Ford Ranger EV (2001 year). Manual — part 162

414-03B-44

414-03B-44

High Voltage/Traction Battery — Nickel Metal Hydride

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST A: DTC C1836 BATTERY TEMPERATURE OUT OF RANGE

TEST STEP

ACTION TO TAKE

A1 CHECK FOR BATTERY TEMPERATURE SENSOR OUT OF

RANGE FAULT

•

With key ON, monitor battery control module (BCM) PIDs BATTMP1,

Yes =

GO to A2.

BATTMP2, BATTMP3, and BATTMP4.

•

Do any of the BATTMP PIDs indicate YES?

No =

System OK. If DTC C1836

reoccurs intermittently, GO

to A6.

A2 CHECK WIRES TO BATTERY TEMPERATURE SENSOR FOR

OPEN(S)

•

Remove the traction battery and connect Traction Battery High-Voltage

Yes =

GO to A3.

Lockout and Diagnostic Tool to the traction battery high-voltage two-pin

C3994M.

No =

REPAIR the wire(s) in

question.

WARNING: The traction battery contains high-voltage

components and wiring. High-voltage insulated safety gloves and face

shield must be worn when carrying out the following steps. Failure to

follow this warning may result in severe personal injury or death.

•

Connect 104-Pin Breakout Box (BOB) to BCM C1986, C1987 using the

BCM/TIM BOB Adapter Cable and Overlay; leave the BCM

disconnected.

•

Measure the resistance of the wires indicated below for the battery

temperature sensor in question.

Battery Temperature Sensor #1:

•

With key OFF, disconnect battery temperature sensor #1 C1813 and

measure the resistance of the BR wire between BOB pin A40 and

temperature sensor #1 C1813.

•

With key OFF, measure the resistance of the BR/W wire between BOB

pin A9 and temperature sensor #1 C1813.

Battery Temperature Sensor #2:

•

With key OFF, disconnect battery temperature sensor #2 C1814 and

measure the resistance of the GY/BK wire between BOB pin A21 and

temperature sensor #2 C1814.

•

With key OFF, measure the resistance of the DG wire between BOB pin

A22 and temperature sensor #2 C1814.

Battery Temperature Sensor #3:

•

With key OFF, disconnect battery temperature sensor #3 C1815 and

measure the resistance of the LG/BK wire between BOB pin A24 and

temperature sensor #3 C1815.

•

With key OFF, measure the resistance of the R/W wire between BOB

pin A25 and temperature sensor #3 C1815.

Battery Temperature Sensor #4:

•

With key OFF, disconnect battery temperature sensor #4 C1816 and

measure the resistance of the BK/LB wire between BOB pin A26 and

temperature sensor #4 C1816.

•

With key OFF, measure the resistance of the O/R wire between BOB pin

A27 and temperature sensor #4 C1816.

•

Are the resistances less than 5 ohms?

A3 CHECK SIGNAL WIRE TO BATTERY TEMPERATURE SENSOR

FOR SHORT TO GROUND

•

With key OFF, measure the resistance between the BOB pins indicated

Yes =

GO to A4.

below for the battery temperature sensor in question.

(Continued)

414-03B-45

414-03B-45

High Voltage/Traction Battery — Nickel Metal Hydride

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST A: DTC C1836 BATTERY TEMPERATURE OUT OF RANGE

TEST STEP

ACTION TO TAKE

No =

REPAIR the BR/W wire

(#1), DG wire (#2), R/W

wire (#3), or O/R wire (#4).

Battery Temperature Sensor #1
— BOB pins A9 and A33
Battery Temperature Sensor #2
— BOB pins A22 and A33
Battery Temperature Sensor #3
— BOB pins A25 and A33
Battery Temperature Sensor #4
— BOB pins A27 and A33

•

Is the resistance greater than 10,000 ohms?

A4 CHECK SIGNAL WIRE TO BATTERY TEMPERATURE SENSOR

FOR SHORT TO POWER

•

Connect Traction Battery Low-Voltage Service Cord to traction battery

Yes =

REPAIR the BR/W wire

support tray in-line C1939F and in-line C1939M.

(#1), DG wire (#2), R/W

•

With key OFF, disconnect high-voltage auxiliary load in-line C1935 from

wire (#3), or O/R wire (#4).

the traction battery support tray and connect Traction Battery

high-voltage Service Cord to traction battery support tray in-line C1935F

and in-line C1935M.

•

With key ON, measure the voltage between the BOB pins indicated

below for the battery temperature sensor in question.

Battery Temperature Sensor #1

No =

GO to A5.

— BOB pins A9 and A33
Battery Temperature Sensor #2
— BOB pins A22 and A33
Battery Temperature Sensor #3
— BOB pins A25 and A33
Battery Temperature Sensor #4
— BOB pins A27 and A33

•

Is the voltage greater than 0 volts?

A5 CHECK BATTERY TEMPERATURE SENSOR

•

With key OFF, measure the resistance between the terminals of the

Yes =

REPLACE the BCM.

battery temperature sensor in question.

•

Is the resistance between 430 and 280,000 ohms?

No =

REPLACE the battery

temperature sensor.

A6 CHECK WIRING FOR INTERMITTENT CONNECTIONS

•

Remove the traction battery and connect Traction Battery High-Voltage

Yes =

REPAIR the wire(s) for

Lockout and Diagnostic Tool to the traction battery high-voltage two-pin

intermittent connections.

C3994M.

•

Connect Traction Battery Low-Voltage Service Cord to traction battery

No =

System OK. If DTC C1836

support tray in-line C1939F and in-line C1939M.

keeps occurring, REPLACE

•

Connect Traction Battery High-Voltage Service Cord to traction battery

the BCM.

support tray in-line C1935F and in-line C1935M.

•

Clear the BCM DTCs.

•

With key ON, monitor BCM PID BATTMP for the battery temperature

sensor in question.

•

Exercise (wiggle) the wiring harness to the battery temperature sensor.

•

Does the BATTMP PID indicate YES?

414-03B-46

414-03B-46

High Voltage/Traction Battery — Nickel Metal Hydride

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST C: DTC C1838 CHARGER SYSTEM FAULT

TEST STEP

ACTION TO TAKE

C1 CHECK FOR CHARGING SYSTEM FAULT

NOTE: Clear the diagnostic trouble codes (DTCs) from the battery control

Yes =

GO to C2.

module (BCM) continuous memory before connecting the vehicle to a

power control station (PCS). The vehicle may need to be left on charge for

up to five minutes to set a charging system fault (DTC C1838).

•

Connect the vehicle to the PCS and press the START button to begin

charging.

•

Wait approximately five minutes and retrieve continuous DTCs from the

No =

System OK.

BCM.

•

Does DTC C1838 Charging System Fault occur?

C2 IDENTIFY CHARGING SYSTEM FAULT

•

With vehicle on-charge, monitor the following BCM PIDs:

Yes =

REFER to Symptom Chart.

No =

REPEAT test step C1. IF

DTC C1838 does not occur,

system OK. CHECK wiring

for intermittent connections.

Charging System Fault PID/Description
— CHG

ABD = Charger Charging After Being Disabled

— CHG

CYF = Charger Cycling Fault

— CHG

LCF = Charger Line Capacity Fault

— CHG

LUF = Charger Latchup Fault

— CHG

MFF = Charger Mode Feedback Fault

— CHG

OAF = Charger Over Amp-Hours Fault

— CHG

OCF = Charger Over Current Fault

— CHG

OTF = Charger Over-Temperature Fault

— CHG

OVF = Charger Over Voltage Fault

— CHG

UCF = Charger Under Current Fault

— IOMH

F = IOM to BCM Diagnostic Input Stuck High Fault

— IOML

F = IOM to BCM Diagnostic Input Stuck Low Fault

•

Do any of the charging system fault PIDs indicate YES?

PINPOINT TEST D: CHARGER CHARGING AFTER BEING DISABLED FAULT

TEST STEP

ACTION TO TAKE

D1 CHECK CHARGER CHARGING AFTER BEING DISABLED

STATUS

•

Verify the vehicle is connected to the power control station (PCS) and

Yes =

DISCONNECT the PCS

the START button has been depressed to begin charging.

from the vehicle. GO to D2.

NOTE: Wait approximately up to five minutes to allow the CHG ABD

No =

System OK. CHECK wiring

PID to be set.

for intermittent connections.

•

With key OFF and vehicle on-charge, monitor BCM PID CHG ABD.

•

Does the CHG ABD PID indicate YES?

D2 CHECK CONTACTOR BOX AUXILIARY CURRENT SENSOR

FOR IN-RANGE FAILURE

•

With key ON, monitor BCM PID AUX CNT.

Yes =

GO to D3.

•

Turn the headlamps on.

No =

REPLACE the contactor

•

Does the amperage for the AUX CNT PID increase by at least 0.5

box.

amps?

D3 CHECK CIRCUIT 3827 (GY/W) (OUTSIDE OF TRACTION

BATTERY SUPPORT TRAY) FOR OPEN

(Continued)

414-03B-47

414-03B-47

High Voltage/Traction Battery — Nickel Metal Hydride

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST D: CHARGER CHARGING AFTER BEING DISABLED FAULT

TEST STEP

ACTION TO TAKE

•

With key OFF, disconnect traction battery support tray in-line C1939 and Yes =

GO to D4.

connect 104-Pin Breakout Box (BOB) to in-line C1939M using Traction

Battery Low-Voltage Service Cord; do not connect Traction Battery

Low-Voltage Service Cord to in-line C1939F.

•

With key OFF, disconnect traction battery charger C1991 and measure

No =

REPAIR the GY/W wire.

the resistance of the GY/W wire between pin 4 on traction battery

charger C1991 and BOB pin 57.

•

Is the resistance less than 5 ohms?

D4 CHECK CIRCUIT 3827 (GY/W) (OUTSIDE OF TRACTION

BATTERY SUPPORT TRAY) FOR SHORT TO GROUND

•

With key OFF, measure the resistance between BOB pin 57 and ground

Yes =

GO to D5.

(BOB pin 65).

•

Is the resistance greater than 10,000 ohms?

No =

REPAIR the GY/W wire.

D5 CHECK CIRCUIT 3827 (GY/W) (INSIDE OF TRACTION

BATTERY SUPPORT TRAY) FOR OPEN

•

Disconnect the BOB from in-line C1939M, remove the traction battery,

Yes =

GO to D6.

and connect Traction Battery High-Voltage Lockout and Diagnostic Tool

to the traction battery high-voltage two-pin C3994M.

No =

REPAIR the GY/W wire.

WARNING: The traction battery contains high-voltage

components and wiring. High-voltage insulated safety gloves and face

shield must be worn when carrying out the following steps. Failure to

follow this warning may result in severe personal injury or death.

•

Connect 104-Pin Breakout Box (BOB) to traction battery support tray

in-line C1939F using Traction Battery Low-Voltage Service Cord; do not

connect Traction Battery Low-Voltage Service Cord to in-line C1939M.

•

With key OFF, disconnect BCM C1986 and measure the resistance of the

GY/W wire between pin 8 on BCM C1986 and BOB pin 57.

•

Is the resistance less than 5 ohms?

D6 CHECK CIRCUIT 3827 (GY/W) (INSIDE OF TRACTION

BATTERY SUPPORT TRAY) FOR SHORT TO GROUND

•

With key OFF, measure the resistance between BOB pin 57 and ground

Yes =

REPLACE the traction

(BOB pin 65).

battery charger.

•

Is the resistance greater than 10,000 ohms?

No =

REPAIR the GY/W wire.

PINPOINT TEST F: CHARGER LATCHUP FAULT

TEST STEP

ACTION TO TAKE

F1 CHECK CHARGER OVER-TEMPERATURE STATUS

•

Verify the vehicle is connected to the power control station (PCS) and

Yes =

GO to Pinpoint Test E.

the START button has been depressed to begin charging.

NOTE: Wait approximately five minutes to allow the CHG OTF PID to

No =

DISCONNECT the PCS

be set.

from the vehicle. GO to F2.

•

With key OFF and vehicle on-charge, monitor BCM PID CHG OTF.

•

Does the CHG OTF PID indicate YES?

F2 CHECK CIRCUIT 3800 (LG/BK) (OUTSIDE OF TRACTION

BATTERY SUPPORT TRAY) FOR OPEN

•

With key OFF, disconnect traction battery support tray in-line C1939 and Yes =

GO to F3.

connect 104-Pin Breakout Box (BOB) to in-line C1939M using Traction

Battery Low-Voltage Service Cord; do not connect Traction Battery

Low-Voltage Service Cord to in-line C1939F.

(Continued)