30N26F0

FCSDTechnical Training

INTERACTIVE STUDY GUIDE

ESCAPE/MARINER HYBRIDELECTRIC VEHICLE NEW

MODEL TRAINING

FCS-13993-DL

ESCAPE\MARINER HYBRID ELECTRIC VEHICLE NEW MODEL TECHNICIAN TRAININGCOURSE CODE: 30N26F003-MAY-04

IMPORTANT SAFETY NOTICE

Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles, aswell as the personal safety of the individual doing the work. This manual provides general directions for accomplishing serviceand repair work with tested, effective techniques. Following them will help assure reliability.

There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of theindividual doing the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each.Accordingly, anyone who departs from instructions provided in this manual must first establish that he compromises neither hispersonal safety nor the vehicle integrity by his choice of methods, tools or parts.

As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each one is there for aspecific purpose. NOTES give you added information that will help you to complete a particular procedure. CAUTIONS are givento prevent you from making an error that could damage the vehicle. WARNINGS remind you to be especially careful in thoseareas where carelessness can cause personal injury. The following list contains some general WARNINGS that you shouldfollow when you work on a vehicle.

• Always wear safety glasses for eye protection. • To prevent serious burns, avoid contact with hot metalparts such as the radiator, exhaust manifold, tail pipe,• Use safety stands whenever a procedure requires you to catalytic converter and muffler.

be under the vehicle.

• Be sure that the ignition switch is always in the OFF • Do not smoke while working on the vehicle.position, unless otherwise required by the procedure.

• To avoid injury, always remove rings, watches, loose• Set the parking brake when working on the vehicle. If youhanging jewelry, and loose clothing before beginning tohave an automatic transmission, set it in PARK unlesswork on a vehicle. Tie long hair securely behind yourinstructed otherwise for a specific service operation. If youhead.have a manual transmission it should be in RE-VERSE

(engine OFF) or NEUTRAL (engine ON) unless instructedotherwise for a specific service operation. • Keep hands and other objects clear of the radiator fan

blades. Electric cooling fans can start to operate at any• Operate the engine only in a well-ventilated area to avoidtime by an increase in underhood temperatures, eventhe danger of carbon monoxide.though the ignition is in the OFF position. Therefore, care

• Keep yourself and your clothing away from moving parts should be taken to ensure that the electric cooling fan iswhen the engine is running, especially the fan and belts. completely disconnected when working under the hood.

The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership parts and/orservice department operations. These recommendations and suggestions do not supersede or override the provisions of the Warrantyand Policy Manual, and in any cases where there may be a conflict, the provisions of the Warranty and Policy Manual shall govern.

The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was approvedfor printing. Ford Motor Company reserves the right to discontinue models at any time, or change specifications, design, ortesting procedures without notice and without incurring obligation. Any reference to brand names in this manual is intendedmerely as an example of the types of tools, lubricants, materials, etc. recommended for use. Equivalents, if available, may beused. The right is reserved to make changes at any time without notice.

WARNING: MANY BRAKE LININGS CONTAIN ASBESTOS FIBERS. WHEN WORKING ON BRAKE COMPONENTS, AVOIDBREATHING THE DUST. BREATHING THE ASBESTOS DUST CAN CAUSE ASBESTOSIS AND CANCER.

Breathing asbestos dust is harmful to your health.

Dust and dirt present on car wheel brake and clutch assemblies may contain asbestos fibers that are hazardous to your health whenmade airborne by cleaning with compressed air or by dry brushing.

Wheel brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with asbestos fibers.Dust and dirt should be disposed of in a manner that prevents dust exposure, such as sealed bags. The bag must be labeled per OSHAinstructions and the trash hauler notified as to the contents of the bag.

If a vacuum bag suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, techniciansshould wear government approved toxic dust purifying respirators.

OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only techniciansconcerned with performing brake or clutch service should be present in the area.

Copyright 2000 Ford Motor Company Produced and Coordinated byTechnical Support OperationsFord Customer Service Division

August, 2000

CUSTOMER EXPECTATIONS

Customer Expectations: Service

1. Make it convenient to have my vehicle 5. Provide me with a clear and thoroughserviced at your dealership. explanation of the service performed.

2. The Service Advisor should 6. Call me within a reasonable amountdemonstrate a genuine concern for of time after my service visit to ensuremy service needs. that I’m completely satisfied.

3. Fix it right the first time. 7. Be responsive to questions orconcerns I bring to your attention.4. Complete servicing my vehicle in a

timely and professional manner.

Expectation 3

‘‘Fix It Right The First Time, on Time.’’Both service advisors and technicians are important players when it comes to Expectation#3.

WhyCustomers tell us ‘‘Fixing It Right The First Time, on Time’’ is one of the reasons theywould decide to return to a dealer to buy a vehicle and get their vehicles serviced.

Technician TrainingIt is our goal to help the technician acquire all of the skills and knowledge necessary to‘‘Fix It Right The First Time, on Time.’’ We refer to this as ‘‘competency.’’

Technician’s RoleAcquire the skills and knowledge for competency in your specialty via:

STST New Model– Self Study – Self Study– FordStar Broadcasts – FordStar Broadcasts– Ford Multimedia Training (FMT) – Instructor Led– Instructor Led

The BenefitsThe successful implementation of expectations means:

– Satisfied customers– Repeat vehicle sales– Repeat service sales– Recognition that Ford and Lincoln/Mercury technicians are ‘‘the Best in the

Business’’

TABLE OF CONTENTS

INTRODUCTION............................................................................................................... Intro-1Technical Training ........................................................................................................ Intro-1Ground Rules for Successful Completion .................................................................... Intro-1Logging On ................................................................................................................... Intro-2Keypad Operation......................................................................................................... Intro-3In-Dealership Training Map .......................................................................................... Intro-4Purpose......................................................................................................................... Intro-5Agenda.......................................................................................................................... Intro-5

LESSON 1: OVERVIEW......................................................................................................... 1-1Objectives .......................................................................................................................... 1-1Introduction ........................................................................................................................ 1-2Hybrid Overview ................................................................................................................ 1-3Operating Characteristics .................................................................................................. 1-4Exterior Features ............................................................................................................... 1-5Interior Features ................................................................................................................ 1-6Safety ................................................................................................................................. 1-9Dealership Requirements ................................................................................................ 1-10Unique Warranty.............................................................................................................. 1-11Maintenance Check Points.............................................................................................. 1-12

LESSON 2: CHASSIS ............................................................................................................ 2-1Objectives .......................................................................................................................... 2-1Brake System .................................................................................................................... 2-2Steering System ................................................................................................................ 2-6

LESSON 3: POWERTRAIN ................................................................................................... 3-1Objectives .......................................................................................................................... 3-1Engine................................................................................................................................ 3-2Transmission System ...................................................................................................... 3-10Motor Electronics Cooling System .................................................................................. 3-13

LESSON 4: ELECTRICAL ..................................................................................................... 4-1Objectives .......................................................................................................................... 4-1Module Communication Network....................................................................................... 4-2Charging System ............................................................................................................... 4-4Climate Control System..................................................................................................... 4-8Electrical Safety ............................................................................................................... 4-11

APPENDIX ................................................................................................................Appendix-1Appendix: Essential Special Service Tools .......................................................... Appendix-1Order Form ........................................................................................................... Appendix-3Glossary Of Terms ............................................................................................... Appendix-5

Escape/Mariner Hybrid Electric Vehicle New Model Training 03-MAY-04 i

TABLE OF CONTENTS

NOTES

Escape/Mariner Hybrid Electric Vehicle New Model Training03-MAY-04ii

INTRODUCTION

FCSDTechnical Training

The distance learning course you are about to take is intended to give you new knowledge and information about

diagnosing and servicing Ford vehicles. We hope you apply this knowledge and information to ‘‘Fix It Right The

First Time’’ as part of our effort to satisfy our customers, the owners of Ford Vehicles.

Ground Rules for Successful Completion

This course is ‘‘score based’’. Successful completion of this course requires a passing score of 80% or greater.

Achievement of 80% or greater will result in a ‘‘PASS’’ in your STARS training history. A score of less than

80% results in a ‘‘FAIL’’ in your STARS training history. If you logon and participate in the class, but choose

NOT to answer any of the questions, your will receive an ‘‘AUDIT’’ in your training history. You may return to

complete the test in a future class session, if desired.

Escape/Mariner Hybrid Electric Vehicle New Model Training 03-MAY-04 Intro-1

INTRODUCTION

LOGGING ON

Your response keypad transmits data and voice between you and the host via telephone lines and satellite. It is

your ‘‘lifeline’’, connecting you to the instructor as well as to other participants. Using the keypad, you can

become involved fully in the seminar, asking questions and contributing relevant comments. To log on at the

beginning of the broadcast session:

1. Enter your I.D. number (in response to the keypad prompt). If you press an incorrect key, press CLEAR and

re-enter the numbers.

2. Press ENTER.

3. The system validates your I.D. number by displaying your name on the keypad. If your name does not appear

on the keypad, re-enter your I.D. number.

4. If you cannot successfully log on, contact the FORDSTAR Help Desk:

a. USA dealers call 1-800-790-HELP (4357).

b. Canadian dealers call 1-800-467-8925.

Escape/Mariner Hybrid Electric Vehicle New Model Training03-MAY-04Intro-2

INTRODUCTION

KEYPAD OPERATION

CALL Key

• Press the CALL key if you have a question or comment. This places you in the call queue. The system indicates

your name and location to the instructor.

• It takes approximately 60 seconds for the instructor to respond. If you change your mind about asking the

question, simply press the CALL key again. As long as the instructor has not accepted your call, this takes you

out of the call queue.

WAIT and SPEAK Lights

• The red WAIT light illuminates when your call is received and placed in the call queue.

• When the instructor calls on you, the green SPEAK light illuminates and your microphone is activated.

• The microphone is the gray dot between the SPEAK and WAIT lights. Speak in a normal tone of voice from a

normal sitting position. The instructor will hear you, as will the other students.

FLAG Key

• Use the FLAG key when requested by the instructor. The FLAG key is usually used to alert the instructor that

you have completed a test or exercise.


INTRODUCTION

IN-DEALERSHIP TRAINING MAP


INTRODUCTION

PURPOSE

The purpose of this FORDSTAR course is to provide Ford service technicians with the knowledge needed to

understand the new systems, new components and unique service procedures for the 2005 Escape Hybrid Electric

Vehicle.

• The benefits of taking this course are that:

– Upon completion, you will have the knowledge that will assist you to service the 2005 Escape Hybrid.

– Service advisors will have completed their portion of the dealership certification requirements.

– Technicians will have completed their pre-requisite for the classroom training.

AGENDA

Following this introduction, information is arranged in the following order:

• Lesson 1: Overview

• Lesson 2: Chassis

• Lesson 3: Powertrain

• Lesson 4: Electrical


INTRODUCTION

NOTES


LESSON 1: OVERVIEW

OBJECTIVES

• Describe hybrid electric vehicle systems and their interrelationship

• Describe operating characteristics

• Identify exterior features

• Identify interior features

• Identify safety issues relating to the Escape Hybrid

• Identify who can sell, diagnose and repair the Escape Hybrid

• Explain warranty repair requirements

• Identify maintenance points and lifting requirements

Escape/Mariner Hybrid Electric Vehicle New Model Training 03-MAY-04 1-1

LESSON 1: OVERVIEW

Introduction

2005 Escape Hybrid Electric Vehicle

The Escape Hybrid Electric Vehicle delivers improved fuel economy and fewer pollutants than a conventional

SUV, without the hassle of daily recharging an electric vehicle.

As a hybrid, the Escape Hybrid runs on electric battery power supplemented by a gasoline engine, depending on

the driving situation. An advanced powertrain control module (PCM) chooses the best power method to run the

vehicle at maximum efficiency.

The Escape Hybrid is expected to achieve EPA fuel economy between 6.7 liters per 100 kilometers (35 miles per

gallon) and 5.9 liters per 100 kilometers (40 miles per gallon) for city driving and nearly 7.8 liters per 100

kilometers (30 miles per gallon) for highway driving in front-wheel-drive configuration. Fuel economy for the

4WD is slightly lower.

The Escape Hybrid meets strict super ultra-low emission vehicle (SULEV) and partial zero emission vehicle

(PZEV) emissions standards.

The Escape Hybrid features several all new systems, including throttle control, braking, shifting and steering.

Escape/Mariner Hybrid Electric Vehicle New Model Training03-MAY-041-2

LESSON 1: OVERVIEW

Hybrid Overview

Electronically Controlled Continuously Variable Transmission (eCVT)

The Escape Hybrid combines an electric transmission (known as the electronically controlled continuously

variable transmission, or eCVT) with an internal-combustion engine (2.3L I4) to effectively meet peak demands

for power and to capture energy that is wasted during braking. Captured energy is converted to electricity and

stored in the high voltage battery.

Understanding how the eCVT works is the key to understanding many other components of the Escape Hybrid.

The eCVT houses the:

• electric motor (known as the traction motor)

• generator

• planetary gear set

During operation, the eCVT coordinates power among the engine, traction motor, generator and drive wheels.

We will cover more of the description and operation of the eCVT later in this course.


LESSON 1: OVERVIEW

Operating Characteristics

The Escape Hybrid exhibits unique operating characteristics. Customers may not understand that all of these

characteristics of the Escape Hybrid are normal.

• Starting – Engine starts and then may shut off.

• Driving:

– The engine starts automatically as needed.

– The transmission changes between operating modes but there is no actual shifting.

– The engine may shut off automatically as needed.

– The engine may shut off when the vehicle comes to a stop to conserve fuel.

– Engine speed is different from a conventional vehicle. The engine speed in a hybrid is not directly tied to the

vehicle speed. Under certain conditions the engine speed may appear much higher than that of a

conventional automobile. This is normal.

• Other:

– Unique noises from the traction battery cooling system (fans and blend doors) and the braking system

(accumulator recharging).

– Driving habits, use of the defrost mode, and use of the A/C affect the fuel economy more than a conventional

gasoline powered engine.


LESSON 1: OVERVIEW

Exterior Features

Exterior Features

Item Description Item Description

1 Traction Battery Cooling System Air 2 Hybrid BadgingIntake

The exterior of the Escape Hybrid is very similar to the 2005 Escape. A few changes to the badging are the only

indicators that this is a hybrid electric vehicle. An additional air intake, for the traction battery cooling system, is

disguised as part of the left-hand rear window.


LESSON 1: OVERVIEW

Interior Features

Interior Features


1 Instrument Panel Gauges and Warning 3 Traction BatteryIndicators

2 Navigation Radio and Energy Flow 4 Traction Battery Cooling SystemScreen


LESSON 1: OVERVIEW

The interior of the Escape Hybrid is very similar to the 2005 Escape. A few of the changes include:

• The HV (or traction) battery and its cooling system are located in the rear of the vehicle. These items will be

covered in more detail later in this course.

• A 110 volt AC electrical power outlet is located on the shift console. A seperate DC/AC inverter is located

under the shift console to power the outlet. The 110 volt accessory outlet is protected by fuse 14 (30 amps) in

the power distribution box.

Additional gauges and warning indicators on the instrument panel:

• Tach and EV mode gauges - The tachometer gauge displays the internal combustion engine revolution speed

and indicates when the vehicle is operating on electric power only (EV mode). A small segment below 0

indicates EV mode when the vehicle is using electric power only.

• Charge and Discharge gauge - The charge/assist gauge feature lets the driver know when the HV battery is

being charged by the internal combustion engine or regenerative braking system or when energy from the HV

battery is being used to assist in moving the vehicle. The gauge movement is referenced from the HV battery

and displays in kilowatts. Discharge (assist) is positive current and the gauge pointer rotates clockwise.

Charging is negative current and the gauge pointer rotates counterclockwise. The charge/assist gauge feature

operates only when the ignition switch is in the RUN position.

• Hybrid Hazard telltale (red triangle) - The Hybrid hazard telltale tells the driver the vehicle should be stopped.

The message STOP SAFELY NOW is displayed in the message center when this indicator is illuminated. This

feature indicates a Hybrid system failure.

• Hybrid Caution telltale (amber wrench) - The Hybrid caution telltale tells the driver that service is required, but

not immediately.


LESSON 1: OVERVIEW

Energy Flow Screen on Radio

The optional navigation radio also displays Hybrid-related information on the display screen.

• The energy flow screen shows how power is being transferred in the hybrid system to either accelerate the

vehicle, or charge the HV battery. Titles describe the modes of the hybrid system. There are four symbols on

the display:

– HV battery represents the high voltage battery. The fill level (shown in green) shows the state of charge of

the HV battery and goes up or down as the battery charges/discharges during normal operation.

– Electric motor represents the traction motor and indicates the vehicle is ready to be driven. This symbol is

highlighted in orange after the vehicle is started and remains highlighted until key off.

– Engine represents the internal combustion engine. This symbol is highlighted in orange only when the

internal combustion engine is running.

– Axle/Wheels represents power delivery to or from the wheels. This symbol is highlighted in orange only

when power is being delivered to or from the wheels.

• The fuel economy screen displays three pieces of information: the instantaneous fuel economy, the average fuel

economy and the one minute average graph.


LESSON 1: OVERVIEW

Safety

Safety Equipment

The Escape Hybrid is a unique vehicle that requires the technician to use approved safety equipment and

procedures while working on the vehicle.

• Equipment - Specialized safety equipment, such as high voltage safety gloves, face shields, and safety cones for

the work area, are used to provide a safe work environment.

• Proper Procedures - The high voltage electrical components require the technician to use proper procedures, not

only when working on the vehicle but also when receiving a vehicle that has been damaged in an accident.

All of these topics will be addressed in detail in the classroom course that all dealership technicians are required

to attend.

CAUTION: The evaporative canister lines and the high voltage cable are near the rear lift locations.

Be sure to place the lift pads properly to prevent damage to the vehicle.


LESSON 1: OVERVIEW

Dealership Requirements

Sales and service:

• Only certified dealers can sell and service the Escape Hybrid. Certification requires:

– Technicians complete this FORDSTAR training plus the classroom training.

– Service advisors complete this FORDSTAR training.

• Certified dealers can place orders for the Escape Hybrid on certain dates. The order bank will be opened May

17, 2004.

• Unique Hybrid repairs can only be done at certified dealers. Non-Hybrid components, such as oil filters, can be

repaired at any Ford dealer.

• Dealer facilities must provide the technician with proper safety equipment and training.

– Safety equipment has to be maintained in proper order by the dealership. For example, high voltage safety

gloves need to be re-certified or replaced every six months.

– In depth safety training will be provided by the classroom course that the technicians must attend.

• Currently, all Hybrid components are replaced as a unit only. No internal repairs can be made by the technician.

• Replacement of Hybrid components requires pre-approval by the hotline. The hotline will provide an

Automated Claims Editing System 2 (ACES II) approval code for the warranty claim. Warranty claims will

NOT be paid without this approval code.


LESSON 1: OVERVIEW

Unique Warranty

The Escape Hybrid is covered by the following warranty:

• 3 year/36,000 miles bumper to bumper, including the engine

• 8 year/100,000 miles on unique Escape Hybrid components

• 10 year/150,000 miles on the high voltage battery in Green States

– California

– Massachusetts

– Maine

– New York

– Vermont


LESSON 1: OVERVIEW

Maintenance Check Points

Maintenance Check Points


1 Engine Coolant Reservoir 6 Battery

2 Motor/Electronics (M/E) Coolant 7 Engine Air Filter AssemblyReservoir

3 Engine Oil Filler Cap 8 Engine Oil Dipstick

4 Brake Fluid Reservoir 9 Windshield Washer Fluid Reservoir

5 Power Distribution Box

It is important to check fluid levels at the recommended maintenance intervals. Always use Ford-specified fluids

and lubricants.


LESSON 2: CHASSIS

OBJECTIVES

• Explain the purpose and function of the electro-hydraulic brake system

• Explain the purpose and function of the electric power assisted steering system


LESSON 2: CHASSIS

Brake System

Electro-Hydraulic Brake System


1 Hydraulic Control Unit 2 Actuation Control Unit

The Escape Hybrid has a new electro-hydraulic brake (EHB) system that replaces a portion of the conventional

hydraulic brake system found on the Escape.

The EHB system includes:

• A new actuation control unit (ACU), which is similar to a modified master cylinder.

– The EHB system has no conventional brake booster. The booster was deleted because the gasoline engine

does not run constantly and cannot provide a sufficient vacuum to the braking system.

– A pedal feel emulator, which is a chamber built into the ACU, provides the familiar sensation of braking.


LESSON 2: CHASSIS

• A modified brake system control module (BSCM) assembly.

– The hydraulic control unit (HCU) portion of the BSCM assembly has two additional lines that provide fluid

from the ACU reservoir to the HCU pump (source line) and return fluid to the ACU reservoir (return line).

– The brake control module assembly also has an additional fluid accumulator below the unit.

– The brake control module assembly filter is not replaceable.

– The brake control module assembly is located on the right hand side of the cowl.

– New heat shields protect the brake control module assembly from high catalytic converter temperatures.

• Sensor inputs to the BSCM include:

– A pedal travel sensor (a magnetic resonant travel sensor mounted on the ACU that measures how fast and

how far the brake pedal has moved).

– A stability assist sensor cluster (although this vehicle does not have stability assist, it uses the same inputs

for the braking system).

The EHB system uses sensor inputs to regulate the amount of hydraulic pressure, supplied by the HCU, that is

applied to the conventional four wheel disc brakes (including the anti-lock braking system).

The EHB system is coordinated with the powertrain management to re-capture energy that would normally be lost

to braking.


LESSON 2: CHASSIS

Rotunda Drain Twin Pressure Bleeder

Brake bleeding procedures require the use of the new Rotunda Drain Twin Pressure Bleeder (service part number

261-00002), in addition to the Worldwide Diagnostic System (WDS).

• A pressure bleeder is capable of maintaining constant 241 kPa (35 psi) of fluid pressure throughout the

bleeding process.

• Do not use a vacuum bleeder. More information on the operation of the pressure bleeder will be given in the

classroom course.

• Replacement brake fluid is High Performance DOT 3 Motor Vehicle Brake Fluid PM-1 (service part number

ESA-M6C25-A).

WARNING: THE REGENERATIVE BRAKING SYSTEM CHECKS THE INTEGRITY OF THE

BRAKE SYSTEM AT TIMES WHEN THE VEHICLE IS PARKED. THIS IS DONE BY

DEVELOPING BRAKE PRESSURE FOR SHORT PERIODS OF TIME. IN ORDER TO

CHANGE THE BRAKE PADS, IT IS NECESSARY TO USE THE SCAN TOOL. THIS WILL

PREVENT BRAKE PRESSURE FROM BEING APPLIED. FAILURE TO FOLLOW THESE

INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.


LESSON 2: CHASSIS

Series Regenerative Braking

Regenerative Braking Components Schematic


1 Engine 4 Generator

2 Traction Motor 5 Driveshaft

3 Traction Battery

In addition to the new EHB system, the PCM can control the traction motor so it is used as a generator to recharge

the HV battery during certain braking events. Regenerative braking captures energy that would otherwise be lost

to friction. This results in increased fuel economy.

• The regenerative braking feature isolates the driver brake demand from the friction brakes in order to allow the

front wheels to turn the traction motor during braking. The turning traction motor acts as a generator causing

the vehicle to slow down. The generated electricity is sent to the high voltage battery.

• Both the traction motor and the friction brakes are used to slow the vehicle. Regenerative braking is used in

conjunction with the base brakes when possible.

• Regenerative braking is automatically controlled by the PCM along with the BSCM.


LESSON 2: CHASSIS

Steering System

Electric Power Assist Steering System


1 Electric Motor 3 Drain Wire

2 Power Steering Control Module

An electric power assist steering (EPAS) system replaces the conventional hydraulic valve steering system.

The 12 volt EPAS system consists of:

• an electric motor coupled directly to the steering gear.

• a rotational sensor mounted between the input shaft and steering gear. Electromagnetic inductance is used to

change the rotational signal into a torque signal.

• a power steering control module (PSCM). The PSCM mounts on the cowl where the brake booster used to be

located. The PSCM drain wire is for electromagnetic compatability. The PSCM drain wire’s purpose is to

prevent the steering system from emitting electromagnetic radiation which could interfere with other vehicle

systems, like the AM radio.

With the exception of the new steering gear assembly and PSCM, the rest of the steering system uses

conventional steering system components.


LESSON 2: CHASSIS

During operation, the rotational sensor senses the driver’s steering effort and sends a signal to the PSCM. The

PSCM combines the rotational sensor input with other inputs from the PCM, such as vehicle speed, and sends a

signal to the steering gear electric motor.

Power steering issues may cause the instument cluster to display the message ‘‘SERVICE PWR STEERING’’

and cause the Hazard indicator (yellow wrench) to light up.

There are two major reasons for using an EPAS system in the Escape Hybrid:

• EPAS allows power steering to be delivered under all operating conditions, since the engine is not always

running to turn a power steering pump.

• EPAS improves fuel economy due to lower energy losses since the EPAS is only used on demand whereas a

conventional system runs all the time.

The EPAS is lubricated for life. There is no reservoir, fluid or hoses.


LESSON 2: CHASSIS

NOTES


LESSON 3: POWERTRAIN

OBJECTIVES

• Describe engine with Atkinson cycle

• Identify changes to the front end accessory drive

• Describe the intake air system and fuel system changes

• Describe the cooling system

• Explain the purpose and function of the eCVT system

• Describe the motor electronics cooling system



Engine

Atkinson Cycle Camshaft Comparison


1 Atkinson Intake Lobe 2 Four Stroke Intake Lobe

The Escape Hybrid uses an Escape 2.3L I4 engine ((133 HP @ 6000 rpm, 125 lb/ft (169 Nm) of torque, 12:1

compression ratio)) that has been modified to use an Atkinson cycle for the valve timing.

• The Atkinson cycle allows the intake valve to remain open during a portion of the compression stroke.

– A modified camshaft lobe design alters the duration of the intake valve opening.

• The Atkinson cycle reduces the amount of energy used to compress the air/fuel mixture (known as pumping

loss) which increases the fuel mileage by 7-10%.

The Escape Hybrid has no starter. A dust seal covers the opening where the starter used to be mounted.

• The starter function is performed by the 330 volt generator inside the eCVT.

The Escape Hybrid uses a new cartridge style oil filter (service part number FL-2017A). 5W20 oil is used and the

change interval is every 10,000 miles.

The Escape Hybrid also has an acoustical engine cover with molded-in logo.



Front End Accessory Drive

Front End Accessory Drive


1 Tensioner 3 A/C Compressor

2 Coolant Pump 4 Crankshaft

The front end accessory drive on the Escape Hybrid powers only the coolant pump and the A/C compressor.

• There is no hydraulic power steering pump. As mentioned earlier, the Escape Hybrid uses an electric motor to

provide power assist to the steering system.

• There is no belt-driven generator. The belt-driven generator function is now carried out by the generator inside

the eCVT and the DC/DC converter.

• The front end accessory drive belt is shorter.

• The tensioner has been relocated.



Switchable Powertrain Mount

Switchable Powertrain Mount


1 Solenoid Control Valve 3 Vacuum Reservoir

2 Switchable Powertrain Mount

In addition to the conventional powertrain mounts, the Escape Hybrid uses one switchable liquid-type powertrain

mount to reduce noise, vibration, and harshness (NVH) at idle and engine start up and shut down.

The switchable powertrain mount consists of:

• the mount

• a vacuum source - vacuum is supplied by the engine intake manifold during engine idle operation

• a solenoid control valve - the control valve is located on the left side of the climate control system vacuum

reservoir

• vacuum hoses



At or near idle, the PCM commands the solenoid control ON which allows the vacuum to open a second flow path

(orifice) inside the powertrain mount. The secondary flow path (orifice) changes the damping characteristics of

the powertrain mount.



Intake Air Distribution and Filtering

Intake Air Sytem


1 Air Filter Box 3 Side Branch Resonator

2 Fender Well Resonator 4 Carbon Trap

The intake air system features:

• a new side branch resonator

• a modified fender well resonator

• a carbon trap to retain hydrocarbon emissions during engine off

The intake air system uses a conventional air filter (service number 5M6Z-9601-AA).



Fuel System

Electronic Throttle Control

The Escape Hybrid uses electronic throttle control (ETC).

• Components of the ETC system are similar to other ETC systems but the strategy is very different.



Front and Rear Inertia Switches


1 Front Inertia Switch 2 Rear Inertia Switch

The Escape Hybrid has a rear inertia switch in addition to a front inertia switch. Either switch tripping results in a

no start and a no crank condition.

• The front inertia switch cuts off both fuel and high voltage.

• The rear inertia switch cuts off only power to the high voltage contactors located inside the battery case. In

response to the loss of power at the contactors, fuel is shut off indirectly by the PCM.

• The additional rear inertia switch disconnects faster which provides an extra margin of safety.



Engine Cooling

Helper Pump

The Escape Hybrid uses an engine cooling system similar to the one used on the Escape but with one significant

change. A PCM-controlled helper pump is located in series with the hoses leading to the heater core.

• The 12 volt helper pump is needed because the gasoline engine is not always running and driving the

engine-driven cooling pump.

• If the driver requests cabin heating while the engine is off, the PCM commands the helper pump to turn on.

• The engine cooling system uses Motorcraft Premium Gold Engine Coolant ((service part number VC-7-A

(except CA and OR, where it is VC-7-B)) like the Escape. The service interval is 5 years/100,000 miles for the

first change, then 3 years/50,000 miles for subsequent changes.

• An optional block heater is available.



Transmission System

Electronically Controlled Continuously Variable Transmission


1 Traction Motor 2 Generator Motor

The new electronically controlled continuously variable transmission (eCVT) consists of:

• a 65 kW (87 HP) traction motor

• a 36 kW (48 HP) generator motor

• a planetary gear set

• a transmission control module (TCM) located on top of the eCVT case

The planetary gear set connects the engine, traction motor, and generator with the drive wheels. Based on

commands from the PCM for optimum fuel efficiency, the TCM continuously adjusts the contribution of the

engine, traction motor and generator.

• Either the electric motor or the engine can be used to provide power to the wheels.



The eCVT operates in several modes:

• The electric motor in the eCVT can be used to accelerate the vehicle from a stop.

– During acceleration, the high voltage battery voltage drops as low as 216 volts while the maximum current is

approximately 181 amps (39 kW).

– When the need for extra power is detected, the gasoline engine automatically turns on.

At slower speeds (up to 64 kph/40 mph) and while the vehicle is idling, the gasoline engine may automatically

shut off to save fuel. The gasoline engine may remain on to charge the battery or maintain the air conditioning.

• At higher speeds the gasoline engine is mainly used to power the vehicle.

• The traction motor is used as a generator to recover the vehicle energy during braking that would otherwise be

lost to friction. This process is called regenerative braking.

– During regenerative braking, the high voltage battery voltage rises as high as 397 volts while the maximum

current is approximately 78 amps (31 kW).

• The generator motor is used to start the gasoline engine quickly and automatically when required.

– The generator motor is used in combination with the electronic throttle to control the speed of the gasoline

engine. It does this by generating electricity which is used directly in the traction motor or stored in the high

voltage battery for later use.

– The on-board generator eliminates the need to plug in the Escape Hybrid.

The eCVT incorporates the functions of both the starter and the belt-driven generator. The DC/DC converter

provides the equivalent output of the belt-driven generator.

The transmission is filled for life with Mercon fluid.

• The transmission fluid is only used for lubrication and cooling (through the M/E cooling system) purposes.

• The transmission fluid for the Escape Hybrid is unique. Do not replace the transmission fluid with Mercon V,

Mercon SP or CVT transmission fluid.

• Located on the left side of the transmission case is a fill plug and a drain plug for unique service situations.



Floor-Mounted Shifter


1 Transmission Range Sensor 2 Shift Cable for Parking Pawl

The floor-mounted shifter has been modified from three (D-1-2) to two drive positions (D-L).

• Located on the side of the floor shifter assembly is a new transmission range sensor for the shift feature.

– There are no gears to change in the eCVT. The range sensor only sends a signal to the PCM.

• The shift cable controls only the parking pawl in the eCVT and provides shifter feel to the driver.



Motor Electronics Cooling System

M/E Cooling System


1 DC/DC Converter 3 M/E Cooling System Radiator

2 Coolant Hoses 4 M/E Cooling System Degas Bottle

The Escape Hybrid has a motor electronics (M/E) cooling system that is completely separate from the engine

cooling system.

The M/E cooling system cools:

• the eCVT power electronics (the TCM)

• the electric motors inside the eCVT

• the DC/DC converter

The M/E cooling system consists of:

• An additional M/E radiator filled with Motorcraft Premium Gold Engine Coolant ((service part number

VC-7-A (except CA and OR, where it is VC-7-B)). The service interval is 5 years/100,000 miles for the first

change, then 3 years/50,000 miles for subsequent changes.



• A PCM-controlled 12 volt electric coolant pump. The coolant pump is mounted near the bottom-rear of the

radiator assemblies.

• A separate degas bottle. The M/E degas bottle is part of a single assembly that includes the engine cooling

degas bottle.

• Hoses.

• A coolant temperature sensor. The coolant temperature sensor is located on the eCVT. The coolant temperature

sensor is serviceable without having Hotline and ACES II approval.

The M/E cooling system bleed hole is located on top of the eCVT.

There is no conventional transmission cooler on the Escape Hybrid because the M/E cooling system cools the

transmission.


LESSON 4: ELECTRICAL

OBJECTIVES

• Describe the module communication network

• Describe the charging system

• Describe the climate control system

• Identify safety features, equipment and procedures



Module Communication Network

High Speed Controller Area Network (CAN)

The 2005 Escape Hybrid module communication network allows module-to-module communication on two

different networks.

The high speed controller area network (CAN) contains the following modules:

• powertrain control module (PCM)

• brake system control module (BSCM)

• power steering control module (PSCM)

• transaxle control module (TCM)

• traction battery control module (TBCM)

• instrument cluster (IC)

• active torque coupling controller (ATC), if 4WD equipped



Medium Speed CAN

The medium speed CAN contains the following modules:

• instrument cluster (IC)

• smart junction box (SJB)



Charging System

High Voltage Battery and Low Voltage Battery


1 Low Voltage Battery 4 Electronically Controlled ContinuouslyVariable Transmission

2 High Voltage Battery 5 DC/DC Converter

3 High Voltage Cable



The charging system on the Escape Hybrid includes a conventional low voltage (12 volt DC) system and a new

high voltage (330 volt DC) system.

The low voltage battery is the same one that is used in the Escape. The low voltage battery:

• is charged by the DC/DC converter.

• is not the source to spin the engine during cranking.

• provides for the low voltage needs of the Escape Hybrid, such as the electric power assisted steering,

headlights, climate control and audio.

There is no belt-driven generator on the Escape Hybrid. The belt-driven generator function is performed by the

generator inside the eCVT. The output of the generator is 110 amps at 12 volts.

The high voltage (330 volt) battery, also known as the traction battery, is designed to provide electrical power to

the traction motor, generator motor and DC/DC converter.

The high voltage system includes:

• The nickel metal hydride (NiMH) batteries. The battery case contains 250 individual cells. All 250 cells are

connected to produce the 330 volts.

• The jump start battery charger and contactor box, which are built into the battery case.

• The high voltage and the low voltage wiring.

• The high voltage service disconnect switch. This switch opens to disconnect the HV battery and isolate the 330

volts inside the HV battery during service procedures. This switch also contains the HV fuse which may open

under unusual circumstances. An opened HV fuse requires a new service disconnect switch to be installed.

• The traction battery control module (TBCM), which is built into the battery case. The TBCM is capable of

detecting faults within the high voltage battery subsystem and controlling the high voltage battery function.

Thermal sensors provide information to the TBCM and the PCM. Ground fault detection is also performed by

the TBCM.

– The high voltage system does not use a chassis ground.

• The battery cooling system fans.

All of the above components contained inside the HV battery case are not serviceable except for the service

disconnect switch.

A high voltage battery heater, which is integral to the engine block heater package, is standard for Canada and

cold weather states (AK, MN, ND, SD, MT, WI, WY) and optional for other states. A small black box, located

between the water bottle and the right side head lamp, is wired to the 120 volt power line that comes from the

wall to the engine block heater. The box inverts the 120 volt AC into 18.33 volt DC. The 18.33 volts travel

through the wiring harness back to the jump start control module, and then to some resistive element heaters that

are mounted on printed circuit boards sandwiched inside the two layers of battery cells. The heaters are turned on

automatically if the cell temperature drops below 10 degrees Celsius (50 degrees Fahrenheit). The heaters are

turned off automatically if the cell temperature rises too high.



Jump Start Strategy for the High Voltage Battery

Jump Start Switch

A jump start switch is located on the driver’s side kick panel. Pushing the jump start switch starts an 8 minute

timer and a dedicated 12 volt to high voltage battery charger located inside the HV battery case. This battery

charger allows a customer to charge the high voltage battery from a 12 volt donor source.

• The jump start feature is needed because the starter function is built into the eCVT which is powered by the

high voltage system.

– Over extended periods of time at high temperatures the HV battery can lose its charge just as a low voltage

battery can.

• The 12 volt donor is initially the Escape Hybrid’s own 12 volt battery. If this fails, the jump start procedure can

be repeated using an auxillary 12 volt power supply connected to the Escape Hybrid’s 12 volt battery like a

conventional jump start procedure.



DC/DC Converter

DC/DC Converter

The DC/DC converter converts high voltage (330 volt) battery power to low voltage (12 volt) battery power.

• The DC/DC converter is located near the right side shock tower.

• High voltage cables enter the DC/DC converter and low voltage cables leave the DC/DC converter.

• The DC/DC converter is PCM controlled.

• The maximum output of the DC/DC converter is 110 amps at 12 volts.

• The DC/DC converter is cooled, along with the eCVT, by the M/E cooling system.



Climate Control System

Traction Battery Cooling System


1 Traction Battery Cooling Unit 3 Compressor

2 Traction Battery Refrigerant Lines



The air conditioning (A/C) system for the Escape Hybrid has been modified to provide cooling to the traction

battery in addition to the passenger compartment cooling function. A traction battery cooling request to the PCM

results in the engine turning on in order to drive the compressor.

• A serviceable air filter (service part number FP-51, interval 1 year or 15,000 miles) is accessible in the left rear

interior panel.

• The A/C system has two parallel refrigerant loops; one for the passenger compartment and a new one for the

traction battery cooling unit evaporator.

– Each refrigerant loop has its own shut off valve.

– The A/C system can cool each zone independently of the other.

• A single compressor is used to pump refrigerant through both loops. The A/C compressor and the condenser on

the Escape Hybrid are different than the Escape to handle the change in capacity.

• An air temperature thermistor was added to the front and rear A/C systems to control compressor cycling.

• The TBCM requests A/C, controls the battery refrigerant solenoid valve, and sends the evaporator temperature

status and solenoid status to the PCM.

– The TBCM is built into the battery case and is not serviceable.

– The TBCM communicates with the PCM over the CAN.

– The TBCM controls the airflow mode actuator on the rear A/C cooling unit. This electric actuator moves two

baffles to use either outside air or recirculated air to cool the traction battery.

• The air inlet for the traction battery cooling unit is in the left rear quarter window. The air outlet is below the

inlet and behind the bumper.



Idle Shutdown Override Settings


1 Max A/C Setting 3 Defrost Setting

2 Defrost/Floor Setting

Another change to the climate control system is a full A/C function, shown as Max A/C on the mode selection

switch.

• Max A/C, defrost and defrost/floor modes run the engine continuously, overriding the hybrid engine shut down.

These modes impact the ability of the Escape Hybrid to obtain the maximum fuel economy.

• A/C and A/C recirculation modes operate the A/C only when the engine is normally on, which provides better

fuel economy than Max A/C. The air coming out the vents gets warmer when the engine is off.

• HV battery cooling needs override the engine shutdown as well.

You may hear some unique sounds with an Escape Hybrid. You may hear a slight clunk or tap noise as the vent

door operates. In addition, you may hear a fan noise in the rear of the vehicle. This is the traction battery cooling

fan. These noises are normal and do not require service.

A vacuum aspirator has been added by the throttle to boost the available vacuum level in order to operate the

climate control vacuum acuators.



Electrical Safety

High Voltage System Safety Features


1 Rear Inertia Switch 5 Low Voltage Battery

2 High Voltage Service Disconnect Switch 6 eCVT

3 High Voltage Battery 7 DC/DC Converter

4 High Voltage Wire Harness 8 Front Inertia Switch



The 2005 Escape Hybrid high voltage related components include:

• the high voltage battery

• the high voltage service disconnect

• the high voltage wiring - orange colored for easy identification

• the front inertia switch

• the rear inertia switch

• the DC/DC converter

• the eCVT



High Voltage Connector


1 Interlock Circuit 2 High Voltage Circuit

Electrical safety on the Escape Hybrid is enhanced by many redundant disconnect features:

• Two inertia switches which are located in the front and rear.

• Key off disconnect. There is no high voltage present, outside of the battery, when the ignition is off.

• A service disconnect fuse which is located on the battery pack.

• Ground fault detection which is performed by the TBCM.

• An electrical connector interlock circuit. Whenever any high voltage cable is disconnected, the electrical

connector interlock circuit shuts off all high voltage power.



Safety Gloves and Cones

Safety is also enhanced by properly using high voltage safety equipment:

• HV rubber safety gloves

– The HV gloves are designed for working around equipment rated up to 1,000 volts. The HV rubber insulated

safety gloves are protected by durable leather gloves that serve as an outer shell. Use the HV gloves when

working around the high voltage components of the Escape Hybrid.

– Safety gloves must checked before each use and be re-certified every six months or new ones must be

purchased.

• Face shields - Wear a face shield when working around the high voltage components of the Escape Hybrid.

• Buffer zone - Place orange cones around the vehicle during all service procedures to alert the entire shop to the

presence of lethal electricity.



High Voltage Service Disconnect Switch

Always follow high voltage safety procedures:

• Use the cones to establish a buffer zone around the Escape Hybrid.

• Disconnect the high voltage service disconnect switch before performing any service procedures related to the

high voltage components. Store the switch in the battery case.

• Wear HV rubber gloves, HV leather outer gloves and a face shield.

• Follow approved diagnostic tests. Do not use a digital multimeter on any high voltage circuit unless told to do

so by the diagnostic tests in the workshop manual or the PCED manual.

• Perform the safety procedure as written into the diagnostic procedures. Before disconnecting the high voltage

components, you must wait five minutes after key off and the removal of the high voltage service disconnect

switch from the high voltage battery pack. This procedure allows for the internal capacitors to discharge in the

event there is a system failure that prevents automatic discharge.



High Voltage Warning

Hybrid vehicle identification alerts the technician to the presence of high voltage components:

• badging on the exterior of the vehicle

• warning decals on high voltage components


APPENDIX: ESSENTIAL SPECIAL SERVICE TOOLS

ESSENTIAL SPECIAL SERVICE TOOLS

Escape/Mariner Hybrid Electric Vehicle New Model Training 03-MAY-04 Appendix-1


NOTES

Escape/Mariner Hybrid Electric Vehicle New Model Training03-MAY-04Appendix-2





APPENDIX: GLOSSARY OF TERMS

GLOSSARY OF TERMS

ACU Actuation Control Unit PSCM Power Steering Control Module

ATC Active Torque Coupling PZEV Partial Zero Emission Vehicle

BSCM Brake System Control Module SJB Smart Junction Box

EHB Electro-Hydraulic Braking SULEV Super Ultra-Low Emission Vehicle

EPAS Electric Power Assist Steering TBCM Traction Battery Control Module

ETC Electronic Throttle Control TCM Transmission Control Module

IC Instrument Cluster eCVT Electronically Controlled

M/E Motor Electronics Continuously Variable

PCM Powertrain Control Module Transmission


APPENDIX: GLOSSARY OF TERMS

NOTES


30N26F0

Documents

high voltage cable

ground fault detection

coolant temperature sensor

high voltage components

high voltage battery

cooling system cools

jump start switch

high voltage system