Ford ESCAPE HYBRID FCS-15101-10 manual

ESCAPE HYBRID MARINER HYBRID MODIFIERS GUIDE 2010 2010 FCS-15101-10[...]

T ABLE OF CONTENTS 1 General Information 2 Electrical 3 Mounting 4 Reference INTRODUCTION SECTIONS NOTE: The descriptions and specifications contained in this manual were in ef fect at the time this manual was approved for printing. Ford Motor Company reserves the right to discontinue models at any time, or change specifications or design without n[...]

SECTION 0 Introduction Contents Introduction ....................................................................................... 0-1 Genuine Ford Accessories For Your Vehicle .............................. 0-1 Considerations When Using or Installing Accessories ............ 0-2 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009[...]

Introduction 0-1 Introduction Note: The descriptions and specifications contained in this manual were in effect at the time this manual was approved for printing. Ford Motor Company reserves the right to discontinue models at any time, or change specifications or design without notice and without incurring any obligation. All rights reserved. Repro[...]

0-2 Introduction Introduction This means that Genuine Ford Accessories purchased along with your new vehicle and installed by the dealer are covered for the full length of your New Vehicle’s Limited Warranty — 3 years or 36,000 miles (60,000 km) (whichever occurs first). Contact your dealer for details and a copy of the warranty. Considerations[...]

SECTION 1 General Information Contents Section 1: General Information ........................................................ 1-1 Important Safety Notice ................................................................ 1-1 Notes, Notices and Warnings ................................................... 1-2 Making Safety Devices and Elements Inopera[...]

SECTION 1 General Information Contents (Continued) Vehicle Storage — Fuel System .............................................. 1-7 Vehicle Storage — Tires........................................................... 1-7 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009[...]

General Information 1-1 Section 1: General Information Important Safety Notice Note: The descriptions and specifications contained in this guide were in effect at the time this manual was approved for printing. Ford Motor Company reserves the right to discontinue models at any time, or change specifications or design without notice and without incu[...]

1-2 General Information Section 1: General Information Notes, Notices and Warnings As you read through this guide, you will come across NOTES, NOTICES and WARNINGS. Each one is there for a specific purpose. NOTES give you added information that will help you to complete a particular procedure. NOTICES are given to prevent you from making an error t[...]

General Information 1-3 Section 1: General Information • Keep yourself and your clothing away from moving parts when the engine is running, especially the drive belts. • To reduce the risk of serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. • Do not smoke whil[...]

1-4 General Information Section 1: General Information Quality Assurance Completed unit sign-off: All control items should be inspected with a written sign-off. All labels should be inspected and signed off, including verification that the information on the labels is correct. All appropriate systems should be checked for leaks. A road test should [...]

General Information 1-5 Section 1: General Information Using Snow Tires and Traction Devices Note: Snow tires must be the same size and grade as originally equipped on your vehicle. The tires on your vehicle have all-weather treads to provide traction in rain and snow. However, in some climates, using snow tires or traction devices may be necessary[...]

1-6 General Information Section 1: General Information Gross Axle Weight Rating (GAWR) — is the maximum allowable weight that can be carried by a single axle (front or rear). These numbers are shown on the Safety Compliance Certification Label located on the B-pillar or the edge of the driver’s door. The total load on each axle must never excee[...]

General Information 1-7 Section 1: General Information If your vehicle is to be stored for 30 days or longer, the low-voltage (underhood) battery negative terminal must be disconnected. Failure to do this could damage your vehicle’s battery systems. Vehicle Storage — Body • Wash vehicle thoroughly to remove dirt, grease, oil, tar or mud from [...]

SECTION 2 Electrical Contents Section 2: Electrical ......................................................................... 2-1 Electrical Basics ........................................................................... 2-1 Electrical Terms ........................................................................ 2-1 Control Modules — Red Area[...]

SECTION 2 Electrical Contents (Continued) High-Voltage Traction Battery (HVTB) Systems Depowering ................................................................................. 2-7 Electrical Systems Management ...................................... ............ 2-9 Generator Output ...............................................................[...]

SECTION 2 Electrical Contents (Continued) Recommended Splicing Method — Solder (For 16 AWG and Smaller Diameter Wire Only) ............................... 2-20 Heat Shrinkable Tubing (Heat Shrink) (Ford Specification ESB-M99D56-A2) ............................................ 2-23 Recommended Splicing Method — Crimp (For 10 - 22 AWG Diameter Wi[...]

Electrical 2-1 Section 2: Electrical Electrical Basics Inside a vehicle, electricity is supplied through ‘‘hot’’ wires, comparable to the pressurized supply pipes of a plumbing system. At various points along the wires are outlets in the form of lights, switches and receptacles. Turning on a light switch is somewhat like opening a faucet to[...]

2-2 Electrical Section 2: Electrical Control Modules — Red Area Do not install any components into the control modules or module harness. Connecting into this system may affect control module operation. As an example: connection of aftermarket electrical equipment into the brake light circuit or any other circuit which is connected to the PCM, an[...]

Electrical 2-3 Section 2: Electrical The high-voltage system has a floating ground. When the engine is operating or the vehicle is moving, the high-voltage generator begins to generate high voltage, AC electricity. High-voltage AC electricity can be consumed or generated by the motor generator, the traction motor or a combination of both motors. Ex[...]

2-4 Electrical Section 2: Electrical 1. High-voltage connector shield 2. Service disconnect 3. High-voltage battery case DC/DC Converter The DC/DC converter is a liquid-cooled component that converts high-voltage (216-397 volts) DC power to low-voltage (12 volts) DC power while maintaining electrical isolation between the 2 DC power systems. The co[...]

Electrical 2-5 Section 2: Electrical Auxiliary Power Point — 12V NOTICE: Power outlets are designed for accessory plugs only. Do not insert any other object in the power outlet as this will damage the outlet and blow the fuse. Do not hang any type of accessory or accessory bracket from the plug. Improper use of the power outlet can cause damage n[...]

2-6 Electrical Section 2: Electrical 2. Position 4 orange cones around the corners of the vehicle to mark off a 1 m (3 ft) perimeter around the vehicle. 3. Do not allow any unauthorized personnel into the buffer zone during repairs involving the high-voltage system. Only personnel trained for repair on the high-voltage system are to be permitted in[...]

Electrical 2-7 Section 2: Electrical High-Voltage Traction Battery (HVTB) Systems Depowering WARNING: The nominal high-voltage traction battery (HVTB) voltage is 330 volt DC. A buffer zone must be set up and high-voltage insulated safety gloves and a face shield must be worn when modifying the vehicle in close proximity to the high-voltage system. [...]

2-8 Electrical Section 2: Electrical 4. Remove the service disconnect plug. a. Rotate the service disconnect plug from the LOCK (1) position to the UNLOCK (2) position. b. Remove the service disconnect plug and place in the SERVICE SHIPPING (3) position. 5. NOTICE: Place the service disconnect plug into the SERVICE SHIPPING position while carrying [...]

Electrical 2-9 Section 2: Electrical Electrical Systems Management Care must be given in deciding what equipment should be installed into a vehicle given the power demands of the equipment and the power available from the vehicle. A power load strategy should be developed to minimize the risk of running out of power. Examine the proposed equipment [...]

2-10 Electrical Section 2: Electrical Component Amps A/C Clutch 3.7 A/C Fan to Face — High Speed 21.7 (recirculating air) A/C Fan to Face — M/H Speed 11.9 (recirculating air) Heater Fan to Foot — M/H Speed 10.7 (fresh air) Lighting Exterior and IP Lamps 4.5 (non-dimmable) Headlamps — Low Beam 10.0 Fog Lamps 8.0 Brake Lights (with CHMSL) 7.5[...]

Electrical 2-11 Section 2: Electrical General Guidelines • Provide circuit protection (fuses) for all wiring. The fuse rating should not exceed either the rated wiring current capacity or the total current requirements for all the add-on components on the circuit. Install fuses as close to the point of tapped power as possible. • Document all r[...]

2-12 Electrical Section 2: Electrical Keep-Alive Memory Power The electronic engine and transmission control modules require battery power to be supplied at all times to maintain the keep-alive memory. Keep this in mind when installing load disconnect switches or solenoids. Equipment Grounding Guidelines • Do not ground the body to the transmissi[...]

Electrical 2-13 Section 2: Electrical When a connection is not defined (typical situation — harness-to-harness connectors), the following suggestions should be implemented: • Determine the connector type. If it will be located in a hostile environment, use a sealed connector; if not, use an open connector. A hostile environment is defined as be[...]

2-14 Electrical Section 2: Electrical • When adding loads to a base vehicle-protected circuit, make sure that the total electrical load through the base vehicle fuse or circuit breaker is less than the device’s load rating. • Use 80% of the fuse rating to determine maximum steady state load to reduce nuisance fuse failures. • Use 135% of th[...]

Electrical 2-15 Section 2: Electrical Electrical Protection • Properly route wires away from noise-generating wires or components. However, if routing near noisy wires or plugging into noisy components is unavoidable, additional protection must be designed into the harness. • Shielding — Electro Magnetic Interference (EMI) — Consider shield[...]

2-16 Electrical Section 2: Electrical Note: This is not meant to be an all-inclusive list of methods for physically protecting the wires. There are other means of protection available that are not listed. Grommets and Sealing Requirements Any additional wiring routed through sheet metal must pass through a grommet that both seals the opening and lo[...]

Electrical 2-17 Section 2: Electrical • Route wires to avoid metal edges, screws, trim fasteners and abrasive surfaces. When such routing is not possible, use protective devices (shields, caps) to protect the wires. Cover metal edges with a protective shield and fasten the wiring within 76 mm (3 in) on each side of the edge (see figure below). ?[...]

2-18 Electrical Section 2: Electrical Wire Retention and Routing Use the following criteria to determine the location of retainers: • Size and weight of wire bundle. • Holes with poor accessibility that prevent installation of locators. • Movement of wires that can result in abrasion, squeaks and rattles. • When wiring is routed between 2 m[...]

Electrical 2-19 Section 2: Electrical For retainer screws, the following guidelines apply: • Avoid using fasteners that are too long for the application or are in an area which might damage vehicle components, including wiring, brake lines, fuel tank and lines, powertrain components, exhaust system and suspension. • Do not use pointed screws fo[...]

2-20 Electrical Section 2: Electrical Splices and Repairs For quality splicing and to reduce potential problems, the following guidelines are recommended: • Stagger the splices within a harness to reduce increased harness diameter. Splice only on straight areas as installed, not on bends. • Strip wire ends making sure that individual conductor [...]

Electrical 2-21 Section 2: Electrical 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist the wires together. 5. Note: Use resin-core mildly-activated (RMA) solder. Do not use acid-core solder. Solder wires together. 6. Note: Wait for solder to cool before moving wires. Bend wire No. 1 back in a straight line. 2010 Escape [...]

2-22 Electrical Section 2: Electrical 7. Note: Overlap tubing on both wires. Evenly position heat shrink tubing over wire repair. 8. Use a shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009[...]

Electrical 2-23 Section 2: Electrical 9. Reconnect the battery ground cable. Sealed Connectors Ford Part Number Part Name Class E6FZ-14488-A Butt Connector C Gauge: 18-22, Color: Red E6FZ-14488-B Butt Connector C Gauge: 14-16, Color: Blue E6FZ-14488-C Butt Connector C Gauge: 10-12, Color: Yellow Heat Shrinkable Tubing (Heat Shrink) (Ford Specificat[...]

2-24 Electrical Section 2: Electrical 4. Select the appropriate wire splice for the wires to be spliced from Rotunda Wire Splice Kit 164-R5903. 5. Note: Rotunda 164-R5901 Pro-Crimper supplied with the wire splice kit is the only tool that can be used with these splices. Identify the appropriate chamber on the Rotunda Pro-Crimper by matching the wir[...]

Electrical 2-25 Section 2: Electrical 8. Check for acceptable crimp. (1) Crimp should be centered on each end of the butt splice. (2) Wire insulation does not enter butt splice. (3) Wire is visible through inspection hole of splices. 9. Evenly position supplied heat shrink tubing over wire repair. 10. Use shielded heat gun to heat the repaired area[...]

2-26 Electrical Section 2: Electrical Wiring Reference Information 2009 Escape/Mariner Hybrid Wiring Diagram Excerpts The following pages are from sections of the 2009 Escape/Mariner Hybrid Wiring Diagrams. Ordering Information To obtain information about ordering complete copies of Ford or Lincoln/Mercury publications, call 1-800-782-4356. Availab[...]

Electrical 2-27 Section 2: Electrical 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009[...]

2-28 Electrical Section 2: Electrical Note: Smart junction box (SJB) fuse 1 (30A), circuit SBP01 (RD) for the DC/AC power inverter is at maximum available current limit when the power inverter is installed and used. Do not splice into this fused circuit when the DC/AC power inverter is installed and used. 2010 Escape Hybrid, Mariner Hybrid Modifier[...]

Electrical 2-29 Section 2: Electrical Connector End Views 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009[...]

2-30 Electrical Section 2: Electrical 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009[...]

Electrical 2-31 Section 2: Electrical Connector and Ground Locator 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009[...]

2-32 Electrical Section 2: Electrical 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009[...]

Electrical 2-33 Section 2: Electrical 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009[...]

2-34 Electrical Section 2: Electrical 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009[...]

Electrical 2-35 Section 2: Electrical 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009[...]

2-36 Electrical Section 2: Electrical 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009[...]

Electrical 2-37 Section 2: Electrical 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009[...]

SECTION 3 Mounting Contents Section 3: Mounting ......................................................................... 3-1 Push Bumpers .............................................................................. 3-1 Using the Vehicle for Snowplowing.............................................. 3-1 Using the Vehicle as an Ambulance ..........[...]

Mounting 3-1 Section 3: Mounting Push Bumpers Ford Motor Company does not recommend the installation of any type of push bumper. Using the Vehicle for Snowplowing Do not use the vehicle for snowplowing. The Escape/Mariner Hybrid is not equipped with a snowplowing package. Using the Vehicle as an Ambulance Do not use the vehicle as an ambulance. The[...]

3-2 Mounting Section 3: Mounting • Do not mount equipment to the high-voltage connector shield located under the RH rear seat back and bottom. NOTICE: The side impact sensor is tuned to excite based on its mass (including wiring), as well as the host sheet metal. Any alteration to these components must be avoided. Additions, such as padding, wire[...]

Mounting 3-3 Section 3: Mounting WARNING: The partition and the installation hardware of the partition must not interfere with the proper operation of the safety belt, safety belt retractor, side impact sensor and the safety belt height adjusters. Failure to follow these instructions may result in personal injury. WARNING: Installation of prisoner [...]

3-4 Mounting Section 3: Mounting Refer to the following illustration for locations that must not be used for partition mounting: 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009[...]

Mounting 3-5 Section 3: Mounting Side Impact Sensor (if equipped) The side impact sensors are located in the base of the B-pillars. They are positioned below the safety belt retractors. The location and orientation are critical for the correct operation of all the impact sensors. Do not use the attachment bolts of the impact sensors to mount any eq[...]

3-6 Mounting Section 3: Mounting Air Bag Deployment Interference WARNING: Do not place objects or mount equipment in front of the air bag module cover or in front seat areas that may come in contact with a deploying air bag. Dash-, tunnel- or console-mounted equipment should be placed within the specified zone. Failure to follow these instructions [...]

Mounting 3-7 Section 3: Mounting WARNING: Do not attempt to service, repair or modify the safety canopy system (if equipped), its fuses, the A-, B-, or C-pillar trim, or the headliner on a vehicle containing a safety canopy. See your Ford or Lincoln Mercury dealer. WARNING: To reduce risk of injury, do not obstruct or place objects in the deploymen[...]

SECTION 4 Reference Contents Section 4: Reference ....................................................................... 4-1 Engineering Drawings .................................................................. 4-1 Air Bag Deployment Interference ............................................. 4-1 Evaporative Emissions and Fuel Systems ...........[...]

Reference 4-1 Section 4: Reference Engineering Drawings Air Bag Deployment Interference WARNING: Do not place objects or mount equipment in front of the air bag module cover or in front seat areas that may come in contact with a deploying air bag. Dash-, tunnel- or console-mounted equipment should be placed within the specified zone. Failure to fol[...]

4-2 Reference Section 4: Reference WARNING: Do not attempt to service, repair or modify the safety canopy system (if equipped), its fuses, the A-, B-, or C-pillar trim, or the headliner on a vehicle containing a safety canopy. See your Ford or Lincoln Mercury dealer. Failure to follow these instructions may result in personal injury. WARNING: To re[...]

Reference 4-3 Section 4: Reference Note: Do not mount equipment on the instrument panel between the driver and passenger airbags due to deployment variability. Figure 1. 1. 324 mm (12.75 in) from center of air bag door 2. 450 mm (17.7 in) from center of air bag door 3. 610 mm (24 in) 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009[...]

4-4 Reference Section 4: Reference Figure 2. 1. 648 mm (25.5 in) from center of air bag door 2. 229 mm (9.0 in) from center of air bag door 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009[...]

Reference 4-5 Section 4: Reference Figure 3. 1. 730 mm (28.7 in) from center of air bag door 2. 650 mm (25.6 in) from center of air bag door 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009[...]

4-6 Reference Section 4: Reference Note: Vehicles equipped with safety canopy module and side air bag module only. Figure 4. NOTICE: The side impact sensor is tuned to excite based on its mass (including wiring), as well as the host sheet metal. Any alteration to these components must be avoided. Additions, such as padding, wire connectors, retaine[...]

Reference 4-7 Section 4: Reference Evaporative Emissions and Fuel Systems 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009[...]

4-8 Reference Section 4: Reference 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009[...]

Reference 4-9 Section 4: Reference High-Voltage System 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009[...]

4-10 Reference Section 4: Reference 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009[...]

Reference 4-11 Section 4: Reference High Voltage Traction Battery (HVTB) Vent Note: The HVTB vent is located on the left rear interior trim panel. Do not block vent or system shutdown can occur. 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009[...]