20. Lesson One Workstation 4
What code indicates that the brake system initialization is incomplete?
DTC C (16:24 of video)
Discuss the cause of the DTC.

21. 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.
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.

22. Lesson One Workstation 5
Can you verify this concern. Are there any messages being displayed in the message center?
YES – Check Charging System
Review vehicle symptoms.

23. Lesson One Workstation 5
Does your visual inspection reveal any obvious flaws? NO
Review visual inspection points on a hybrid vehicle.

24. Lesson One Workstation 5
Perform the KOEO self-test, then clear all DTCs. Repeat the KOEO (ALL CMDTCs) self-test 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.
Discuss the DTCs.

25. Lesson One Workstation 5
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
Explain that by comparing the pinpoint tests for the DTCs all indicate a common source for DTCs that are set in different modules.

26. Lesson One Workstation 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
Explain that these PIDs will tell the techs that the capacitors have discharged.

27. Lesson One Workstation 5
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 of WSM. They should find the blown HV-LC fuse. Have students complete questions 7-10 then instruct them to remove fuse.
Discuss process students followed to get the correct test. Ask them what they found.

28. Lesson One Workstation 5
What section of the Workshop Manual contains directions for performing this service?
414-03
Discuss service procedure for fuse replacement. Section 414 is the high voltage section of the WSM.
Point out that almost all pinpoint tests for the high voltage system will be in the Battery and Charging System section of the WSM.

29. Lesson One Workstation 5
At the beginning of the directions for replacing this component, summarize the WARNING about the service disconnect switch.
Emphasize warning. Explain that during the class the service disconnect switch is installed with the cover removed for training purposes. This is not to be done during normal service in the field.

30. Lesson One Workstation 5
Why must the high-voltage/low-current bus bar be removed during this service procedure?
To prevent bending the High-voltage/low-current circuit bus bar
Emphasize the need for extra care during removal and replacement of fuse to various components, since damage to even a small part will require replacement of BEC.

31. Lesson One Workstation 5
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)
Emphasize the need for extra care during removal and replacement of fuse to various components, since damage to even a small part will require replacement of BEC.

32. Lesson One Workstation 6 (Part 1)
DIRECTIONS: Use IDS recording L1_WKS6 of the Milan to answer the following questions.
Review worksheet instructions

33. Lesson One Workstation 6 (Part 1)
The three PIDS listed below are shown in this recording. Write the IDS definition next to each PID.
PID
PID Description
GENMODE
Generator Control Mode
RPM TCM
Engine Revolutions Per Minute (as measured by the TCM)
Use the PowerPoint slide to review the meanings of the PIDS
VSS
Vehicle Speed Sensor

34. Lesson One Workstation 6 (Part 1)
List the PID readings at approximately 8 seconds into the recording.
PID
PID Description
GENMODE
Speed
RPM TCM
1290 RPM
Use the PowerPoint slide to review the PID readings at 8 seconds
VSS
6.83 mph

35. Use the PowerPoint slide to review the PID readings at 8 seconds

36. Lesson One Workstation 6 (Part 1)
List the PID readings at approximately 28 seconds of the recording.
PID
PID Description
GENMODE
Torque
RPM TCM
0 RPM
Use the PowerPoint slide to review the PID readings at 28 seconds
VSS
14 Kph

37. Use the PowerPoint slide to review the PID readings at 28 seconds

38. Lesson One Workstation 6 (Part 1)
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
Discuss the GENMODE PID indications of gasoline engine operation

39. 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
Discuss the GENMODE PID indications of gasoline engine starting and shutdown

40. 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
Explain that when diagnosing a hybrid it is essential that knowing when the engine is starting, running, or shutdown is essential.
Give examples for this, i.e. a vehicle has a customer concern of vibration. While road testing the vehicle you find the vibration occurs only when the engine is shutting down. While viewing the GENMODE and RPM TCM PIDS you find that the engine rpm is not stopping completely when commanded. What might be occurring? One answer is that the engine might be dieseling at shutdown.
Use other examples as appropriate.

41. Lesson One Workstation 6 (Part 2)
DIRECTIONS: A 2008 Escape Hybrid is brought to you with a customer concern of “Hard Steering”.
Review worksheet instructions

42. Lesson One Workstation 6 (Part 2)
What type of EPAS system does this vehicle have?
Column Mounted
Review the different EPAS systems and which vehicles they will be found on.

43. 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.

44. Lesson One Workstation 6 (Part 2)
Diagnostic Step
Result
Verify the Concern
Concern exists as stated by the customer
Visual Inspection
All OK
Connect Scan Tool and Retrieve DTCs
DTC B2277 is present
View DTC Charts and Descriptions in PC/ED
Note Bxxxx
View Master Diagnostic Trouble Code (DTC) Index in Workshop Manual
Go to Section in WSM
View PSCM DTC Chart
Go to Pinpoint Test B

45. Lesson One Workstation 6 (Part 2)
Diagnostic Step
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