Ford Ranger EV (2001 year). Manual — part 14

100-09-1

100-09-1

Powertrain Diagnostic Routines Identification

Manual Table of Contents

SECTION 100-09 Powertrain Diagnostic Routines

Identification

VEHICLE APPLICATION:

Ranger EV

CONTENTS

PAGE

DIAGNOSIS AND TESTING

Powertrain Diagnostic Routines Identification . . . . . . . . . . . . . 100-09-2

Diagnostic Preface . . . . . . . . . . . . . . . . . . . . . 100-09-2
Diagnostic Routines . . . . . . . . . . . . . . . . . . . . 100-09-3
Directions . . . . . . . . . . . . . . . . . . . . . . .... 100-09-2
Powertrain Diagnostic Routines Index . . . . . . . . . . . . . . .. 100-09-2

100-09-2

100-09-2

Powertrain Diagnostic Routines Identification

1. Unless a fault is evident, it is recommended

DIAGNOSIS AND TESTING

that all diagnosis begin with a thorough visual

Powertrain Diagnostic Routines

inspection of a suspected system or component.

Identification

2. If an obvious cause for an observed or reported

Diagnostic Preface

malfunction can be found, correct the cause of
the malfunction before proceeding to the next

The diagnostic routines are based on symptom

step.

related vehicle operation and performance concerns.
The diagnostic routines are to be carried out when a

3. If the cause of a malfunction cannot be found

vehicle driveability or traction battery charging

by visual inspection, proceed to Powertrain

concern exists and no diagnostic trouble codes

Diagnostic Routines Index.

(DTCs) occur when the Diagnostic Process is

4. After each repair is made, check to see if

carried out. Refer to

Section 100-07

for

symptom(s) are still present.

information regarding the Diagnostic Process.

5. After all repairs are made, verify vehicle

The diagnostic routines list, in test step form, the

operation as follows:

systems that can contribute to a particular condition

•

Carry out the Diagnostic Process. Refer to

in order of probability, ease of accomplishment, and

Section 100-07

.

accessibility. These routines can be used as check
lists for reference in the event of unusual or

•

Test drive the vehicle. Check for driveability

infrequent causes of a malfunction.

symptoms, abnormal vehicle performance,
and illumination of instrument cluster

Directions

indicator lamps.

When performing the diagnostic routines, adhere to
the following steps:

Powertrain Diagnostic Routines Index

Driveability and Traction Battery Charging

Routine

Concern

Condition

Number

•

Starting Concerns

•

Vehicle Does Not Start (Lead Acid Vehicles)

1

•

Vehicle Does Not Start (NiMH Vehicles)

2

•

Vehicle Starts, But Does Not Move

3

•

Performance While Driving

•

Vehicle Quits While Driving (Lead Acid Vehicles)

1

Concerns

•

Vehicle Quits While Driving (NiMH Vehicles)

2

•

Vehicle Operates at Reduced Power (Lead Acid Vehicles)

4

•

Vehicle Operates at Reduced Power (NiMH Vehicles)

5

•

Noticeable Decrease in Vehicle Driving Range (Lead Acid

6

Vehicles)

•

Noticeable Decrease in Vehicle Driving Range (NiMH Vehicles)

7

•

Vehicle Charging Concerns

•

Vehicle Does Not Charge (Lead Acid Vehicles)

8

•

Vehicle Does Not Charge (NiMH Vehicles)

9

•

Vehicle Charging Takes Longer Than Normal to Reach Full

10

State of Charge (SOC) (Lead Acid Vehicles)

•

Vehicle Charging Takes Longer Than Normal to Reach Full

11

State of Charge (SOC) (NiMH Vehicles)

•

Coolant Pump and DC/DC Converter Operate When Power

12

Control Station (PCS) Is Disconnected From the Charger Inlet

Connector

100-09-3

100-09-3

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

Special Tool(s)

Diagnostic Routines

Traction Battery Low Voltage Service Cord 418-F219

Special Tool(s)

Traction Battery High-Voltage Lockout and Diagnostic

104-Pin Breakout Box (BOB) 418-049 (014-00950) or

Tool 418-F207

equivalent

High-Voltage Insulated Safety Gloves 100-F036 or

BCM/TIM Breakout Box (BOB) Adapter Cable

equivalent

418-F212

Face Shield 100-F035 or equivalent

BCM/TIM Breakout Box (BOB) Overlay 418-F220

Electric Motor/Transaxle Test Box 418-F211

Traction Battery High Voltage Service Cord 418-F218

(Continued)

ROUTINE 1: VEHICLE DOES NOT START/VEHICLE QUITS WHILE DRIVING (LEAD ACID VEHICLES)

TEST STEP

ACTION TO TAKE

1-1 CHECK AUXILIARY BATTERY VOLTAGE

•

With key OFF, measure the voltage of the 12-volt auxiliary battery.

Yes =

GO to 1-2.

•

Is the voltage greater than 11.5 volts?

No =

CARRY OUT the Auxiliary

Battery Capacity Test.

REFER to

Section 414-02

.

1-2 CHECK STATUS OF BATTERY CONTROL MODULE (BCM)

OPERATING STATE

•

With key ON, monitor BCM PID BCM OP.

Yes =

If BCM OP PID indicates

48, GO to 1-3.
If BCM OP PID indicates

49, CHARGE the traction

battery. REFER to

Section

100-05

.

If BCM OP PID indicates

51, GO to 1-6.

•

Does the BCM OP PID indicate 48 (shutdown-low battery module

No =

GO to 1-10.

voltage), 49 (shutdown-low SOC), or 51 (no start-battery under

temperature)?

1-3 CHARGE TRACTION BATTERY TO FULL STATE OF CHARGE

(SOC)

•

Disconnect and reconnect the 12-volt auxiliary battery negative cable.

Yes =

GO to 1-4.

•

Charge the traction battery to full SOC.

No =

System OK.

•

With key ON, monitor BCM PID BCM OP.

•

Does the BCM OP PID still indicate 48 (shutdown-low battery

module voltage)?

1-4 CHECK STATUS OF TRACTION BATTERY MODULES BY

CARRYING OUT THE BATTERY MODULE DIAGNOSTIC TEST

•

With key ON, carry out the Battery Module Diagnostic Test. Refer to the Yes =

GO to 1-5.

procedure in Traction Battery System

Section 414-03A

.

•

Does the Battery Module Diagnostic Test indicate to replace any

No =

CHARGE the traction

battery modules?

battery to full SOC. CHECK

the BCM OP PID. If the

BCM OP PID still

indicates 48, REPLACE the

BCM. REFER to

Section

414-03A

.

1-5 INPUT BATTERY MODULE DATA

(Continued)

100-09-4

100-09-4

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

ROUTINE 1: VEHICLE DOES NOT START/VEHICLE QUITS WHILE DRIVING (LEAD ACID VEHICLES)

TEST STEP

ACTION TO TAKE

•

With key ON, monitor BCM PIDs BAT INT, BAT MC, CHG CYC, Yes =

REPLACE the battery

and LOWVOLT, and enter the values on the Dealer Battery Return Form

module(s) in question.

that is packaged with the cycled service (battery) module.

REFER to

Section

414-03A

.

•

Fill out all the required data on the Dealer Battery Return Form and

No =

ENTER the indicated data.

return the form with the damaged battery module to the supplier.

REPLACE the battery

•

Is the correct data entered on the Dealer Battery Return Form?

module(s) in question.

REFER to

Section

414-03A

.

1-6 CHECK TRACTION BATTERY TEMPERATURE SENSORS FOR

UNDERTEMPERATURE CONDITION

•

With key ON, monitor BCM PIDs TMPSEN1, TMPSEN2, TMPSEN3,

Yes =

GO to 1-7.

and TMPSEN4.

If all TMPSEN PIDs are

less than -20

°

C (-4

°

F),

PARK the vehicle indoors

and if the vehicle is

equipped with traction

battery heaters, CONNECT

it to the power control

station (PCS) to warm the

traction battery to a

temperature greater than

-15

°

C (5

°

F).

•

Do any of the TMPSEN PIDs indicate less than -20

°

C (-4

°

F)?

No =

DISCONNECT and

RECONNECT the 12-volt

auxiliary battery negative

cable and RECHECK the

BCM OP PID. If the

BCM OP PID still

indicates 51, REPLACE the

BCM. REFER to

Section

414-03A

.

1-7 IDENTIFY VEHICLE OPTION

•

Determine if the vehicle is equipped with traction battery heaters.

Yes =

GO to 1-8.

•

Is the vehicle equipped with traction battery heaters?

No =

GO to 1-9.

1-8 CHECK TEMPERATURE DIFFERENCE BETWEEN BATTERY

TEMPERATURE SENSORS

•

With key ON, monitor BCM PIDs TMPSEN1, TMPSEN2, TMPSEN3,

Yes =

GO to 1-9.

and TMPSEN4.

•

Is there a temperature difference of greater than 7

°

C (13

°

F) between

No =

CONNECT the vehicle to

the temperature sensor that is below -20

°

C (-4

°

F) and the other

the power control station

temperature sensors?

(PCS) to warm the traction

battery to a temperature

greater than -15

°

C (5

°

F).

MONITOR the TMPSEN

PIDs while the vehicle is

connected to the PCS. If the

temperature of the battery

temperature sensor that was

less than -20

°

C (-4

°

F) does

not increase, GO to 1-9.

1-9 CHECK BATTERY TEMPERATURE SENSOR

(Continued)