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Ford Ranger EV (2001 year). Manual - part 16

100-09-9

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

ROUTINE 2: VEHICLE DOES NOT START/VEHICLE QUITS WHILE DRIVING (NIMH VEHICLES)

TEST STEP

ACTION TO TAKE

•

Connect jumper wires between the connector for the temperature sensor

in question and the known good temperature sensor that was

disconnected.

•

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

TMPSEN3.

•

Does the TMPSEN PID that indicated less than -30

C (-22

F) still

indicate the same value?

2-8 CHECK TRACTION BATTERY TEMPERATURE SENSORS FOR

OVERTEMPERATURE CONDITION

•

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

Yes =

PARK the vehicle indoors in

TMPSEN3.

a cooler environment.

CONNECT the vehicle to a

power control station (PCS)

to allow the traction battery

fans to operate. GO to 2-9.

•

Do any of the TMPSEN PIDs indicate greater than 70

C (158

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 54, REPLACE the

BCM. REFER to

Section

414-03B

2-9 CHECK IF OVERTEMPERATURE STATE IS CAUSED BY AN

ACTUAL OVERTEMPERATURE CONDITION

NOTE: Allow adequate time for vehicle to cool before checking for

Yes =

ALLOW temperature(s) to

temperature decrease.

decrease below 55

•

While vehicle is connected to the PCS, monitor BCM PIDs TMPSEN1,

(131

F). System OK.

TMPSEN2, and TMPSEN3.

•

Do the TMPSEN PIDs that were greater than 70

C (158

No =

GO to 2-10.

decrease?

2-10 CHECK BATTERY TEMPERATURE SENSORS

•

Remove the traction battery and connect Traction Battery High-Voltage

Yes =

REPLACE the BCM.

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

REFER to

Section

C3994M.

414-03B

No =

REPLACE the battery

WARNING: The traction battery contains high-voltage

temperature sensor in

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

question.

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

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

•

Connect Traction Battery High Voltage Service Cord to traction battery

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

•

Connect Traction Battery Low Voltage Service Cord to traction battery

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

•

With key OFF, disconnect the battery temperature sensor in question and

one of the other temperature sensors.

•

Connect jumper wires between the connector for the temperature sensor

in question and the known good temperature sensor that was

disconnected.

•

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

TMPSEN3.

•

Does the TMPSEN PID that indicated greater than 70

C (158

F) still

indicate the same value?

(Continued)

100-09-10

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

ROUTINE 2: VEHICLE DOES NOT START/VEHICLE QUITS WHILE DRIVING (NIMH VEHICLES)

TEST STEP

ACTION TO TAKE

2-11 CHECK STATUS OF KEY START SIGNAL TO TRACTION

INVERTER MODULE (TIM)

•

With key ON, monitor TIM PID IGN S.

Yes =

GO to 2-14.

•

Turn the ignition key to the START position.

No =

GO to 2-12.

•

Does the IGN S PID indicate YES when the ignition key is turned

to the START position?

2-12 CHECK FUSE (HOT IN START) TO TIM

•

Check 7.5A fuse 24, 10A fuse 9 and 7.5A fuse 11 in the I/P fuse panel.

Yes =

GO to 2-13.

•

Is the fuse OK?

No =

REPLACE the fuse. If the

fuse fails again,

CHECK/REPAIR for a short

to ground.

2-13 CHECK KEY START SIGNAL TO TIM

•

Connect 104-Pin Breakout Box (BOB) to TIM C4998, C4999 using the

Yes =

REPLACE the TIM. REFER

BCM/TIM BOB Adapter Cable & Overlay; leave the TIM disconnected.

Section 303-14

•

Connect a multimeter between BOB pins B8 and A29.

No =

REPAIR the W/BK wire

•

Turn the ignition key to the START position.

between pin 8 on TIM

•

Is the voltage greater than 10 volts when the ignition key is turned to

C4999 and the I/P fuse

the key START position?

panel.

2-14 CHECK EMERGENCY POWER OFF (EPO) STATUS TO TIM

•

With key ON, monitor TIM PID EMG PO.

Yes =

GO to 2-15.

•

Does the EMG PO PID indicate ENABLE?

No =

GO to 2-20.

2-15 CHECK EPO SIGNAL TO TIM

•

Connect 104-Pin Breakout Box (BOB) to TIM and TIM C4998, C4999

Yes =

GO to 2-16.

using the BCM/TIM BOB Adapter Cable & Overlay.

•

With key ON, monitor TIM PID EMG PO.

No =

GO to 2-18.

•

Connect a jumper wire between BOB pins A19 and A35.

•

Does the EMG PO PID indicate DISABLE?

2-16 CHECK CIRCUIT 3997 (DG) (OUTSIDE OF TRACTION

BATTERY SUPPORT TRAY) FOR OPEN

•

With key OFF, disconnect BOB from TIM and TIM C4998, C4999.

Yes =

GO to 2-17.

•

With key OFF, disconnect in-line C1939 on the traction battery support

No =

REPAIR the DG wire.

tray and connect BOB to in-line C1939M using Traction Battery Low

Voltage Service Cord; do not connect Traction Battery Low Voltage

Service Cord to traction battery support tray in-line C1939F.

•

With key OFF, measure the resistance of the DG wire between pin 35 on

TIM C4998 and BOB pin 24.

•

Is the resistance less than 5 ohms?

2-17 CHECK CIRCUIT 3997 (DG) (INSIDE OF TRACTION BATTERY

SUPPORT TRAY) FOR OPEN

•

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

Yes =

REPLACE the contactor

connect Traction Battery High-Voltage Lockout and Diagnostic Tool to

box. REFER to

Section

the traction battery high-voltage two-pin C3994M.

414-03B

(Continued)

100-09-11

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

ROUTINE 2: VEHICLE DOES NOT START/VEHICLE QUITS WHILE DRIVING (NIMH VEHICLES)

TEST STEP

ACTION TO TAKE

No =

REPAIR the DG 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 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 contactor box C1982 and measure the

resistance of the DG wire between pin 16 on contactor box C1982 and

BOB pin 24.

•

Is the resistance less than 5 ohms?

2-18 CHECK CIRCUIT 3997 (DG) (OUTSIDE TRACTION BATTERY

SUPPORT TRAY) FOR SHORT TO GROUND

•

With key OFF, disconnect BOB from TIM and TIM C4998, C4999.

Yes =

GO to 2-19.

•

With key OFF, disconnect in-line C1939 on the traction battery support

No =

REPAIR the DG wire.

tray and connect BOB to in-line C1939M using Traction Battery Low

Voltage Service Cord; do not connect Traction Battery Low Voltage

Service Cord to traction battery support tray in-line C1939F.

•

With key OFF, measure the resistance between BOB pin 24 and ground

(BOB pin 65).

•

Is the resistance greater than 10,000 ohms?

2-19 CHECK CIRCUIT 3997 (DG) (INSIDE OF TRACTION BATTERY

SUPPORT TRAY) FOR SHORT TO GROUND

•

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

Yes =

REPLACE the contactor

connect Traction Battery High-Voltage Lockout and Diagnostic Tool to

box. REFER to

Section

the traction battery high-voltage two-pin C3994M.

414-03B

No =

REPAIR the DG 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 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 contactor box C1982 and measure the

resistance BOB pin 24 and ground (BOB pin 65).

•

Is the resistance greater than 10,000 ohms?

2-20 CHECK STATUS OF TIM OPERATING STATE

•

With key ON, monitor TIM PID TIM OP.

Yes =

GO to 2-21.

•

Does the TIM OP PID indicate 20 (shutdown)?

No =

System OK.

2-21 CHECK KEY RUN/START SIGNAL TO CONTACTOR BOX AT

TRACTION BATTERY SUPPORT TRAY

•

With key OFF, disconnect in-line C1939 on the traction battery support

Yes =

GO to 2-22.

tray.

•

Connect BOB to in-line C1939M using Traction Battery Low Voltage

No =

REPAIR circuit 295

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

(LB/BK).

to traction battery support tray in-line C1939F.

•

With key ON, measure the voltage between BOB pin 21 and ground

(BOB pin 65).

•

Is the voltage greater than 10 volts?

2-22 CHECK CIRCUIT 295 (LB/PK) (INSIDE OF TRACTION

BATTERY SUPPORT TRAY) FOR OPEN

(Continued)

100-09-12

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

ROUTINE 2: VEHICLE DOES NOT START/VEHICLE QUITS WHILE DRIVING (NIMH VEHICLES)

TEST STEP

ACTION TO TAKE

•

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

Yes =

REPLACE the contactor

and connect Traction Battery High-Voltage Lockout and Diagnostic Tool

box. REFER to

Section

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

414-03B

No =

REPAIR the LB/PK 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 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 contactor box C1982 and measure the

resistance of the LB/PK wire between pin 13 on contactor box C1982

and BOB pin 21.

•

Is the resistance less than 5 ohms?

ROUTINE 3: VEHICLE STARTS, BUT DOES NOT MOVE

TEST STEP

ACTION TO TAKE

3-1 CHECK STATUS OF BATTERY CONTROL MODULE (BCM)

OPERATING STATE

•

With key ON, monitor BCM PID BCM OP.

Yes =

CHARGE the traction

battery. REFER to

Section

100-05

•

Does the BCM OP PID indicate 69 (limited operating strategy

drive-low state of charge )?

No =

GO to 3-2.

3-2 CHECK FOR PARK MECHANISM FAILURE

•

Disconnect the shift linkage.

Yes =

GO to 3-3.

•

Set the transmission range selector lever to the any position except P

No =

REPLACE the

(Park).

motor/transaxle. REFER to

•

Raise the vehicle on a hoist.

Section 303-01.

•

Rotate both rear wheels simultaneously in the same direction.

•

Do the wheels rotate freely?

3-3 CHECK VEHICLE SPEED SENSORS

NOTE: The traction inverter module (TIM) diagnostic trouble code (DTC)

Yes =

REPAIR as indicated in

C1856 Traction Motor Encoder Circuit Failure will not be set if either

Pinpoint Test B.

vehicle speed sensor (VSS) fails below 3 km/h (2 mph).

•

Carry out Pinpoint Test B: DTC C1856 Traction Motor Encoder Circuit

Failure. Refer to

Section 303-14

•

Are any faults indicated?

No =

REPLACE the

motor/transaxle. REFER to

303-01.

ROUTINE 4: VEHICLE OPERATES AT REDUCED POWER (LEAD ACID VEHICLES)

TEST STEP

ACTION TO TAKE

4-1 CHECK STATUS OF BATTERY CONTROL MODULE (BCM)

OPERATING STATE

•

With key ON, monitor BCM PID BCM OP.

Yes =

If BCM OP PID indicates

67, GO to 4-2.
If BCM OP PID indicates

68, GO to 4-5.

(Continued)

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