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Hybrid Vehicle Operation and Diagnosis Course Code 30N10T1

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Presentation on theme: "Hybrid Vehicle Operation and Diagnosis Course Code 30N10T1"— Presentation transcript:

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 Fill in instructor information

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 STI’s 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 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 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 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 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 P0AD9:00 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 (Don’t spread them too far or they will break. Bet you can’t 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 Female Flex Probes for DVOM leads Set 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.

36 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 Brake Pedal Simulator

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 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 it’s 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 1 Escape/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 1 Escape/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 2 FUSION/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 2 FUSION/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 2 FUSION/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 3 High 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 3 High Voltage Safety Quiz
Required Equipment PC on table Training Service Publications DVD Student Guide - Lesson One - Workstation 3 Worksheet

52 Lesson One Workstation 4 Escape/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 4 Escape/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 5 Fusion/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 P0AFA:16 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 5 Fusion/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 R57 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 6 Hybrid 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 6 Hybrid Diagnostic Procedures
Required Equipment PC on table Training Service Publications DVD Student Guide - Lesson One - Workstation 6 Worksheet

58 Lesson Two Demonstration Hybrid 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 Demonstration Hybrid 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 Demonstration Hybrid 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 1 IDS 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 1 IDS Hybrid Diagnosis
Required Equipment PC on table Training Service Publications DVD Student Guide – Lesson Two - Workstation 2 Worksheet

63 Lesson Two Workstation 2 High 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 2 High Voltage System Diagnosis
B A C E Required Equipment QTY ITEM R57 Digital Multi-Meter (A) 1 IDS (B) 1 Long flat tip screwdriver (C) 1 Set Female Flex Probes for DVOM leads (D) 1 Set Male Flex Probes for DVOM leads (E) D

65 Lesson Two Workstation 3 Hybrid 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 3 Hybrid 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 P0B37:00 now appears.


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