Ford Ranger EV. Electric Manual - part 40

5-1

LESSON 5: DIAGNOSIS

TECHNICIAN OBJECTIVES

•

Explain diagnostic strategy (symptom-to-system-to-component-to-

cause)

•

Accurately and safely perform diagnostic and service procedures

on a 1998 Ranger EV.

CONTENTS

•

Introduction to Ranger EV Diagnosis and Service Procedures

•

Symptom-to-System-to-Component-to-Cause Diagnosis

•

Ranger EV Diagnostic Flowchart

•

Multiplexing System Diagnosis

•

New Generation Star Tester

•

Contractor Box Diagnosis

•

Activity 5 – Worksheet K

•

Charging Concerns

•

Activity 6 – Worksheet L

•

Power Control Station (PCS) Diagnostic Procedures

•

Traction Battery Removal

•

Activity 7 – Worksheet M

•

Activity 8 – Worksheet N

•

Activity 9 – Worksheet O

•

Activity 9 – Worksheet P

•

Electric Motor/Transaxle Diagnosis

•

Activity 10 – Demonstration

•

Traction Battery Pack Components Demonstration

•

Activity 11 – Demonstration

•

Traction Battery Diagnosis

•

Activity 12 – Worksheet Q

•

Activity 12 – Worksheet R

•

Activity 13 – Worksheet S1 (BDS)

•

Activity 13 – Worksheet S2 (NON-BDS)

•

Activity 13 – Worksheet T

•

Activity 14 – Worksheet U

LESSON 5: DIAGNOSIS

5-2

INTRODUCTION TO RANGER EV DIAGNOSIS AND
SERVICE PROCEDURES

As you have seen, the 1998 Ranger EV is unique in many ways from

previous vehicles that you have seen. The differences in this vehicle

mean that the diagnosis and service procedures are also unique.

Ford’s service goal for all vehicles is to “Fix it Right the First Time,

On Time.” This goal also applies to the Ranger EV.

Although the 1998 Ranger EV is a completely new vehicle, service

procedures for some of its systems are similar to those with which you

are familiar. However, many systems on this vehicle are unique.

These systems require service procedures that will be completely new

to you. This portion of this course will show you the most accurate

and efficient methods of performing vehicle diagnosis and service.

SYMPTOM-TO-SYSTEM-TO-COMPONENT-TO-CAUSE
DIAGNOSIS

When diagnosing an automotive system, you should always follow

standard procedures to locate clues to the cause of a concern. Using

these clues, you can then determine what component(s) must be

repaired or replaced in order to correct a concern. These clues can

usually be found by using a logical, time-effective method. The

“Symptom-to-System-to-Component-to-Cause” diagnostic technique

is very effective in locating and correcting vehicle concerns.

To use the “Symptom-to-System-to-Component-to-Cause” diagnostic

routine, all you have to do is follow the words in the title.

•

First, determine the “Symptom” of the customer concern.

– Ensure you understand the customer concern.

•

Next, determine which “System” on the vehicle could be causing

the symptom.

– By eliminating systems that cannot cause the concern, time is

saved by testing only systems that could cause the concern.

– For example, there’s not much sense in checking the air pressure

of the tires if the vehicle has no power.

LESSON 5: DIAGNOSIS

5-3

•

Once you identify the particular system, you then want to

determine which “Component(s)” within that system could be the

cause for the customer concern.

– This usually consists of a series of isolation tests.

– These specific tests and routines can be found in the Workshop

Manual or the Electrical and Vacuum Troubleshooting Manual

(EVTM).

•

Once the failed component is identified, you should always try and

determine the “Cause” of the failure.

– When the faulty or damaged component is located, the cause of

the failure or damage must be identified and corrected to prevent

repeated component failure.

– For example, the component causing a system not to get power

may be a blown fuse, but if you don’t repair the short that caused

the fuse to fail, then the new fuse will fail as well.

•

Diagnostic tests are usually isolation tests. The idea behind them is

to check the operation of a specific component, without other

components in the system affecting the component being tested. On

the Ranger EV, this requires product knowledge, skill, and your

ability to know how to use and interpret special tools.

LESSON 5: DIAGNOSIS

5-4

RANGER EV DIAGNOSTIC FLOWCHART

Ranger EV Diagnostic Flowchart

The Ranger EV Diagnostic Flowchart will help provide you with a standardized procedure for diagnosing the

Ranger EV. In many instances following the steps outlined in the flowchart will help you locate and correct many

vehicle concerns.

ER094-A

• Verify Customer Concern
• Perform Visual Inspection
• Check for Non-Factory Add-On Equipment
• Retrieve Continuous and On-Demand DTCs 

(Retrieve in the following order: IAA, TIM, 
then BCM.)

Refer to Symptom-Based Diagnostics in 
Section 100-09 or in Symptom Chart at 
Beginning or Individual Section or 
Workshop Manual.

Go to DTC Index Chart.
Preform Actions Described for
DTC Retrieved.

Verify Repair, Clear DTCs and 
Return Vehicle to Customer

Contact Ford Technical
Hotline for Assistance.

Data Link Diagnostics Failed. 
Repair Network Concern First,
Then Rerun on-Board Diagnostic 
Test.

Data Link Diagnostics Passed,
Refer to 100-07 for “Phantom” 
Codes.

Are Any

Network 

DTCs

Present?

Are Any

DTCs

Present?

Is Concern

Corrected?

Is Concern

Corrected?

NO

NO

NO

NO

YES

YES

YES

YES