Ford Ranger EV (2001 year). Manual - part 206

2001 ELECTRIC RANGER VEHICLE

2-3

HOW TO USE THIS MANUAL

Some engine circuits may need special test equip-

ment and special procedures. See the Workshop
Manual and other service books for details. You will
find the circuits in this manual to be helpful with those
special test procedures.

TROUBLESHOOTING TOOLS

JUMPER WIRE

This is a test lead used to connect two points of a

circuit. A Jumper Wire can bypass an open to com-
plete a circuit.

WARNING

Never use a jumper wire across loads (motors,
etc.) connected between hot and ground. This
direct battery short may cause injury or fire.

VOLTMETER

A DC Voltmeter measures circuit voltage. Connect

negative (- or black) lead to ground, and positive (+
or red) lead to voltage measuring point.

OHMMETER

OHMS

Figure 1 – Resistance Check

An Ohmmeter shows the resistance between two

connected points (Figure 1).

TEST LAMP

TEST
LAMP

Figure 2 – Test Lamp

A Test Light is a 12-volt bulb with two test leads

(Figure 2).

Uses: Voltage Check, Short Check.

SELF-POWERED TEST LAMP

SELF-
POWERED
TEST
LAMP

SWITCH

Figure 3 – Continuity Check

The Self-Powered Test Lamp is a bulb, battery and

set of test leads wired in series (Figure 3). When con-
nected to two points of a continuous circuit, the bulb
glows.

Uses: Continuity Check, Ground Check.

CAUTION

When using a self-powered test lamp or ohmme-
ter, be sure power is off in circuit during testing.
Hot circuits can cause equipment damage and
false readings.

FUSE

BATTERY

M

TEST LAMP

MOTOR

JUMPER
WIRE
ACROSS
SWITCH

Figure 4 – Switch Circuit Check and

Voltage Check

In an inoperative circuit with a switch in series with

the load, jumper the terminals of the switch to power
the load. If jumpering the terminals powers the cir-
cuit, the switch is inoperative (Figure 4).

CONTINUITY CHECK 
(Locating open circuits)

Connect one lead of Self-Powered Test Lamp or

Ohmmeter to each end of circuit (Figure 3). Lamp will
glow if circuit is closed. Switches and fuses can be
checked in the same way.

2001 ELECTRIC RANGER VEHICLE

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HOW TO USE THIS MANUAL

VOLTAGE CHECK

Connect one lead of test lamp to a known good

ground or the  negative  (-)  battery terminal. Test for
voltage by touching the other lead to the test point.
Bulb goes on when the test point has voltage (Figure
4).

BATTERY

TEST 
LAMP

FUSE BLOCK

C1

C2

M

C3

MOTOR
DISCONNECTED

X

C4

Figure 5 – Short Check

A fuse that repeatedly blows is usually caused by

a short to ground. It’s important to be able to locate
such a short quickly (Figure 5).

1. Turn off everything powered through the fuse.

2. Disconnect other loads powered through the

fuse:

D Motors: disconnect motor connector (Con-

nector C4 in Figure 5).

D Lights: remove bulbs.

3. Turn Ignition Switch to RUN (if necessary) to

power fuse.

4. Connect one Test Lamp lead to hot end of blown

fuse. Connect other lead to ground. Bulb should
glow, showing power to fuse. (This step is just a
check to be sure you have power to the circuit.)

5. Disconnect the test lamp lead that is connected

to ground, and reconnect it to the load side of the
fuse at the connector of the disconnected compo-
nent. (In Figure 5, connect the test lamp lead to
connector C4.)

D If the Test Lamp is off, the short is in the dis-

connected component.

D If the Test Lamp goes on, the short is in the

wiring. You must find the short by discon-
necting the circuit connectors, one at a time,
until the Test Lamp goes out. For example,
in Figure 5 with a ground at X, the bulb goes
out when C1 or C2 is disconnected, but not
after disconnecting C3. This means the short
is between C2 and C3.

SELF-
POWERED
TEST
LIGHT
OR
OHMMETER

VOLTAGE
CHECK
USING
VOLTMETER

VOLTS

Figure 6 – Ground Check

Turn on power to the circuit. Perform a Voltage

Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the
ground is inoperative (Figure 6).

Turn off power to the circuit. Connect one lead of

a Self-Powered Test Lamp or Ohmmeter to the wire
in question and the other lead to a known ground. If
the bulb glows, the circuit ground is OK (Figure 6).

The circuit schematics in this manual make it easy

to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For
example, if several circuits fail at the same time,
check for a common power or ground connection
(see Power Distribution or Grounds). If part of a cir-
cuit fails, check the connections between the part
that works and the part that doesn’t work.

For example, if the lo beam headlamps work, but

the high beams and the indicator lamp don’t work,
then power and ground paths must be good. Since
the dimmer switch is the component that switches
this power to the high beam lights and indicator, it is
most likely the cause of failure.

Intermittent
Signals
Through
Pierced
Insulation

Proper
Crimp

Insulation
Not
Removed

Wire
Strands
Missing

DEFECTIVE INSULATION STRIPPING

Locked
Terminal

Check for unlocked terminals
by pulling each wire at the end
of the connector.

Male Half

Female Half

Seal

Unlocked
Terminal
(Hidden by
Wire Seal)

Seal

Intermittent
Contact

TERMINAL NOT PROPERLY SEATED

PARTIALLY MATED CONNECTORS

Lock may be displaced into an
unlocked position; pull on the
connector to verify the lock.

Female
Half

Displaced
Tab

Seal

Seal

Male
Half

Intermittent
Contact

Type A

Type B

Intermittent
Contact

2001 ELECTRIC RANGER VEHICLE

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HOW TO USE THIS MANUAL

TROUBLESHOOTING WIRING HARNESS
AND CONNECTOR HIDDEN CONCERNS

The following illustrations are known examples of wiring harness,
splices and connectors that will create intermittent electrical con-
cerns.  The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.

NOTE:  Several components, such as the PCM, utilize gold plated
terminals in their connections to the wiring harness. If those termi-
nals need to be replaced, they must be replaced with a gold plated
terminal. 

DEFORMED (ENLARGED) FEMALE TERMINALS

Any probe entering the
terminal may 
enlarge the contact
spring opening creating
an intermittent signal.
Insert the correct mating
terminal (Location A)
from the service kit and
feel for a loose fit.

Enlarged

Normal

A

A

ELECTRICAL SHORT WITHIN THE HARNESS

Harness Tape

Operate the system
and flex the harness
at splice location
noted in Section 152.

Splice Tape

Wire Strand

Splice Tape Removed

Intermittent Short

Splice Covered

ELECTRICAL SHORT INSIDE THE HARNESS

Solder coated wire pierced through
the insulation of another circuit.

Solder Coated
Wire to Ground

Harness
Protective Tape

Intermittent
Short

Grounding Foil

BROKEN WIRE STRANDS IN HARNESS

Remove the tape and
flex/feel each circuit
for a reduction in
diameter at break.

Circuit Insulation

Wiring
Strand

Broken Strands
Intermittent Signal

Wiring Harness Tape

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HOW TO USE THIS MANUAL