Ford Ranger EV (2001 year). Manual — part 8

100-07-3

100-07-3

Electric Vehicle (EV) Diagnostic Direction

DIAGNOSIS AND TESTING (Continued)

NOTE: If the vehicle will not start and the

NOTE: Do not carry out diagnostic procedures for

malfunction indicator lamp (MIL), power limit

IAA module DTC C1862 Contactor Circuit Failure

warning indicator, low state of charge (SOC)

unless there is a multiple auxiliary load failure and

indicator, auxiliary battery indicator, red brake

DTC C1862 occurs after the IAA module

warning indicator, and/or electrical hazard warning

on-demand self-test is performed. A multiple

indicator are illuminated and there are no

auxiliary load failure occurs when the power

diagnostic trouble codes (DTCs) present on any of

steering, DC/DC converter, heating system, and air

the modules, it may be necessary to charge the

conditioning (if equipped) fail to operate.

traction battery to a full state of charge (SOC).

•

The IAA module logs DTCs C1862 Contactor

•

If the vehicle will not start and the malfunction

Circuit Failure, U1110 SCP (J1850)

indicator lamp (MIL), power limit warning

Invalid/Missing Data for Primary ID 6E, and

indicator, low state of charge (SOC) indicator,

U1117 Invalid Data for Electrical Energy

auxiliary battery indicator, red brake warning

Management in continuous memory when the

indicator, and/or electrical hazard warning

on-demand self-test is performed by the BCM.

indicator are illuminated and no DTCs exist on

Do not carry out diagnostic procedures for IAA

any of the modules, connect the vehicle to a

module DTC C1862 unless there is a multiple

power control station (PCS) and use the New

auxiliary load failure and DTC C1862 occurs after

Generation STAR (NGS) Tester to monitor

the IAA module on-demand self-test is performed.

battery control module (BCM) PID BCM OP.

•

IAA module DTC U1262 SCP (J1850)

Press the START button on the PCS and monitor

Communication Bus Fault may occur if the

the BCM OP PID for approximately 5 minutes.

ignition key is quickly cycled ON/OFF/ON. This

If the BCM OP PID indicates 48

may cause the malfunction indicator lamp (MIL)

(Shutdown-Low Module Voltage) or 114 (LOS

to illuminate. If this occurs, clear the IAA module

charge-Low Battery Voltage), allow the vehicle to

DTCs and slowly cycle the ignition key.

charge to a full SOC. If the BCM OP PID

•

TIM DTC C1184 ABS System Is Not Operational

indicates 96 (EPO Detected), disconnect the

occurs if the ignition key is cycled OFF/ON too

negative auxiliary battery cable, wait

fast. Do not carry out any pinpoint tests related to

approximately one minute, and reconnect.

the ABS unless the yellow ABS warning indicator
is illuminated and ABS DTCs occur.

Retrieving Diagnostic Trouble Codes (DTCs)

•

The red brake warning indicator and malfunction

The process for retrieving diagnostic trouble codes

indicator lamp (MIL) illuminate and TIM DTC

(DTCs) is the same for the interface adapter

U2015 Signal Link Fault (Non SCP) occurs if the

assembly (IAA) module and the battery control

ignition key is cycled OFF/ON before the

module (BCM). The IAA module and BCM use

anti-lock brake control module completes its

continuous DTCs and on-demand self-tests to

pump check. If this occurs, clear the TIM DTCs,

determine concerns in their systems. The traction

turn the ignition key to the ON position, and wait

inverter module (TIM) uses only continuous DTCs

for the completion of the ABS pump check. Carry

to determine concerns within its system. It does not

out the diagnostic procedures only if TIM DTC

have on-demand self-test capability. Refer to the

U2015 occurs after the completion of the ABS

DTC indices to determine if it is necessary to

pump check.

retrieve continuous DTCs and carry out on-demand
self-tests for the IAA module and BCM. Note the
following concerns that relate to retrieving DTCs:

100-07-4

100-07-4

Electric Vehicle (EV) Diagnostic Direction

DIAGNOSIS AND TESTING (Continued)

Diagnostic Process

PINPOINT TEST DP: DIAGNOSTIC PROCESS

TEST STEP

ACTION TO TAKE

DP1 VERIFY CUSTOMER CONCERN

NOTE: Check technical service bulletins (TSBs), OASIS, and vehicle

Yes =

GO to DP2.

repair records before proceeding. Also, check for any non-factory add-on

equipment. Determine if any of these have impact on vehicle concern.

•

Verify the customer concern is valid by operating the system(s) in

question.

•

Is the customer concern valid?

No =

ENSURE customer

understands the operating

characteristics of the vehicle.

DP2 PERFORM INSPECTION AND VERIFICATION

•

Perform a system inspection for the system(s) in question. Refer to

Yes =

REPAIR as necessary and

Inspection and Verification in this section.

RETEST.

•

Are any obvious concerns detected?

No =

GO to DP3.

DP3 PERFORM DATA LINK DIAGNOSTICS NETWORK TEST

•

Run the DATA LINK DIAGNOSTICS Network Test.

Yes =

GO to DP4.

•

Is SYSTEM PASSED obtained?

No =

REFER to

Section 418-00

.

DP4 DETERMINE IF CONCERN IS RELATED TO VEHICLE

CHARGING

•

Determine if concern is related to vehicle charging.

Yes =

GO to DP5.

•

Was vehicle brought in for repair due to a vehicle charging concern? No =

GO to DP6.

DP5 RETRIEVE DIAGNOSTIC TROUBLE CODES (DTCs) FROM

BATTERY CONTROL MODULE (BCM)

•

Access DTCs from BCM and record codes, including previous OP_State

Yes =

REFER to Traction Battery

(PREV_OP).

Charging/Heating System in

•

Clear continuous DTCs from the BCM.

Section 414-03A

or

Section 414-03B

.

•

Connect the vehicle to a power control station (PCS) and press the

No =

REFER to

Section 100-09

START button to begin charging.

Powertrain Diagnostic

•

Wait approximately five minutes and retrieve continuous DTCs from the

Routines Identification for

BCM. Note the DTCs.

symptom-related charging

•

Clear continuous DTCs (if necessary) and perform the BCM on-demand

diagnostics.

self-test. Note the DTCs.

•

Does DTC C1838 Charging System Fault occur?

DP6 RETRIEVE DTCs FROM INTERFACE ADAPTER ASSEMBLY

(IAA) MODULE

•

Retrieve continuous DTCs from the IAA module. Note the DTCs.

Yes =

REFER to the Interface

Adapter Assembly (IAA)

Module Diagnostic Trouble

Code (DTC) Index. CARRY

OUT the appropriate

diagnostic procedures. GO

to DP7.

•

Clear the continuous DTCs.

No =

GO to DP7.

(Continued)

100-07-5

100-07-5

Electric Vehicle (EV) Diagnostic Direction

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST DP: DIAGNOSTIC PROCESS

TEST STEP

ACTION TO TAKE

NOTE: It may take up to one minute for a DTC to be set in IAA module

continuous memory. If the concern is related to climate control, turn on the

system in question.

•

Wait one minute and retrieve continuous DTCs from the IAA module.

Note the DTCs.

•

Clear continuous DTCs (if necessary) and perform the IAA module

on-demand self-test. Note the DTCs.

•

Do any DTCs occur?

DP7 RETRIEVE DTCs FROM TRACTION INVERTER MODULE

(TIM)

•

Retrieve continuous DTCs from the TIM. Note the DTCs.

Yes =

REFER to the Traction

Inverter Module (TIM)

Diagnostic Trouble Code

(DTC) Index. CARRY OUT

the appropriate diagnostic

procedures. GO to DP8.

•

Clear the continuous DTCs.

No =

GO to DP8.

NOTE: It may take up to one minute for a DTC to be set in TIM

continuous memory. Some TIM DTCs will not be set unless the vehicle is

driven.

•

Wait one minute and retrieve continuous DTCs from the TIM. Note the

DTCs.

•

Do any DTCs occur?

DP8 RETRIEVE DTCs FROM BATTERY CONTROL MODULE

(BCM)

•

Retrieve DTCs from the BCM. Note the DTCs.

Yes =

REFER to the Battery

Control Module (BCM)

Diagnostic Trouble Code

(DTC) Index. CARRY OUT

the appropriate diagnostic

procedures.

•

Clear the continuous DTCs.

No =

If no DTCs occur for any of

•

Retrieve continuous DTCs from the BCM. Note the DTCs.

the modules and the vehicle

•

Clear continuous DTCs (if necessary) and perform the BCM on-demand

exhibits abnormal powertrain

self-test. Note the DTCs.

symptoms, REFER to

•

Do any DTCs occur?

Section 100-09

Powertrain

Diagnostic Routines

Identification for

symptom-related

diagnostics.
If no DTCs occur for any of

the modules and there is a

system concern related to

the heating system, air

conditioning system, cooling

system, power steering

system, vacuum system, or

instrument cluster, REFER

to the Symptom Chart in the

appropriate section for

symptom-related diagnostics.

(Continued)

100-07-6

100-07-6

Electric Vehicle (EV) Diagnostic Direction

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST DP: DIAGNOSTIC PROCESS

TEST STEP

ACTION TO TAKE

If no DTCs occur for any of

the modules and the heater,

air conditioning (if

equipped), power steering,

and DC/DC converter all do

not operate, REFER to

Multiple Auxiliary Load

Failure Diagnosis in

Section 414-03A

or

Section 414-03B

.

Inspection and Verification

Mechanical

1. Visually inspect the system’s components.

•

Section 206-07 Vacuum System

Check for obvious signs of electrical and

— Vacuum system leak

mechanical damage.

— Integrity of vacuum hose(s)/line(s)

2.

WARNING: The vehicle contains

— Vacuum hose/line connection(s)

high-voltage components and wiring.

— Vacuum hose/line routing

High-voltage insulated safety gloves and face
shield must be worn when performing the

— Climate control vacuum reservoir

following step for high-voltage systems.

— Vacuum pump housing rubber isolator mounts

Failure to follow this warning may result in

•

Section 206-09 Anti-Lock Control

severe personal injury or death.

— Parking brake cable

Check the wiring and connectors to detect
concerns due to looseness, corrosion, or other

— Tire pressure

damage.

— Tire size or mismatched tires

3. If any obvious case for an observed or reported

— Anti-lock brake sensor mounting

concern can be found, correct the cause of the

— Tone ring

concern before proceeding to the next step.

•

Section 211-02 Power Steering

4. If the cause of the concern cannot be found by

system inspection, proceed to the next step (in

— Power steering fluid leak

test step DP2) in Diagnostic Process.

— Low power steering fluid level

Electrical

— Power steering fluid reservoir
— Power steering pump hoses/tubes

•

Fuse(s)

•

Auxiliary battery/cables

•

Auxiliary battery voltage

•

Integrity of connectors

•

Integrity of wiring