Ford Ranger EV (2001 year). Manual — part 57
303-03-6
303-03-6
Engine Cooling
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST A: DTC C1774 COOLANT TEMPERATURE SENSOR OUT OF RANGE
TEST STEP
ACTION TO TAKE
A3 CHECK CIRCUITS 3064 (BK/O) AND 3065 (LG/P) FOR OPEN(S)
•
Connect 104-Pin Breakout Box (BOB) to IAA module C1945; leave IAA Yes =
GO to A4.
module disconnected.
•
With key OFF, disconnect coolant temperature sensor C1966 and
No =
REPAIR the wire(s) in
measure the resistance of the BK/O wire between BOB pin 70 and
question.
coolant temperature sensor C1966.
•
With key OFF, measure the resistance between BOB pin 95 and coolant
temperature sensor C1966.
•
Are the resistances less than 5 ohms?
A4 CHECK CIRCUITS 3064 (BK/O) AND 3065 (LG/P) FOR SHORT(S)
TO GROUND
•
With key OFF, measure the resistance between BOB pins 70, 95, and
Yes =
GO to A5.
ground (BOB pin 80).
•
Are the resistances greater than 10,000 ohms?
No =
REPAIR the wire(s) in
question.
A5 CHECK COOLANT TEMPERATURE SENSOR
•
With key OFF, measure the resistance between the terminals of the Yes = REPLACE the IAA module.
coolant temperature sensor and compare the reading to the values below: REFER to
Actual Temperature (Approximate) No = REPLACE the coolant
temperature sensor.
— 0
°
C (32
°
F) = 91,000-100,700 ohms
— 5
°
C (41
°
F) = 71,100-78,700 ohms
— 10
°
C (50
°
F) = 56,000-62,000 ohms
— 15
°
C (59
°
F) = 44,400-49,100 ohms
— 20
°
C (68
°
F) = 37,300-39,200 ohms
— 25
°
C (77
°
F) = 28,500-31,500 ohms
— 30
°
C (86
°
F) = 23,000-25,500 ohms
— 35
°
C (95
°
F) = 18,700-20,700 ohms
— 40
°
C (104
°
F) = 15,300-16,900 ohms
— 45
°
C (113
°
F) = 12,500-13,900 ohms
— 50
°
C (122
°
F) = 10,300-11,500 ohms
— 55
°
C (131
°
F) = 8,600-9,500 ohms
— 60
°
C (140
°
F) = 7,100-7,900 ohms
•
Is the resistance OK?
PINPOINT TEST B: COOLANT PUMP DOES NOT OPERATE
TEST STEP
ACTION TO TAKE
B1 CHECK FUSE AND POWER TO COOLANT PUMP RELAY
•
Check 20A fuse 20 in the electric vehicle power distribution box
Yes =
RECONNECT the coolant
(EVPDB).
pump relay. GO to B2.
•
With key OFF, remove the coolant pump relay from the EVPDB and
No =
REPAIR as necessary.
measure the voltage between pins 85, 87 on the coolant pump relay
connector and ground. (V > 10 volts)
•
Is everything OK?
B2 CHECK COOLANT PUMP
•
Enter the interface adapter assembly (IAA) module active command
Yes =
System OK. CHECK wiring
mode CLIMATE SYSTEM CONTROL and set the active command
for intermittent connections.
PUMP/VBC to ON.
•
Does the coolant pump operate?
No =
GO to B3.
B3 CHECK POWER TO COOLANT PUMP
(Continued)
303-03-7
303-03-7
Engine Cooling
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST B: COOLANT PUMP DOES NOT OPERATE
TEST STEP
ACTION TO TAKE
•
With key OFF, disconnect coolant pump C1998.
Yes =
REPLACE the coolant
pump.
•
Enter the IAA module active command mode CLIMATE SYSTEM
No =
GO to B4.
CONTROL, set the active command PUMP/VBC to ON, and measure
the voltage between the W/R wire and BK wire on coolant pump C1998.
•
Is the voltage greater than 10 volts?
B4 CHECK GROUND TO COOLANT PUMP
•
With key OFF, measure the resistance between the BK wire on coolant
Yes =
GO to B5.
pump C1998 and ground.
•
Is the resistance less than 5 ohms?
No =
REPAIR the BK wire.
B5 CHECK COOLANT PUMP RELAY CONTROL CIRCUIT
•
With key OFF, remove the coolant pump relay from the EVPDB.
Yes =
GO to B7.
•
Enter the IAA module active command mode CLIMATE SYSTEM
No =
GO to B6.
CONTROL, set the active command PUMP/VBC to ON, and measure
the resistance between pin 86 on the coolant pump relay connector and
ground.
•
Is the resistance less than 5 ohms?
B6 CHECK CIRCUIT 3020 (LB) FOR OPEN
•
Connect 104-Pin Breakout Box (BOB) to IAA module C1945; leave IAA Yes =
REPLACE the IAA module.
module disconnected. REFER to
•
With key OFF, measure the resistance of the LB wire between pin 86 on
No =
REPAIR the LB wire.
the coolant pump relay connector and BOB pin 19.
•
Is the resistance less than 5 ohms?
B7 CHECK CIRCUIT 3229 (W/R) FOR OPEN
•
With key OFF, measure the resistance of the W/R wire between coolant
Yes =
REPLACE the coolant pump
pump C1998 and pin 30 on the coolant pump relay connector.
relay.
•
Is the resistance less than 5 ohms?
No =
REPAIR the W/R wire.
PINPOINT TEST C: COOLANT PUMP RUNS WITH THE IGNITION KEY IN THE OFF POSITION
TEST STEP
ACTION TO TAKE
C1 CHECK CIRCUIT 3229 (W/R) FOR SHORT TO POWER
•
Remove the coolant pump relay from the electric vehicle power
Yes =
GO to C2.
distribution box (EVPDB).
•
Does the coolant pump stop running?
No =
REPAIR the W/R wire.
C2 CHECK COOLANT PUMP RELAY
•
Measure the resistance between terminals 30 and 87 on the coolant pump Yes =
REPLACE the coolant pump
relay.
relay.
•
Is the resistance less than 5 ohms?
No =
GO to C3.
C3 CHECK CIRCUIT 3020 (LB) FOR SHORT TO GROUND
•
With key OFF, disconnect interface adapter assembly (IAA) module
Yes =
REPLACE the IAA module.
C1945 and measure the resistance between pin 86 on the coolant pump REFER to
relay connector and ground.
•
Is the resistance greater than 10,000 ohms?
No =
REPAIR the LB wire.
PINPOINT TEST D: COOLING FAN DOES NOT OPERATE
TEST STEP
ACTION TO TAKE
D1 CHECK FUSE AND POWER TO FAN SPEED RELAYS
•
Check 50A fuse 5 in the electric vehicle power distribution box
Yes =
RECONNECT the fan speed
(EVPDB).
(Continued)
303-03-8
303-03-8
Engine Cooling
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST D: COOLING FAN DOES NOT OPERATE
TEST STEP
ACTION TO TAKE
•
With key OFF, remove the fan low speed relay from the cooling fan
No =
REPAIR as necessary.
relay box and measure the voltage between pins 85, 87 on the fan low
speed relay C1954 and ground. (V > 10 volts)
•
With key OFF, remove the fan high speed relay from the cooling fan
relay box and measure the voltage between pins 2, 3 on the fan high
speed relay C1955 and ground. (V > 10 volts)
•
Is everything OK?
D2 CHECK LOW SPEED FAN OPERATION
•
Enter the interface adapter assembly (IAA) module active command
Yes =
GO to D8.
mode FAN SPEED CONTROL and set the active command FAN SPD
to LOW.
•
Does the cooling fan operate at low speed?
No =
GO to D3.
D3 CHECK POWER TO COOLING FAN
•
With key OFF, disconnect cooling fan C1967.
Yes =
REPLACE the cooling fan.
•
Enter the IAA module active command mode FAN SPEED CONTROL,
No =
GO to D4.
set the active command FAN SPD to LOW, and measure the voltage
between the R/O wire and BK wire on cooling fan C1967.
•
Is the voltage greater than 10 volts?
D4 CHECK GROUND TO COOLING FAN
•
With key OFF, measure the resistance between the BK wire on the
Yes =
GO to D5.
cooling fan C1967 and ground.
•
Is the resistance less than 5 ohms?
No =
REPAIR the BK wire.
D5 CHECK FAN LOW SPEED RELAY CONTROL CIRCUIT
•
With key OFF, remove the fan low speed relay from the cooling fan
Yes =
GO to D7.
relay box.
•
Enter the IAA module active command mode FAN SPEED CONTROL,
No =
GO to D6.
set the active command FAN SPD to LOW, and measure the resistance
between pin 86 on the fan low speed relay C1954 and ground.
•
Is the resistance less than 5 ohms?
D6 CHECK CIRCUIT 3828 (O/BK) FOR OPEN
•
Connect 104-Pin Breakout Box (BOB) to IAA module C1945; leave IAA Yes =
REPLACE the IAA module.
module disconnected.
REFER to Section 412-04.
•
With key OFF, measure the resistance of the O/BK wire between pin 86
No =
REPAIR the O/BK wire.
on the fan low speed relay C1954 and BOB pin 69.
•
Is the resistance less than 5 ohms?
D7 CHECK CIRCUIT 260 (R/O) FOR OPEN
•
With key OFF, measure the resistance of the R/O wire between cooling
Yes =
REPLACE the fan low
fan C1967 and pin 30 on the fan low speed relay C1954.
speed relay.
•
Is the resistance less than 5 ohms?
No =
REPAIR the R/O wire.
D8 CHECK HIGH SPEED FAN OPERATION
•
Enter the IAA module active command mode FAN SPEED CONTROL
Yes =
System OK. CHECK wiring
and set the active command FAN SPD to HIGH.
for intermittent connections.
•
Does the cooling fan operate at high speed?
No =
GO to D9.
D9 CHECK POWER TO COOLING FAN
•
With key OFF, disconnect cooling fan C1967.
Yes =
REPLACE the cooling fan.
•
Enter the IAA module active command mode FAN SPEED CONTROL,
No =
GO to D10.
set the active command FAN SPD to HIGH, and measure the voltage
between the O/BK wire and BK wire on cooling fan C1967.
•
Is the voltage greater than 10 volts?
D10 CHECK GROUND TO COOLING FAN
(Continued)
303-03-9
303-03-9
Engine Cooling
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST D: COOLING FAN DOES NOT OPERATE
TEST STEP
ACTION TO TAKE
•
With key OFF, measure the resistance between the BK wire on the
Yes =
GO to D11.
cooling fan C1967 and ground.
•
Is the resistance less than 5 ohms?
No =
REPAIR the BK wire.
D11 CHECK FAN HIGH SPEED RELAY CONTROL CIRCUIT
•
With key OFF, remove the fan high speed relay from the cooling fan
Yes =
GO to D13.
relay box.
•
Enter the IAA module active command mode FAN SPEED CONTROL,
No =
GO to D12.
set the active command FAN SPD to HIGH, and measure the resistance
between pin 1 on the fan high speed relay C1955 and ground.
•
Is the resistance less than 5 ohms?
D12 CHECK CIRCUIT 3829 (LB/BK) FOR OPEN
•
Connect 104-Pin Breakout Box (BOB) to interface adapter assembly
Yes =
REPLACE the IAA module.
(IAA) module C1945; leave IAA module disconnected. REFER to
•
With key OFF, measure the resistance of the LB/BK wire between pin 1
No =
REPAIR the LB/BK wire.
on the fan high speed relay C1955 and BOB pin 101.
•
Is the resistance less than 5 ohms?
D13 CHECK CIRCUIT 261 (O/BK) FOR OPEN
•
With key OFF, measure the resistance of the O/BK wire between cooling Yes =
REPLACE the fan high
fan C1967 and pin 5 on the fan high speed relay C1955.
speed relay.
•
Is the resistance less than 5 ohms?
No =
REPAIR the O/BK wire.
PINPOINT TEST E: COOLING FAN RUNS AT LOW SPEED AT ALL TIMES
TEST STEP
ACTION TO TAKE
E1 CHECK CIRCUIT 260 (R/O) FOR SHORT TO POWER
•
Remove the fan low speed relay from the cooling fan relay box.
Yes =
GO to E2.
•
Does the cooling fan stop running?
No =
REPAIR the R/O wire.
E2 CHECK FAN LOW SPEED RELAY
•
Measure the resistance between terminals 30 and 87 on the fan low
Yes =
REPLACE the fan low
speed relay.
speed relay.
•
Is the resistance less than 5 ohms?
No =
GO to E3.
E3 CHECK CIRCUIT 3828 (O/BK) FOR SHORT TO GROUND
•
With key OFF, disconnect interface adapter assembly (IAA) module
Yes =
REPLACE the IAA module.
C1945 and measure the resistance between pin 86 on the fan low speed REFER to
relay C1954 and ground.
•
Is the resistance greater than 10,000 ohms?
No =
REPAIR the O/BK wire.
PINPOINT TEST F: COOLING FAN RUNS AT HIGH SPEED AT ALL TIMES
TEST STEP
ACTION TO TAKE
F1 CHECK CIRCUIT 261 (O/BK) FOR SHORT TO POWER
•
Remove the fan high speed relay from the cooling fan relay box.
Yes =
GO to F2.
•
Does the cooling fan stop running?
No =
REPAIR the O/BK wire.
F2 CHECK FAN HIGH SPEED RELAY
•
Measure the resistance between terminals 3 and 5 on the fan high speed
Yes =
REPLACE the fan high
relay.
speed relay.
•
Is the resistance less than 5 ohms?
No =
GO to F3.
F3 CHECK CIRCUIT 3829 (LB/BK) FOR SHORT TO GROUND
•
With key OFF, disconnect interface adapter assembly (IAA) module
Yes =
REPLACE the IAA module.
C1945 and measure the resistance between pin 1 on the fan high speed REFER to
relay C1955 and ground.
•
Is the resistance greater than 10,000 ohms?
No =
REPAIR the LB/BK wire.
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