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Ford 2001 Ranger, Manual

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2001 RANGER ELECTRIC VEHICLE

150-1

CONNECTOR FACES

3029 (DG/OG)

*

-

4048 (RD/YE)

*K (OG)

3985 (PK)

3827 (GY/WH)

566 (DG)

-

3037 (GY/WH)

3035 (LG/OG)

3031 (BK/PK)

*

-

3022 (RD/YE)

679 (GY/BK)

-

3036 (YE/WH)

3260 (OG/WH)

1

2

3

4

5

6

7

8

9

10

11

12

13

14

PIN NUMBER

CIRCUIT

3230 (LB/OG)

3229 (WH/RD)

3030 (DG/OG)

*

-

3002 (OG/LB)

3009 (OG/RD)

3033 (BK/LB)

3220 (PK)

*

-

3023 (BK/OG)

-

3226 (BK/LG)

3227 (RD)

3228 (BN)

3800 (LG/BK)

3993 (YE/RD)

29

30

31

32

33

34

35

36

37

38

39

40

41

42

C124F

PIN NUMBER

CIRCUIT

3261 (PK/YE)

3990 (LB/RD)

3008 (VT)

3992 (BN/YE)

3038 (OG)

3834(LG)

3006 (PK/LG)

3221 (BN/LB)

*

-

3032 (DB/LG)

3034(LG/RD)

4009 (LB/RD)

*3984(RD)

3401 (DB/LG)

3826 (WH)

57 (BK)

15

16

17

18

19

20

21

22

23

24

25

26

27

28

PIN NUMBER

CIRCUIT

12B637

34

35

36

37

38

39

40

4

1

4

2

28

29

30

31

32

33

22

23

24

25

26

27

16

17

18

19

20

21

10

11

12

13

14

15

1

2

3

4

5

6

7

8

9

* POSTAL

Summary of Contents for 2001 Ranger

Page 1: ...al Information 100 00 Identification Codes 100 01 Jacking Towing and Lifting 100 02 Noise Vibration and Harshness 100 04 Standard Service Procedures 100 05 Pre Delivery Form 100 06 Electric Vehicle EV...

Page 2: ...1 Noise Vibration and Harshness 100 04 1 Standard Service Procedures 100 05 1 Pre Delivery Instructions 100 06 1 Electric Vehicle EV Diagnostic Direction 100 07 1 Powertrain Diagnostic Routines Identi...

Page 3: ...hat can be easily damaged if components High voltage wiring is identified by its the procedures are not followed orange color or orange wrapping on the harness Components that have larger connectors o...

Page 4: ...llowing steps must be taken before 6 Verify that the ignition is in the OFF position any welding is done on the EV The traction battery can be stored out of the vehicle 1 Disconnect the 12 volt batter...

Page 5: ...entification Codes Manual Table of Contents SECTION 100 01 Identification Codes VEHICLE APPLICATION Ranger EV CONTENTS PAGE DESCRIPTION AND OPERATION Identification Codes 100 01 2 Warnings 100 01 2 20...

Page 6: ...t is installed in the Electric Vehicle A and an icon to inform technicians that the proper number 7 indicates a Lead Acid Battery Pack PbA service information should be used prior to and a number 1 in...

Page 7: ...100 01 3 100 01 3 Identification Codes DESCRIPTION AND OPERATION Continued Nickel Metal Hydride NiMH Battery Pack This label indicates a Nickel Metal Hydride NiMH battery pack 2001 Ranger EV 01 2001...

Page 8: ...1 Jacking Towing and Lifting Manual Table of Contents SECTION 100 02 Jacking Towing and Lifting VEHICLE APPLICATION Ranger EV CONTENTS PAGE GENERAL PROCEDURES Jacking 100 02 2 Towing 100 02 3 2001 Ra...

Page 9: ...t A arms and lift the vehicle Jacking Point Rear 1 Block the front wheels CAUTION Do not lift the vehicle from any point on the axle other than the pads as axle damage may result 2 NOTE LH pad shown R...

Page 10: ...o turn the vehicle off before servicing may result in personal injury or death CAUTION Do not disconnect the halfshafts if the motor transaxle is inoperable This may result in damage to the motor tran...

Page 11: ...the wheels If a front wheel locking device is not available position wheel dollies underneath the front wheels 2 Secure the tires to the wheel lift 3 On normal roads limit speed to 88km hr 55mph On r...

Page 12: ...S Continued 2 Position the hoist pad extensions 1 Locate the rear hoist pad extensions on the front of the rear leaf spring hanger eyes 2 Locate the front hoist pad extensions on the front cab mount e...

Page 13: ...bration and Harshness VEHICLE APPLICATION Ranger EV CONTENTS PAGE DESCRIPTION AND OPERATION Condenser Fan 100 04 2 Condenser Fan Postal Ranger EV 100 04 2 Power Steering Pump 100 04 2 Traction Battery...

Page 14: ...er Fan Postal Ranger EV cooling fan WARNING Disconnect the cooling fan prior to performing any underhood repairs Transaxle because the fan could cycle The transaxle is located in the rear of the vehic...

Page 15: ...er EV CONTENTS PAGE GENERAL PROCEDURES Buffer Zone 100 05 2 Rubber Insulating Gloves Testing 100 05 2 Traction Battery Auxiliary Load High Voltage Connector 100 05 6 Traction Battery Charging 100 05 3...

Page 16: ...of the glove begins to balloon from the resulting air pressure If the glove leaks any air it must not be used 2 The gloves should not be used if they exhibit any signs of wear and tear 3 The leather...

Page 17: ...y unauthorized personnel into the buffer zone during repairs involving high voltage Only personnel trained for service on the high voltage systems of the EV are to be permitted in the buffer zone Trac...

Page 18: ...te charging of the vehicle is desired press the Charge Now button If the economy mode is desired no further steps are necessary The EVI unit is equipped with an autostart feature If the unit is in the...

Page 19: ...ter to the vehicle and monitor the battery control module BCM PID OPSTATE with the ignition key in the OFF position and the vehicle connected to the PCS To determine what the PID OPSTATE indicates ref...

Page 20: ...lt in severe personal injury of death Observe the EV specific precautions Refer to Section 100 00 1 Set up the buffer zone 2 Test and wear the rubber insulating gloves 3 Wear the face shield 2 If conn...

Page 21: ...olts DC The buffer zone must be set up and insulated rubber gloves and a face shield must be worn Failure to follow these precautions may result in severe personal injury of death Observe the EV speci...

Page 22: ...in 2 Lift up on the connector latch 3 Pull the connector out 6 Install Traction Battery High Voltage Lockout and Diagnostic Tool in the two pin high voltage connector 7 Inspect the seal on the two pin...

Page 23: ...Refer to Section 100 02 3 WARNING The nominal traction battery voltage is 300 volts DC The buffer zone must be set up and insulated rubber gloves and a face shield must be worn Failure to follow these...

Page 24: ...high voltage connector 1 Remove the retaining pin 2 Lift up on the connector latch 3 Pull the connector out 6 Remove the traction inverter module TIM cover plate Remove the 12 screws 7 Connect the Cap...

Page 25: ...h the leads from the Capacitor Discharge Tool The voltmeter will display any voltage present Continue to probe the terminals until the voltmeter reads 0 volts 9 Probe the positive terminal and the cas...

Page 26: ...1 Pre Delivery Instructions Manual Table of Contents SECTION 100 06 Pre Delivery Instructions VEHICLE APPLICATION Ranger EV CONTENTS PAGE DESCRIPTION AND OPERATION Pre Delivery Form 100 06 2 2001 Ran...

Page 27: ...e Delivery Form The following pages are pre delivery sheets that are to be used to check the Electric Ranger prior to customer delivery Make additional copies of the sheets as needed and be sure to ke...

Page 28: ......

Page 29: ...Lead Acid 100 07 10 Battery Control Module BCM Diagnostic Trouble Code DTC Index NiMH 100 07 11 Interface Adapter Assembly IAA Module Diagnostic Trouble Code DTC Index 100 07 7 Traction Inverter Modul...

Page 30: ...t in severe personal What s Different About This Manual injury or death The format of this supplement has been changed to assist in the diagnosis of vehicle concerns Note the Carry out high voltage di...

Page 31: ...1850 Press the START button on the PCS and monitor Communication Bus Fault may occur if the the BCM OP PID for approximately 5 minutes ignition key is quickly cycled ON OFF ON This If the BCM OP PID i...

Page 32: ...TED TO VEHICLE CHARGING Determine if concern is related to vehicle charging Yes GO to DP5 Was vehicle brought in for repair due to a vehicle charging concern No GO to DP6 DP5 RETRIEVE DIAGNOSTIC TROUB...

Page 33: ...Some TIM DTCs will not be set unless the vehicle is driven Wait one minute and retrieve continuous DTCs from the TIM Note the DTCs Do any DTCs occur DP8 RETRIEVE DTCs FROM BATTERY CONTROL MODULE BCM...

Page 34: ...erforming the Climate control vacuum reservoir following step for high voltage systems Vacuum pump housing rubber isolator mounts Failure to follow this warning may result in Section 206 09 Anti Lock...

Page 35: ...alignment Tripped inertia switch Digital transmission range DTR sensor High voltage connector disconnected adjustment Power control station PCS plugged into Transmission range selector lever charger i...

Page 36: ...412 02 3 C1777 Continuous Vacuum Pressure Circuit Failure REFER to Page 206 07 3 On Demand C1778 Continuous Power Steering Failure REFER to Page 211 02 3 C1779 Continuous Blower Switch Failure REFER t...

Page 37: ...y Pack Voltage Out of Range REFER to Main Precharge Contactor Relay Control in Page 414 03A 10 lead acid vehicles or Page 414 03B 11 NiMH vehicles C1750 Continuous Acceleration Position Sensor Out of...

Page 38: ...Continuous Current Sense Circuit Failure REFER to Contactor Box On Demand Current Sensors in Page 414 03A 22 C1836 Continuous Battery Temperature Out of Range REFER to Traction Battery On Demand Char...

Page 39: ...n Bus Fault No action required B1342 Continuous ECU Defective CARRY OUT BCM On Demand On Demand Self Test three times If DTC B1342 keeps occurring REPLACE the BCM REFER to Section 414 03B B1671 Contin...

Page 40: ...ation PID Indexes Interface Adapter Assembly IAA Module Parameter Identification PID Index Interface Adapter Assembly IAA Module Parameter Identification PID Index PID Description Expected Values A CP...

Page 41: ...r Value Refer to Interface Adapter Assembly IAA Module Operating State Index for a detailed description of integer value IGN R S Ignition Switch Run Start Position YES NO INER SW Inertia Switch Status...

Page 42: ...n Inverter Temperature C F TRNTEMP Trans Motor Temperature C F TPCCO Traction Pre Charge Contactor Output Status ENABLE DISABLE TPCCOF Traction Pre Charge Contactor Output Fault YES NO TPMCO Traction...

Page 43: ...CHG LCF Charger Line Capacity Fault YES NO CHG LUF Charger Latch Up Fault YES NO CHG LVL Charging Level Output Status Percent CHG MFF Charger Mode Feedback Fault YES NO CHG OAF Charger Over Amp Hours...

Page 44: ...Minimum Temperature C F NMBICO Negative Main Bus Inhibit Contactor Output ENABLE DISABLE Status NMBICOF Negative Main Bus Inhibit Contactor Output YES NO Fault PREV OS Previous ECU Operating State Int...

Page 45: ...arging Capacity Percent CHG CCF Charger Cord Circuit Fault YES NO CHG CO Charger Contactor Output Status ENABLE DISABLE CHG COF Charger Contactor Output Fault YES NO CHG CYC Charge Cycles Integer Valu...

Page 46: ...tion Integer Value LEAKHCF High Level Leakage During Charge Fault YES NO LEAKLCF Low Level Leakage During Charge Fault YES NO LEAKRES Parallel Combination of Bus Leakage OHM Resistance LKRESB Leakage...

Page 47: ...Operating Strategy faults LOS 3 12 LOS 3 EPO State Battery Control Module BCM Operating 13 Pre LOS 4 State Index Lead Acid 14 LOS 4 Under Voltage Battery Control Module BCM Operating State 15 Key Off...

Page 48: ...Operating 85 No Charge High Temperature Delta State Index NiMH 86 No Charge Temperature Sense Fault Battery Control Module BCM Operating State 87 No Charge Battery Full Index NIMH 88 No Charge Underc...

Page 49: ...e 83 No Charge Battery Over 115 LOS Charge Voltage Sense Fault Temperature 116 LOS Charge Recirculation Fan 84 No Charge Battery Under Inoperative Temperature 117 LOS Charge Flow Trough Fan 85 No Char...

Page 50: ...HI HIGH ECON Indicator Lamp ON OFF MODE Control HTR PWR Climate Control ON OFF Command FUEL LOW Indicator Lamp ON OFF Control II HTR A Climate Control ON OFF Command CHARGE Indicator Lamp ON OFF Contr...

Page 51: ...Commands DISABLE FAN SPEED Fan Speed Control PWM BAT HTR2 BCM Packeted ENABLE RESET Parameter Reset LDATA Commands DISABLE Command BATTERY Battery Module Select 1 39 Battery Control Module BCM Active...

Page 52: ...ssful Commands CLOSE The following DTC relates to the battery control CHG PWR BCM Packeted ENABLE Commands DISABLE module BCM CHG PILOT BCM Packeted ENABLE DTC B2477 Module Configuration Failure Comma...

Page 53: ...es REPLACE the IAA module REFER to Section 412 04 Does the OPSTATE PID indicate 32 Power On Self Test Failed No GO to A2 A2 PERFORM ON DEMAND SELF TEST Perform the On Demand Self Test for the IAA modu...

Page 54: ...o the module in question are secure and the New B2477 keeps occurring Generation STAR NGS Tester is securely connected to data link REPLACE the module connector DLC C209 REFER to Section 303 14 Clear...

Page 55: ...rtrain Diagnostic Routines Identification VEHICLE APPLICATION Ranger EV CONTENTS PAGE DIAGNOSIS AND TESTING Powertrain Diagnostic Routines Identification 100 09 2 Diagnostic Preface 100 09 2 Diagnosti...

Page 56: ...accomplishment and Section 100 07 accessibility These routines can be used as check lists for reference in the event of unusual or Test drive the vehicle Check for driveability infrequent causes of a...

Page 57: ...ODULE BCM OPERATING STATE With key ON monitor BCM PID BCM OP Yes If BCM OP PID indicates 48 GO to 1 3 If BCM OP PID indicates 49 CHARGE the traction battery REFER to Section 100 05 If BCM OP PID indic...

Page 58: ...n battery heaters CONNECT it to the power control station PCS to warm the traction battery to a temperature greater than 15 C 5 F Do any of the TMPSEN PIDs indicate less than 20 C 4 F No DISCONNECT an...

Page 59: ...START SIGNAL TO TRACTION INVERTER MODULE TIM With key ON monitor TIM PID IGN S Yes GO to 1 13 Turn the ignition key to the START position No GO to 1 11 Does the IGN S PID indicate YES when the igniti...

Page 60: ...and BOB pin 24 Is the resistance less than 5 ohms 1 17 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...

Page 61: ...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 Ba...

Page 62: ...an 30 C 22 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 51 REPLACE the BCM REFER to Section 414 03B 2 6 CHECK...

Page 63: ...ase decrease below 55 C 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 F No GO to 2 10 decrease 2...

Page 64: ...4 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...

Page 65: ...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...

Page 66: ...TEP 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 indicat...

Page 67: ...he 12 volt auxiliary battery negative cable and RECHECK the BCM OP PID If the BCM OP PID still indicates 67 REPLACE the BCM REFER to Section 414 03A 4 3 CHECK TEMPERATURE DIFFERENCE BETWEEN BATTERY TE...

Page 68: ...Does the TMPSEN PID that indicated greater than 65 C 149 F still indicate 65 C 149 F 4 5 CHECK TRACTION BATTERY TEMPERATURE SENSORS FOR UNDERTEMPERATURE CONDITION With key ON monitor BCM PIDs TMPSEN1...

Page 69: ...ge 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 j...

Page 70: ...20 C 428 F 2 006 ohms 230 C 446 F 2 088 ohms 240 C 464 F 2 196 ohms 250 C 482 F 2 293 ohms 260 C 500 F 2 392 ohms 270 C 518 F 2 490 ohms 280 C 536 F 2 584 ohms 290 C 554 F 2 688 ohms 300 C 572 F Is th...

Page 71: ...ONNECT the vehicle to a power control station PCS to allow the traction battery fans to operate GO to 5 3 Do any of the TMPSEN PIDs indicate greater than 55 C 131 F No DISCONNECT and RECONNECT the 12...

Page 72: ...TMPSEN PID that indicated greater than 55 C 131 F still indicate the same value 5 5 CHECK TRACTION BATTERY TEMPERATURE SENSORS FOR UNDERTEMPERATURE CONDITION With key ON monitor BCM PIDs TMPSEN1 TMPS...

Page 73: ...te the same value 5 8 CHECK STATUS OF TRACTION BATTERY MODULES BY CARRYING OUT THE BATTERY MODULE DIAGNOSTIC TEST With key ON carry out the Battery Module Diagnostic Test Refer to the Yes REPLACE the...

Page 74: ...o Section 303 14 compare the temperature to the TRNTEMP PID from test step 5 10 Is the TIMTEMP PID approximately equal to the motor No GO to 5 12 temperature 5 12 VERIFY THE MEASURED RESISTANCE TEMPER...

Page 75: ...mponents 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...

Page 76: ...charging NOTE Wait approximately five minutes to allow the BCM OP PID to be set With key OFF and vehicle on charge monitor BCM PID BCM OP Check for the following numbers 48 shutdown low battery module...

Page 77: ...ve cable and RECHECK the BCM OP PID If the BCM OP PID still indicates 83 REPLACE the BCM REFER to Section 414 03A 8 5 CHECK TEMPERATURE DIFFERENCE BETWEEN BATTERY TEMPERATURE SENSORS With key ON monit...

Page 78: ...the TMPSEN PID that indicated greater than 60 C 140 F still indicate 60 C 140 F 8 7 CHECK TRACTION BATTERY TEMPERATURE SENSORS FOR UNDERTEMPERATURE CONDITION With key ON monitor BCM PIDs TMPSEN1 TMPSE...

Page 79: ...t the following steps Failure to follow this warning may result in severe personal injury or death Connect Traction Battery Low Voltage Service Cord to traction battery support tray in line C1939F and...

Page 80: ...ls on the charger inlet connector With key OFF measure the resistance between pin 5 R wire on charger No GO to 8 16 inlet C5000 and ground Is the resistance greater than 2 5 megaohms 8 15 CHECK CIRCUI...

Page 81: ...to the traction battery high voltage two pin C3994M Connect BOB to traction battery support tray in line C1939F using No REPAIR the wire s in Traction Battery Low Voltage Service Cord do not connect...

Page 82: ...lowing 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...

Page 83: ...Low Voltage Service Cord do not connect Traction Battery Low Voltage Service Cord to in line C1939M With key OFF disconnect BCM C1987 Measure the resistance of the Y wire between pin 12 on BCM C1987 a...

Page 84: ...2 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 9 6 Do any of the TMPSEN PIDs...

Page 85: ...EN PID that indicated greater than 45 C 113 F still indicate the same value 9 7 CHECK TRACTION BATTERY TEMPERATURE SENSORS FOR UNDERTEMPERATURE CONDITION With key ON monitor BCM PIDs TMPSEN1 TMPSEN2 a...

Page 86: ...4M 414 03B Connect Traction Battery High Voltage Service Cord to traction battery No REPLACE the battery support tray in line C1935F and in line C1935M temperature sensor in question WARNING The tract...

Page 87: ...the resistance less than 5 ohms No REPAIR the P LG wire 9 14 CHECK CHARGER PILOT SIGNAL AT TRACTION BATTERY CHARGER With key OFF disconnect traction battery charger C1993 Yes GO to 9 22 Connect the ve...

Page 88: ...he resistance of the R wire between pin 33 on IOM C1810 and BOB pin 20 With key OFF measure the resistance of the LB R wire between pin 34 on IOM C1810 and BOB pin 14 Are the resistances less than 5 o...

Page 89: ...Yes GO to 9 26 connect Traction Battery High Voltage Lockout and Diagnostic Tool to the traction battery high voltage two pin C3994M Connect BOB to traction battery support tray in line C1939F using...

Page 90: ...lated 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 supp...

Page 91: ...ollow 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 Bat...

Page 92: ...gh Voltage Service Cord to traction battery No REPLACE the battery support tray in line C1935F and in line C1935M temperature sensor in question WARNING The traction battery contains high voltage comp...

Page 93: ...vehicle in a between the temperature sensor that is below 15 C 5 F and the warm environment to warm other temperature sensors the vehicle above 15 C 5 F for the temperature sensor in question 11 4 CH...

Page 94: ...TEP ACTION TO TAKE 12 1 CARRY OUT RESET NOTE The coolant pump and DC DC converter sometimes operate after Yes System OK disconnecting the power control station PCS from the charger inlet connector Thi...

Page 95: ...wer Brake Actuation 206 07 1 Anti Lock Control 206 09 1 Power Steering 211 02 1 Steering Column Switches 211 05 1 SECTION 204 02 Rear Suspension VEHICLE APPLICATION Ranger EV CONTENTS PAGE SPECIFICATI...

Page 96: ...11 Rear Spring Mounting 116 85 Brake Line Bracket to 12 107 Bolts Axle Bolt Spring Clamp Plate 103 43 Caliper Adapter Bolts 55 40 5 Bolts Caliper Bolts 25 18 5 Upper Shock Absorber 55 40 5 Hub Nut 25...

Page 97: ...es are machined to accept the brake backing plates and the hubs The hubs are supported by pressed on bearings and connect to the splined halfshaft ends REMOVAL AND INSTALLATION Hub Special Tool s Spri...

Page 98: ...the bracket 4 NOTE LH shown RH similar Disconnect the LH and RH parking brake cables 5 NOTE LH shown RH similar NOTE The caliper adapter is removed with the brake pads installed Remove the LH and RH b...

Page 99: ...similar Remove the two LH and RH harness clamp bolts 8 NOTE LH shown RH similar Disconnect the brake lines from the axle 1 Unclip the ABS wire from the axle 2 Remove the brake line bracket bolt 9 Uncl...

Page 100: ...ontinued 11 Install the special tool to flatten the LH rear spring 12 Position the front spring clamp 13 Position the rear spring clamp 14 Tighten the spring clamps alternately until the spring is par...

Page 101: ...s been lowered and the rear suspension is in the curb position Position the spring and install the rear through bolt Hand tighten the bolt 2 NOTE Do not fully tighten the bolt until the vehicle has be...

Page 102: ...ntinued 4 Install the special tools to flatten both the rear springs 5 Position the front spring clamps 6 Position the rear spring clamps 7 Tighten the spring clamps alternately until the spring is pa...

Page 103: ...8 Apply a soap and water solution to the inside of the spring clamp plate 9 Position the rear leaf spring shim in the spring clamp plate 10 Position the insulator on top of the rear leaf spring shim 1...

Page 104: ...own and loosely install the bolts 1 15 mm socket 2 Spring clamp plate 3 Rear leaf spring shim 4 Lower insulator 5 Spacer 6 Upper insulator 7 Spring 8 Axle 14 With the 15 mm socket still in place pull...

Page 105: ...e bolt until the edges of the spring clamp plate and the hub assembly are parallel 17 Tighten the bolts 18 Remove the special tools 19 Using the special tool install the rear leaf spring shim If the s...

Page 106: ...ll the rear leaf spring shim bolt 21 NOTE LH shown RH similar Install the LH and RH lower shock mount bolts 22 NOTE LH shown RH similar Install the brake line bracket bolt and clip the ABS wire onto t...

Page 107: ...wn RH similar Position the LH and RH ABS wheel speed sensors and install the bolts 25 NOTE LH shown RH similar Position the LH and RH backing plates and install the bolts 26 Lower the vehicle 27 Tight...

Page 108: ...aise and support the vehicle Refer to Section 100 02 2 CAUTION Do not position the jack stand under the tube portion of the rear axle or vehicle damage may result Support the axle Position the jack st...

Page 109: ...204 02 15 204 02 15 Rear Suspension REMOVAL AND INSTALLATION Continued 5 Remove the shock absorber Remove the nut Installation 1 To install reverse the removal procedure 2001 Ranger EV 01 2001...

Page 110: ...Removal NOTE Both Spring Flattening Tools 204 F002 must be used to flatten the rear springs NOTE The LH spring procedure is shown the RH procedure is similar NOTE The rear lifting points are changed f...

Page 111: ...Continued 3 Install the special tools to flatten both the rear springs 4 Position the front spring clamp 5 Position the rear spring clamp 6 Tighten the spring clamps alternately until the spring is pa...

Page 112: ...INSTALLATION Continued 7 Remove the LH spring clamping plate 8 Remove the front spring mount through bolt 9 Remove the rear spring mount through bolt Installation 1 Position the spring and install the...

Page 113: ...ALLATION Continued 2 Install the front spring mount through bolt 3 Position the upper spring insulator between the spring and the axle 4 Install the special tools to flatten both the rear springs 5 Po...

Page 114: ...the rear spring clamp 7 Tighten the spring clamps alternately until the spring is parallel to the bar of the special tool 8 Apply a soap and water solution to the inside of the spring clamp plate 9 Po...

Page 115: ...top of the insulator 12 Place a 15 mm deep socket through the hole in the spring clamp plate assembly to align all of the components 13 Install the spring clamp plate assembly as shown and loosely ins...

Page 116: ...ring clamp plate is contacting the hub assembly If the two surfaces do not contact each other replace the steel spacer with a thinner shim four available 16 Using the special tool align the spring cla...

Page 117: ...e special tool install the rear leaf spring shim If the shim does not have enough travel to achieve the correct installation depth remove the steel shim and install a thicker shim four available 20 In...

Page 118: ...tion Kit or equivalent OTC 7686 Slide Hammer Hub Puller 100 D006 D79P 100 A D93P 1175 B Continued Removal 1 Remove the halfshaft Refer to Section 205 05 2 Position the caliper 1 Remove the bolts 2 Pos...

Page 119: ...ued 4 Remove the hub 1 Install Hub Puller Safety Chain and Slide Hammer 2 Remove the hub 5 Remove snap ring 6 Remove the wheel bearing using the Wheel Bearing Removal and Installation Kit or equivalen...

Page 120: ...t or equivalent 3 Install the snap ring 4 Install the halfshaft Refer to Section 205 05 5 Install the hub 1 Position the hub 2 Install the hub washer and nut Tighten the nut to the specified torque to...

Page 121: ...204 02 27 204 02 27 Rear Suspension REMOVAL AND INSTALLATION Continued 7 Install the caliper 1 Position the caliper 2 Install the bolts 8 Install the wheel 9 Lower the vehicle 2001 Ranger EV 01 2001...

Page 122: ...04 2 DESCRIPTION AND OPERATION Safety Precautions 204 04 2 Wheels and Tires 204 04 2 Tire Temporary Spare 204 04 3 DIAGNOSIS AND TESTING Wheels and Tires 204 04 3 Inspection and Verification 204 04 3...

Page 123: ...e of each component before CAUTION Reduce the air pressure as any assembly operations commence Failure to much as possible by pushing the valve core adhere to these instructions can result in an plung...

Page 124: ...front Inspection and Verification suspension alignment Correct tire pressure and driving techniques have an WARNING A vehicle equipped with a important influence on tire life Heavy cornering Traction...

Page 125: ...read grooves Install a new tire recommended on the tire chart attached to the when the indicator bands become visible vehicle Larger or smaller tires can damage the vehicle affect durability and requi...

Page 126: ...of balance assembly Excessive lateral or radial REFER to Component Tests runout of wheel or tire in this section Incorrect tire rotation ADVISE customer of intervals condition Wobble or shimmy Damage...

Page 127: ...hen a wheel is installed always remove any corrosion dirt or foreign material present on the mounting surfaces of the wheel or the surface of the brake disc and hub 1102 that contacts the wheel Instal...

Page 128: ...ness shudder and vibration Tighten the lug nuts to specification 6 Advise the customer that the wheels need to be retightened at 800 km 500 miles after any wheel 1007 change or any other time the lug...

Page 129: ...ear Drive Halfshafts Manual Table of Contents SECTION 205 05 Rear Drive Halfshafts VEHICLE APPLICATION Ranger EV CONTENTS PAGE SPECIFICATIONS 205 05 2 REMOVAL AND INSTALLATION Halfshafts 205 05 2 2001...

Page 130: ...ND INSTALLATION Halfshafts Special Tool s Wheel Bearing Removal and Installation Kit or equivalent OTC 7686 Removal 1 Remove the motor transaxle Refer to Section 303 01 2 Remove the halfshaft hub nut...

Page 131: ...ll the halfshaft Use the installation tool from Wheel Bearing Removal Removal and Installation Kit or equivalent 2 Install the halfshaft end washer and nut Tighten the nut to draw the halfshaft comple...

Page 132: ...TION 206 04 Rear Disc Brake VEHICLE APPLICATION Ranger EV CONTENTS PAGE SPECIFICATIONS 206 04 2 DESCRIPTION AND OPERATION Rear Disc Brakes 206 04 2 REMOVAL AND INSTALLATION Rear Disc Brakes Caliper 20...

Page 133: ...Rotor Runout Silicone Brake Caliper ESE M1C171 A Grease D7AZ 19A331 A DESCRIPTION AND OPERATION Item Description Rear Disc Brakes 1 Rear Disc Brake Caliper 2 Rear Disc Brake Rotor The rear disc brake...

Page 134: ...ts if taken internally drink water and induce vomiting Get medical attention immediately CAUTION Brake fluid is harmful to painted and plastic surfaces If brake fluid is spilled onto a painted or plas...

Page 135: ...Remove and clean the caliper slide pins After cleaning lubricate with Silicone Brake Caliper Grease D7AZ 19A331 A meeting Ford specification ESE M1C171 A Installation 1 To install reverse the removal...

Page 136: ...g water for 15 minutes Get medical attention if irritation persists if taken internally drink water and induce vomiting Get medical attention immediately CAUTION Brake fluid is harmful to painted and...

Page 137: ...caliper and support it so there is no weight on the brake hose 4 Remove the rotor 1 Remove the retaining clips 2 Remove the rotor 5 Inspect the rotor Refer to the Specification chart in this section...

Page 138: ...206 04 7 206 04 7 Rear Disc Brake REMOVAL AND INSTALLATION Continued 2001 Ranger EV 01 2001...

Page 139: ...n VEHICLE APPLICATION Ranger EV CONTENTS PAGE SPECIFICATIONS 206 05 2 REMOVAL AND INSTALLATION Parking Brake Assembly 206 05 2 Parking Brake Cables Front 206 05 7 Parking Brake Cables Intermediate 206...

Page 140: ...plate bolts Description Nm Lb Ft Lb In Control 28 21 Brake cable 12 108 bracket bracket bolts bolts Parking 11 8 Backing 15 11 brake cable plate bolts bracket bolts General Specifications Postal Range...

Page 141: ...he brake shoes 1 Remove the lower spring and adjuster 2 Remove the shoe retaining clips 3 Remove the brake shoes 4 Release tension on the parking brake cable 1 Compress the retainer 2 Remove the parki...

Page 142: ...ALLATION Continued 6 Remove the parking brake linkage 7 Remove the backing plate 1 Drill out the two rivet heads 2 Remove the three bolts 3 Remove the backing plate Installation 1 Install new brake sh...

Page 143: ...inued 2 Install the backing plate 1 Position the backing plate 2 Install two new rivets 3 Install the three bolts 3 Assemble the parking brake linkage 4 NOTE Position the linkage that connects to the...

Page 144: ...shoes 7 NOTE The inside upper brake shoe spring must be installed prior to positioning the brake shoes Position the brake shoes and install the adjuster and spring 1 Install the retaining clips 2 Pos...

Page 145: ...ew as necessary 10 Position the parking brake cable in the bracket 11 Install the hub Refer to Section 204 02 Parking Brake Cables Front Removal 1 The parking brake control cables on the Electric Rang...

Page 146: ...Brake and Actuation REMOVAL AND INSTALLATION Continued 2 Remove the front cable from the bracket 3 Remove the front cable from the rear cable 4 Remove the front cable hold down bolt 5 Lower the vehic...

Page 147: ...the grommet from the bulkhead and remove the parking brake control assembly 8 Remove the front cable from the control assembly 9 To install reverse the removal procedure Parking Brake Cables Intermedi...

Page 148: ...ction battery Refer to Section 414 03A or Section 414 03B 2 Release tension on the parking brake cable 1 Compress the retainer 2 Remove the front parking brake cable from the bracket 3 NOTE RH shown L...

Page 149: ...OVAL AND INSTALLATION Continued 5 Disconnect the rear brake cable from the intermediate brake cable 6 Remove the rear parking brake cable Disconnect the parking brake cable Installation 1 To install r...

Page 150: ...SPECIFICATIONS 206 07 2 DESCRIPTION AND OPERATION Power Disc Brake Actuation 206 07 2 DIAGNOSIS AND TESTING Vacuum System 206 07 3 Electrical Schematic 206 07 3 Inspection and Verification 206 07 3 Pi...

Page 151: ...key is in the RUN or START position The IAA module reads the vacuum signal sent by the vacuum pressure sensor and opens and closes a relay to operate the vacuum pump The vacuum pump cycles in order to...

Page 152: ...en pressed and the vacuum pump has run continuously for more than five minutes DTC C1777 is also set if the vacuum pressure is greater than 93 5 kPa 13 6 psia and the vacuum pump has run continuously...

Page 153: ...R ASSEMBLY IAA MODULE With key OFF disconnect vacuum pressure sensor C1997 Yes GO to A4 Connect 104 Pin Breakout Box BOB to the IAA module and IAA module No REPLACE the IAA module C1945 REFER to Secti...

Page 154: ...resistance between pin 2 on the vacuum pump relay connector and ground Is the resistance less than 5 ohms A10 CHECK CIRCUIT 3021 GY BK FOR OPEN Connect 104 Pin Breakout Box BOB to IAA module C1945 le...

Page 155: ...3034 LG R FOR SHORT S TO POWER With key OFF disconnect the IAA module from the BOB leave BOB Yes REPAIR the wire s in connected to IAA module C1945 question With key ON measure the voltage between BOB...

Page 156: ...and vacuum line joint connection C4 CHECK VACUUM LINE BETWEEN VACUUM LINE JOINT CONNECTION AND VACUUM TEE ASSEMBLY With key ON disconnect the vacuum line leading to the vacuum line Yes RECONNECT the v...

Page 157: ...NTS FOR THE VACUUM PUMP BRACKET Check the torque specifications for the vacuum pump bracket bolts Refer Yes GO to D4 to the Torque Specification Chart Are the torque specifications correct No TIGHTEN...

Page 158: ...Disconnect the vacuum pressure sensor vacuum lines 5 Remove the vacuum pressure sensor 1 Remove the bolt 2 Remove the pressure sensor 6 NOTE If the vacuum tee is being replaced this step is not neces...

Page 159: ...For additional informstion refer to Section 100 02 3 Remove the vacuum pump 1 Disconnect the vacuum line 2 Disconnect the electrical connector 3 Remove the pump bracket bolts 4 Remove the pump Instal...

Page 160: ...06 07 11 206 07 11 Power Brake Actuation REMOVAL AND INSTALLATION Continued 2 Connect the traction battery For additional information refer to Section 414 03A or Section 414 03B 2001 Ranger EV 01 2001...

Page 161: ...GNOSIS AND TESTING Anti Lock Control 206 09 3 Active Command Index 206 09 5 Diagnostic Trouble Code DTC Definition 206 09 3 Electrical Schematic 206 09 4 Inspection and Verification 206 09 4 Parameter...

Page 162: ...anti lock brake sensors A sensor mounted at the HCU and provides the electronic signals to the each of the four wheels provides wheel speed HCU to control solenoid operation Wheel speed information to...

Page 163: ...ng ABS events DTC can be set from a DC DC circuit that is causing pedal pulsations failing intermittently DTCs C1145 C1155 C1165 and C1175 Speed The following DTCs relate to the traction inverter Sens...

Page 164: ...d releasing it back to zero volts If the TIM does not detect either pulse the TIM generates DTC U2015 and disables regenerative braking If DTC U2015 occurs the malfunction indicator lamp MIL red brake...

Page 165: ...t Anti lock brake control Mode module DTC C1155 LF Speed Sensor LF anti lock brake sensor GO to Pinpoint Test B Input Circuit Failure Circuit s Continuous On Demand Test Anti lock brake control Mode m...

Page 166: ...Demand Test Mode DTC B1676 Battery Voltage Fuse GO to Pinpoint Test E Out of Range Circuit s Continuous On Demand Test Voltage supply out of range Mode DC DC Inverter DTC U2015 Signal Link ABS fault...

Page 167: ...4 securely seated No CONNECT the pump motor C1944 securely and RETEST A5 CHECK PUMP MOTOR CONNECTOR FOR CORROSION OR DAMAGE With key OFF disconnect pump motor C1944 and check the pump Yes GO to A6 mot...

Page 168: ...e anti lock brake RF T BK wire LF control module C154 and the LF anti lock brake sensor C151 PK BK wire RR or LG BK wire LR RR Anti Lock Brake Sensor With key OFF disconnect RR anti lock brake sensor...

Page 169: ...rieve ABS DTCs INSPECT all connections Does the same DTC occur for corrosion pin pushout and terminal contact REPAIR as necessary PINPOINT TEST C DTC C1184 ABS SYSTEM IS NOT OPERATIONAL TEST STEP ACTI...

Page 170: ...TEST STEP ACTION TO TAKE E1 CHECK FUSE AND POWER TO ANTI LOCK BRAKE CONTROL MODULE CAUTION If the malfunction indicator lamp MIL is illuminated retrieve diagnostic trouble codes DTCs from the Interfac...

Page 171: ...K No REPLACE the fuse F4 CHECK CIRCUITS 491 O LB ABS ACTIVE LINE FOR OPEN S Connect 104 Pin Breakout Box BOB to TIM C4998 C4999 using the Yes GO to F5 BCM TIM BOB Adapter and Overlay leave the TIM dis...

Page 172: ...F11 Does the ABS WI PID indicate ENABLE No GO to F13 F11 CHECK CIRCUITS 224 T W 603 DG ABS FAULT LINE FOR SHORT TO GROUND Connect breakout box BOB to TIM C4998 and C4999 using the Yes GO to F12 BCM TI...

Page 173: ...essary measure the resistance between pin 8 BK wire pin 24 BK wire on the anti lock brake control module C154 and ground R 5 ohms With key ON measure the voltage between pin 25 R wire on the anti lock...

Page 174: ...e HCU bracket bolts 2 Position the ABS assembly aside to gain access to the anti lock brake control module 5 NOTE The ABS assembly is shown removed from the vehicle for clarity Remove the anti lock br...

Page 175: ...i Lock Brake Sensor Front Removal 1 Refer to Section 206 09 of the 2001 Ranger Workshop Manual Anti Lock Brake Sensor Rear Removal and Installation 1 Raise and support the vehicle Refer to Section 100...

Page 176: ...rs and polyglycols Avoid contact with eyes Wash hands thoroughly after handling If brake fluid contacts eyes flush eyes with running water for 15 minutes Get medical attention if irritation persists I...

Page 177: ...unit HCU electrical connector 1 Pull up on the connector latch 2 Disconnect the electrical connector 3 Disconnect the lower HCU electrical connector 4 Disconnect the brake line fittings 5 Remove the H...

Page 178: ...nued 6 Remove the anti lock brake control module 1 Remove the screws 2 Remove the module Installation 1 To install reverse the removal procedure After installation bleed the brake system Refer to Sect...

Page 179: ...L AND INSTALLATION Power Steering Assembly 211 02 9 Power Steering Gear 211 02 10 Power Steering Gear Postal Ranger EV 211 02 13 Power Steering Pump Hoses Pressure Hose 211 02 14 Power Steering Pump H...

Page 180: ...is released the pump will return to normal At temperatures lower than 6 7 C 20 F the pump may take up to 30 seconds before it is able to provide full assist Power Steering Postal Ranger EV Item Descr...

Page 181: ...m the traction inverter module TIM Based upon this information the electronic controller varies the pump output to meet current vehicle needs Electrical Schematic DIAGNOSIS AND TESTING Power Steering...

Page 182: ...le Turning Power steering assembly the Steering Wheel Circuit s Steering wheel sensor Steering Effort Easier Than Steering alignment GO to Pinpoint Test C Normal at High Speeds Steering gear Power ste...

Page 183: ...A module Yes GO to A7 C1945 to carry out this test step With key OFF reconnect power steering assembly C1992 if disconnected and connect the 104 Pin Breakout Box BOB to the IAA module and IAA module C...

Page 184: ...rsonal injury or death Disconnect power steering assembly high voltage C1895 Disconnect high voltage auxiliary load in line C1935 on the traction battery support tray Measure the resistance between ci...

Page 185: ...raised The speed of Yes CHECK the power steering the power steering pump should increase when the steering wheel is turned fluid level and tire pressures and return to a slower speed after the steeri...

Page 186: ...LACE the steering wheel sensor PINPOINT TEST C STEERING EFFORT EASIER THAN NORMAL AT HIGH SPEEDS TEST STEP ACTION TO TAKE C1 CHECK POWER STEERING PUMP OPERATION NOTE Carry out the following steps with...

Page 187: ...ile rotating the steering wheel from lock to lock or ROTATE steering wheel from lock to lock until shudder stops Does steering wheel shudder No System OK REMOVAL AND INSTALLATION Power Steering Assemb...

Page 188: ...assembly 1 Remove the nuts 2 Remove the assembly Installation 1 To install reverse the removal procedure Purge the power steering system of air Refer to Section 211 00 of the 2001 Ranger Workshop Manu...

Page 189: ...ar A C compressor bolts 4 CAUTION Do not force the compressor into position or damage to the A C lines may result Raise and support the compressor using a 9 5 mm 3 8 in diameter 900 mm 36 in long rod...

Page 190: ...r clarity Remove the two rear bracket bolts 7 Remove the rear half of the A C compressor bracket 8 The power steering gear is the same as the gasoline powered Ranger Remove the power steering gear Ref...

Page 191: ...TION Continued Power Steering Gear Postal Ranger EV Removal and Installation 1 The power steering gear is the same as the gasoline powered Ranger For additional information refer to Section 211 02 of...

Page 192: ...s Pressure Hose Removal 1 Disconnect the pressure hose from the power steering pump 2 Raise and support the vehicle Refer to Section 100 02 3 Disconnect the pressure hose from the steering gear 4 Remo...

Page 193: ...er Steering REMOVAL AND INSTALLATION Continued Installation 1 To install reverse the removal procedure Purge the power steering system of air Refer to Section 211 00 of the 2001 Ranger Workshop Manual...

Page 194: ...Ranger EV Removal 1 Disconnect the pressure hose from the power steering pump 2 Raise and support the vehicle For additional information refer to Section 100 02 3 Disconnect the pressure hose from th...

Page 195: ...er Steering REMOVAL AND INSTALLATION Continued Installation 1 To install reverse the removal procedure Purge the power steering system of air Refer to Section 211 00 of the 2001 Ranger Workshop Manual...

Page 196: ...ION Continued Power Steering Pump Hoses Return Hose Removal 1 Disconnect the return hose from the reservoir 2 Disconnect the return hose from the steering gear 3 Remove the return hose 1 Remove the cl...

Page 197: ...he removal procedure Purge the power steering system of air Refer to Section 211 00 of the 2001 Ranger Workshop Manual Power Steering Pump Hoses Return Hose Postal Ranger EV Removal 1 NOTE Electric Ra...

Page 198: ...return hose from the steering gear 3 Remove the return hose 1 Remove the clamp bolt 2 Remove the return hose Installation 1 To install reverse the removal procedure Purge the power steering system of...

Page 199: ...REMOVAL AND INSTALLATION Continued Power Steering Pump Hoses Supply Hose Removal 1 Disconnect the supply hose from the power steering pump 2 Disconnect the supply hose from the reservoir 3 Remove the...

Page 200: ...Power Steering Pump Hoses Supply Hose Postal Ranger EV Removal 1 Disconnect the supply hose from the power steering pump 2 NOTE Electric Ranger shown Postal Ranger EV similar Disconnect the supply ho...

Page 201: ...eering reservoir 1 Disconnect the lines 2 Remove the screws 3 Remove the reservoir Installation 1 Install the power steering reservoir 1 Position the reservoir 2 Install the screws 3 Connect the hoses...

Page 202: ...r For additional information refer to Section 211 00 of the 2001 Ranger Workshop Manual Steering Wheel Sensor Removal 1 NOTE The steering wheel sensor is located on the steering column inside the cab...

Page 203: ...Steering Column Switches Manual Table of Contents SECTION 211 05 Steering Column Switches VEHICLE APPLICATION Ranger EV CONTENTS PAGE DESCRIPTION AND OPERATION Steering Column Switches 211 05 2 2001...

Page 204: ...located in the contactor box The TIM radio and wipers remains in this state for up to five minutes or until Run the key switch position is changed If the key is RUN is the normal operating position fo...

Page 205: ...controller IMC power steering module and the positive temperature coefficient PTC switching module thereby charging their internal bus capacitors When the voltage differential between the traction ba...

Page 206: ...nsaxle VEHICLE APPLICATION Ranger EV CONTENTS PAGE SPECIFICATIONS 303 01 2 DESCRIPTION AND OPERATION Basic Motor Transaxle 303 01 2 DIAGNOSIS AND TESTING Motor Transaxle Lubrication System 303 01 3 El...

Page 207: ...k Absorber 55 40 5 Nut Nut TIM A B C Cable 3 26 Connector Nut Continued The motor transaxle is lubricated with Tribolube DESCRIPTION AND OPERATION L6 Pro Gear 21 F8AZ 19M544 A oil The oil is Basic Mot...

Page 208: ...re drops below 28 kPa 4 psi the oil pressure switch opens and signals the TIM of a low oil pressure condition DTC C1284 is set if the TIM detects the oil pressure switch open for more than 10 minutes...

Page 209: ...the voltage Is the voltage between 2 5 and 6 5 volts A4 CHECK OIL PRESSURE SWITCH Observe the oil pump pressure LED on Electric Motor Transaxle test Yes GO to A5 box Is the oil pump pressure LED on N...

Page 210: ...round BOB pin A29 Is the resistance less than 5 ohms A12 CHECK CIRCUITS 3004 P LG AND 3005 P LG FOR OPEN S With key OFF disconnect the TIM from the BOB leave BOB connected Yes GO to A13 to TIM C4998 C...

Page 211: ...r to Section 100 02 2 Remove the LH rear wheel 1 Remove the center cap 2 Remove the lug nuts 3 Remove the wheel 3 Remove the oil fill plug The motor transaxle should be filled to the bottom of the fil...

Page 212: ...Change Procedure Special Tool s Electric Motor Transaxle Test Box 418 F211 NOTE The oil capacity of the motor transaxle is approximately 1600 ml 54 oz This procedure will remove 1000 ml 33 oz of oil f...

Page 213: ...e center cap 2 Remove the lug nuts 3 Remove the wheel 4 Disconnect the oil pump electrical connector 5 Connect the Electric Motor Transaxle Test Box electrical connector to the oil pump connector 6 Po...

Page 214: ...ut of the motor transaxle Leave the power on for two minutes 9 Install the drain plug 10 Disconnect the Electric Motor Transaxle Test Box electrical connector from the oil pump connector and connect t...

Page 215: ...4 Install the fill plug 15 Install the wheel 1 Position the wheel 2 Install the lug nuts 3 Install the center cap REMOVAL AND INSTALLATION Motor Transaxle Removal 1 Disconnect the traction battery two...

Page 216: ...Remove the center cap 2 Remove the lug nuts 3 Remove the wheel 4 Disconnect the shift cable 5 Position the shift cable bracket aside 1 Remove the bolts 2 Position the shift cable bracket aside 6 Disco...

Page 217: ...ath the vehicle The connector is shown with the box off the pickup for clarity Disconnect the motor transaxle electrical connector from the top RH side of the motor transaxle by pressing on top tab an...

Page 218: ...ove the nuts 2 Remove the sleeve nuts and slide the cables out of the TIM 12 Support the motor transaxle using a high lift jack Strap the motor transaxle to the high lift jack to secure the motor tran...

Page 219: ...ctrical connections may occur Lower the motor transaxle 4 inches 102 mm to expose the top of the motor transaxle frame 16 NOTE If installing a new motor transaxle remove the LH and RH bracket bolts Di...

Page 220: ...303 01 15 303 01 15 Basic Motor Transaxle REMOVAL AND INSTALLATION Continued 2001 Ranger EV 01 2001...

Page 221: ...303 01 16 303 01 16 Basic Motor Transaxle REMOVAL AND INSTALLATION Continued 2001 Ranger EV 01 2001...

Page 222: ...System 303 03 4 Diagnostic Trouble Code DTC Definition 303 03 4 Electrical Schematic 303 03 4 Inspection and Verification 303 03 4 Pinpoint Tests 303 03 5 Symptom Chart 303 03 5 GENERAL PROCEDURES Co...

Page 223: ...ooling System ESE M97B44 A screws Fluid E2FZ 19549 AA Radiator fan bolts 6 54 Pressure Relief Cap 110 5 kPa 16 psi DESCRIPTION AND OPERATION Cooling System Item Part Number Description Item Part Numbe...

Page 224: ...er motor controller Because of the IAA energizes the pump whenever the ignition key Electric Rangers unique systems vehicle coolant is is in the ON position and during traction battery not used in the...

Page 225: ...liary 12 volt battery The electric fan is also controlled by the IAA If the coolant temperature exceeds 40 C 104 F the cooling fan runs at low speed If the coolant temperature rises above 45 C 113 F t...

Page 226: ...mes Fan low speed relay Interface adapter assembly IAA module Cooling Fan Runs at High Circuit s GO to Pinpoint Test F Speed at All Times Fan high speed relay Interface adapter assembly IAA module Pin...

Page 227: ...below REFER to Section 412 04 Actual Temperature Approximate No REPLACE the coolant temperature sensor 0 C 32 F 91 000 100 700 ohms 5 C 41 F 71 100 78 700 ohms 10 C 50 F 56 000 62 000 ohms 15 C 59 F...

Page 228: ...EPAIR the LB wire the coolant pump relay connector and BOB pin 19 Is the resistance less than 5 ohms B7 CHECK CIRCUIT 3229 W R FOR OPEN With key OFF measure the resistance of the W R wire between cool...

Page 229: ...the fan low speed relay from the cooling fan Yes GO to D7 relay box Enter the IAA module active command mode FAN SPEED CONTROL No GO to D6 set the active command FAN SPD to LOW and measure the resista...

Page 230: ...T LOW SPEED AT ALL TIMES TEST STEP ACTION TO TAKE E1 CHECK CIRCUIT 260 R O FOR SHORT TO POWER Remove the fan low speed relay from the cooling fan relay box Yes GO to E2 Does the cooling fan stop runni...

Page 231: ...hot or if the coolant pump is running Remove the radiator pressure relief cap 3 Raise and support the vehicle Refer to Section 100 02 4 Position a catch pan under the radiator drain cock 5 NOTE This...

Page 232: ...n ESE M97B44 A and distilled water to the radiator until the coolant level reaches the bottom of the radiator filler neck 4 Fill the coolant reservoir with the 50 50 coolant mix until the coolant leve...

Page 233: ...adiator filler neck 9 Install the radiator pressure relief cap 10 Turn the key to the OFF position to deactivate the coolant pump 11 Slowly turn the pressure relief cap counterclockwise to the first s...

Page 234: ...uns along the top of radio und er the hood of the vehicle The hose needs to be cut which bleeds the air between the two hose retainer clips and needs to have a 3 4 hose splice installed and secured wi...

Page 235: ...lant is hot or if the coolant pump is running Turn the radiator pressure relief cap to the first stop to remove any remaining pressure 4 Raise and support the vehicle Refer to Section 100 02 5 Remove...

Page 236: ...emove the bolt 2 Remove the pump Installation 1 To install reverse the removal procedure After installation bleed the cooling system Refer to Cooling System Drain Fill and Bleed Coolant Pump Postal Ra...

Page 237: ...n the radiator pressure relief cap to the first stop to remove any remaining pressure 4 Raise and support the vehicle Refer to Section 100 02 5 Remove the LH inner fender splash shield 6 NOTE When rem...

Page 238: ...nnector 8 Remove the coolant pump 1 Remove the bolt 2 Remove the coolant pump Installation 1 To install reverse the removal procedure After installation bleed the cooling system Refer to Cooling Syste...

Page 239: ...the cooling fan 2 Install the two bolts 3 Connect the cooling fan electrical connector 4 Clip the hose in position 2 Connect the auxiliary battery ground cable Cooling System Tubes and Hoses Removal 1...

Page 240: ...the hoses to prevent coolant loss Position a catch pan to collect the coolant 4 Disconnect the rear coolant tube rubber hose connections Clamp off the hoses to prevent coolant loss Position a catch p...

Page 241: ...m Refer to Bleed Cooling System Cooling System Tubes and Hoses Postal Ranger EV Removal 1 WARNING Do not remove the radiator pressure relief cap if the coolant is hot or if the coolant pump is running...

Page 242: ...hoses to prevent coolant loss Position a catch pan to collect the coolant 4 Disconnect the rear coolant tube rubber hose connections Clamp off the hoses to prevent coolant loss Position a catch pan t...

Page 243: ...Engine Cooling REMOVAL AND INSTALLATION Continued Installation 1 To install reverse the removal procedure After installation bleed the cooling system Refer to Cooling System Drain Fill and Bleed 2001...

Page 244: ...ECIFICATIONS 303 14 2 DESCRIPTION AND OPERATION Electric Motor Management 303 14 2 DIAGNOSIS AND TESTING Traction Inverter Module TIM Control System 303 14 2 Electrical Schematic 303 14 2 Inspection a...

Page 245: ...ontains two vehicle speed System sensors encoders to provide two signals Diagnostic Trouble Code DTC Definition channels A and B to indicate the speed and direction of the vehicle to the TIM At speeds...

Page 246: ...Motor Transaxle Test Box 418 F211 PINPOINT TEST A DTC C1854 MOTOR TEMPERATURE OUT OF RANGE TEST STEP ACTION TO TAKE A1 CHECK MOTOR TEMPERATURE SENSOR Monitor the motor PID TRNTEMP and note the tempera...

Page 247: ...Is the outside recirculation door in the recirculation position No GO to A5 A5 CHECK CIRCUITS 3708 BR FOR SHORT TO GROUND With key OFF measure the resistance between BOB pins A2 and ground Yes GO to...

Page 248: ...B LEDS on the test box blink alternately as the wheels rotate B2 CHECK VEHICLE SPEED SENSORS REFERENCE VOLTAGE Key OFF Yes GO to B3 Connect 104 pin Breakout Box BOB to traction inverter module TIM an...

Page 249: ...D INSTALLATION Traction Inverter Module TIM Removal 1 WARNING The TIM contains capacitors which can retain a high voltage charge even after the traction battery has been disconnected Wear high voltage...

Page 250: ...VAL AND INSTALLATION Continued 3 Disconnect the electrical connectors 1 Loosen the bolts 2 Disconnect the connectors 4 Remove the ground strap bolt 5 Clamp off and disconnect the coolant hoses 6 Remov...

Page 251: ...e TIM 1 Loosen the TIM bracket bolts 2 Remove the bracket to frame bolts 3 Remove the TIM Installation 1 To install reverse the removal procedure 1 If excessive amounts of coolant were lost during the...

Page 252: ...303 14 9 303 14 9 Electric Motor Management REMOVAL AND INSTALLATION Continued 2001 Ranger EV 01 2001...

Page 253: ...303 14 10 303 14 10 Electric Motor Management REMOVAL AND INSTALLATION Continued 2001 Ranger EV 01 2001...

Page 254: ...rnal Controls 307 05 2 DIAGNOSIS AND TESTING Digital Transmission Range DTR Sensor 307 05 2 Electrical Schematic 307 05 2 Inspection and Verification 307 05 2 Pinpoint Tests 307 05 4 Symptom Chart 307...

Page 255: ...n range DTR sensor provides an analog input TR3A along with Sensor three digital inputs to indicate to the traction Diagnostic Trouble Code DTC Definition inverter module TIM which gear has been selec...

Page 256: ...oint Test A Traction inverter module TIM Battery control module BCM Loss of Drive Operation Shift cable alignment CHECK shift cable Vehicle Will Not Move in Digital transmission range alignment REFER...

Page 257: ...cial Tool s High Voltage Insulated Gloves 100 F036 or equivalent 104 Pin Breakout Box BOB 418 049 014 00950 or Face Shield 100 F035 or equivalent equivalent Digital TR Sensor Alignment Tool 307 351 BC...

Page 258: ...ter and TR E Cable GO to A5 Connect TR E Cable to Transmission Tester and DTR sensor No REPLACE the DTR sensor Place the Digital TR Sensor Overlay onto Transmission Tester and ALIGN REFER to Digital T...

Page 259: ...tACT ECONOMY ACTIVE Is the PRNDE 2 PID correct A10 CHECK CIRCUIT 3501 DB FOR OPEN Connect 104 Pin Breakout Box BOB to TIM C4998 C4999 using the Yes GO to A11 BCM TIM BOB Adapter Cable and Overlay leav...

Page 260: ...not connect Traction Battery Low Voltage Service Cord to in line C1939M With key OFF measure the resistance between BOB pin 40 and ground BOB pin 65 Is the resistance greater than 10 000 ohms A15 CHE...

Page 261: ...PLACE the TIM REFER to Section 303 14 A20 CHECK TR4 INPUT SIGNAL STATUS With key ON monitor TIM PID PRNDE 4 Yes System OK CHECK wiring for intermittent connections With brake pedal depressed shift the...

Page 262: ...nd No REPAIR the Y wire BOB pin A29 Is the resistance greater than 10 000 ohms A25 CHECK TR4 SIGNAL LINE TO BATTERY CONTROL MODULE BCM INSIDE OF TRACTION BATTERY SUPPORT TRAY FOR SHORT TO GROUND With...

Page 263: ...efore proceeding Transmission Range DTR Apply the parking brake Sensor Adjustment in this Set the gear selector to NEUTRAL and verify the shift linkage is section adjusted in the NEUTRAL position With...

Page 264: ...ever in D Drive 4 Engage the cable clip push down 5 Verify that the shifter has remained in the D Drive position and check for correct gearshift operation Digital Transmission Range DTR Sensor Alignme...

Page 265: ...s GENERAL PROCEDURES Continued 3 Disconnect the shift cable from the shift lever NOTE The motor transaxle is shown removed from the vehicle 4 Remove the shift lever 1 Remove the nut 2 Remove the shift...

Page 266: ...not remove the alignment tool until the sensor bolts have been tightened Install the digital TR sensor alignment tool to positively locate the sensor in relation to the motor transaxle neutral positio...

Page 267: ...er 1 Install the shift lever 2 Install the nut 10 Connect the shift cable to the shift lever 11 Adjust the shift cable Refer to PRNDE Shifter Adjustment REMOVAL AND INSTALLATION Motor Transaxle Shift...

Page 268: ...the bracket 1 Depress the tabs 2 Slide the cable through the bracket 4 Unclip the shift cable from the four clips located inside the driver side frame rail 5 NOTE The shift cable connection is locate...

Page 269: ...erse the removal procedure After installation adjust the shift cable Refer to PRNDE Shifter Adjustment Digital Transmission Range DTR Sensor Special Tool s Digital Transmission Range TR Sensor Alignme...

Page 270: ...atic Transaxle External Controls REMOVAL AND INSTALLATION Continued 5 Remove the motor mount through bolt 6 Remove the two motor mount nuts 7 Remove the five motor mount bracket to motor transaxle bol...

Page 271: ...mately 2 5 cm 1 in 10 Remove the motor transaxle mount 11 NOTE The motor transaxle is shown removed from the vehicle for clarity NOTE The motor transaxle must be in the N Neutral position prior to ins...

Page 272: ...range DTR sensor lever 1 Remove the nut 2 Remove the lever 13 Disconnect the DTR sensor electrical connector 14 Remove the DTR sensor 1 Remove the two bolts 2 Pry the bracket away from the motor tran...

Page 273: ...ntinued 2 Install the digital TR sensor alignment tool on the sensor 3 NOTE The sensor is installed with alignment tool in place Install the DTR sensor 1 Position the sensor on the motor transaxle 2 I...

Page 274: ...stall the DTR sensor lever 1 Position the lever 2 Install the nut 6 Position the motor transaxle mount 7 Install the five bracket to motor transaxle bolts The motor transaxle may have to be lowered or...

Page 275: ...22 Automatic Transaxle External Controls REMOVAL AND INSTALLATION Continued 8 Loosely install the two motor mount nuts 9 Install the motor mount through bolt 10 Tighten the two motor mount nuts 2001 R...

Page 276: ...23 Automatic Transaxle External Controls REMOVAL AND INSTALLATION Continued 11 Connect the shift cable 12 Install the LH rear wheel 13 Adjust the shift cable Refer to PRNDE Shifter Adjustment 2001 Ra...

Page 277: ...2 DESCRIPTION AND OPERATION Acceleration Control 310 02 2 DIAGNOSIS AND TESTING Acceleration Control 310 02 3 Electrical Schematic 310 02 3 Inspection and Verification 310 02 3 Pinpoint Tests 310 02...

Page 278: ...The Electric Vehicle uses an acceleration position sensor APS to monitor driver demands for acceleration The APS is mounted to the acceleration pedal bracket and moves in direct relation to the throt...

Page 279: ...Motor Transaxle Control for set when one or more of these sensors are out schematic and connector information of range If this failure occurs the malfunction Inspection and Verification indicator lam...

Page 280: ...00 ohms No REPAIR the wire s in question A4 CHECK CIRCUITS 3835 Y W AND 3836 Y LB TO APS1 FOR SHORT S TO POWER With key ON measure the voltage between BOB pins B4 B5 and Yes REPAIR the wire s in groun...

Page 281: ...CE the TIM REFER BOB pin A29 to Section 303 14 Is the voltage between 4 9 and 5 1 volts A12 CHECK APS2 SIGNAL With key OFF reconnect APS C2995 Yes REPLACE the TIM REFER to Section 303 14 With key ON m...

Page 282: ...e the voltage between BOB pins B15 and B16 No REPLACE the APS while depressing the accelerator pedal from idle to wide open throttle WOT Does the voltage vary within the range of 4 00 and 1 56 volts P...

Page 283: ...osition sensor 1 Position the sensor on the clip and swing it into position 2 Install the bolt 2 Connect the electrical connector Acceleration Position Sensor Postal Ranger EV Removal and Installation...

Page 284: ...310 02 8 310 02 8 Acceleration Control REMOVAL AND INSTALLATION Continued 2 To install reverse the removal procedure 2001 Ranger EV 01 2001...

Page 285: ...Charging 414 02 1 High Voltage Traction Battery 414 03A 1 High Voltage Traction Battery Nickel Metal Hydride 414 03B 1 Module Communications Network 418 00 1 SECTION 412 01 Air Distribution and Filte...

Page 286: ...iltering is located in the evaporator assembly behind the The heating and cooling system on the Electric blower motor To ensure maximum climate control Ranger uses an air filter to clean the air befor...

Page 287: ...or 3 Disconnect the windshield solvent pump electrical connector 4 Position the reservoirs 1 Remove the nuts 2 Remove the bolts 3 Position the reservoir toward the front of the vehicle 5 Remove the bl...

Page 288: ...ons Tip the 10 o clock position of the filter towards the outside of the housing and pull the filter out through the blower motor opening Installation 1 Grasp the new filter at the 3 and 9 o clock pos...

Page 289: ...ds the blower motor opening to properly locate the filter 7 CAUTION Overtightening of the blower screws will result in damage to the plastic housing Install the blower motor 1 Position the blower 2 In...

Page 290: ...ibution and Filtering REMOVAL AND INSTALLATION Continued 9 Connect the windshield solvent pump electrical connector 10 Connect the A C electrical connector 11 Connect the blower motor electrical conne...

Page 291: ...ke System ABS control unit bracket 3 NOTE Electric Ranger shown Postal Ranger EV similar Remove the blower motor 1 Disconnect the blower motor air inlet tube 2 Remove the four screws 3 Remove the moto...

Page 292: ...e outside of the housing and pull the filter out through the blower motor opening Installation 1 NOTE Electric Ranger shown Postal Ranger EV similar Grasp the new filter at the 3 and 9 o clock positio...

Page 293: ...ull the filter towards the blower motor opening to properly locate the filter 7 CAUTION Overtightening of the blower screws will result in damage to the plastic housing NOTE Electric Ranger shown Post...

Page 294: ...412 01 10 412 01 10 Air Distribution and Filtering REMOVAL AND INSTALLATION Continued 9 Connect the blower motor electrical connector 2001 Ranger EV 01 2001...

Page 295: ...ATION Heating Defrosting 412 02 2 Heating Defrosting Postal Ranger EV 412 02 2 DIAGNOSIS AND TESTING Heating Defrosting Ventilation System 412 02 3 Electrical Schematic 412 02 5 Inspection and Verific...

Page 296: ...d to for heating defrosting while the vehicle is in the the PTC heater by the PTC switching module The KEY OFF position to help conserve battery energy PTC heater is equipped with an overtemperature T...

Page 297: ...on by the PTC module sets DTC B1238 switching module is open or is in an DTC B1249 Blend Door Failure overcurrent condition the PTC switching The interface adapter assembly IAA module module must see...

Page 298: ...ed mode select switch and the recirculation signal DTC B2514 Blower Fan Circuit Short to Vbat from the fresh recirculation select switch The IAA module sets DTC B1857 if it detects an The interface ad...

Page 299: ...to Pinpoint Test A Temperature Fault coefficient PTC heater overtemperature switch harness assembly Circuit s Interface adapter assembly IAA module PTC switching module DTC B1249 Blend Door Blend doo...

Page 300: ...ive temperature GO to Pinpoint Test J Fault Non SCP coefficient PTC module Circuit s Interface adapter assembly IAA module PTC heater core DTC B2513 Blower Fan Circuit s GO to Pinpoint Test K Circuit...

Page 301: ...n correct one Pre Heat Function Does Not Positive temperature GO to Pinpoint Test E Operate Postal Ranger EV coefficient PTC heater core only with DTC C1776 Circuit s PTC switching module Interface ad...

Page 302: ...AA module C1945 Yes REPAIR the wire s in question With key ON measure the voltage between pin 2 Y W wire pin 3 No REPLACE the PTC GY W wire on PTC switching module C1999 and ground switching module Ar...

Page 303: ...OR ACTUATOR With key OFF reconnect blend door actuator C240 Yes REPLACE the IAA module With key OFF connect the IAA module to BOB leave BOB connected REFER to Section 412 04 to IAA module C1945 NOTE Y...

Page 304: ...wire C4 CHECK CIRCUIT 3050 W O FOR SHORT TO POWER With key ON measure the voltage between BOB pin 49 and ground Yes REPAIR the W O wire BOB pin 80 Is the voltage greater than 0 volts No GO to C5 C5 C...

Page 305: ...TRIEVE CONTINUOUS DIAGNOSTIC TROUBLE CODES DTCs FROM INTERFACE ADAPTER ASSEMBLY IAA MODULE WHILE IN PANEL FLOOR MODE With key ON set the mode select knob to the PANEL FLOOR position Yes REFER to Sympt...

Page 306: ...No REPLACE the IAA module BOB pin 80 REFER to Section 412 04 Is the resistance less than 7 000 ohms E6 CHECK CIRCUIT 3260 O W FOR SHORT TO GROUND Reconnect the 12 volt auxiliary battery negative cabl...

Page 307: ...WER TO PTC SWITCHING MODULE Yes GO to E17 WARNING The following test steps contain high voltage procedures High voltage insulated safety gloves and face shield must be worn when carrying out the follo...

Page 308: ...le PID Yes System OK CHECK wiring BLOWER while rotating the blower control knob through all the blower for intermittent connections speed positions Does the BLOWER PID agree with all the blower speed...

Page 309: ...51 DB W wire terminal Closed Circuit 752 Y R wire terminal Open Circuit 754 LG W wire terminal Open Medium High Blower Position Circuit 751 DB W wire terminal Closed Circuit 752 Y R wire terminal Clos...

Page 310: ...SHORT TO POWER With key ON measure the voltage between BOB pin 50 and ground Yes REPAIR the LG R wire BOB pin 80 Is the voltage greater than 0 volts No GO to G8 G8 CHECK RESISTANCE OF TEMPERATURE CON...

Page 311: ...GO to H9 Measure the resistance between terminals 1 and 2 on the mode select No REPLACE the mode select switch with the mode select knob in the A C and MAX A C positions switch Are the resistances les...

Page 312: ...CHECK RECIRCULATION VACUUM PRESSURE SENSOR GROUND REFERENCE With key OFF measure the resistance between BOB pin 90 and ground Yes GO to H17 BOB pin 80 Is the resistance less than 5 ohms No REPLACE the...

Page 313: ...odule C1999 and ground Is the resistance less than 5 ohms No GO to J5 J5 CHECK CIRCUIT 3036 Y W FOR OPEN Connect 104 Pin Breakout Box BOB to IAA module C1945 leave IAA Yes REPLACE the IAA module modul...

Page 314: ...FOR OPEN Connect 104 Pin Breakout Box BOB to interface adapter assembly Yes REPLACE the IAA module IAA module C1945 leave IAA module disconnected REFER to Section 412 04 With key OFF measure the resis...

Page 315: ...ey OFF remove the blower motor relay from the EVPDB and No REPAIR as necessary measure the voltage between pins 85 87 on the blower motor relay connector and ground V 10 volts Is everything OK K4 CHEC...

Page 316: ...nce less than 5 ohms No GO to K12 K12 CHECK CIRCUIT 3020 LB FOR OPEN Connect 104 Pin Breakout Box BOB to IAA module C1945 leave IAA Yes REPLACE the IAA module module disconnected REFER to Section 412...

Page 317: ...on demand self test for the interface adapter assembly Yes GO to Pinpoint Test N IAA module and check for blower fan system DTCs Do DTC B2514 Blower Fan Circuit Short to Vbat and or DTC No GO to M2 B...

Page 318: ...AA module BOB pin 80 REFER to Section 412 04 Is the voltage greater than 0 volts N5 CHECK BLOWER FAN STATUS With key ON set the mode select knob to the PANEL FLOOR position Yes System OK CHECK wiring...

Page 319: ...ON set the mode select knob to the PANEL FLOOR position No If voltage equals 0 volts and the temperature control knob to the full warm position and monitor REPLACE the IAA module IAA module PIDs CORE...

Page 320: ...rvoir on the vacuum reservoir GO to Q5 Monitor interface adapter assembly IAA module PID VACPRES for a No REPLACE the climate change in vacuum pressure after the vacuum pump shuts off control vacuum r...

Page 321: ...ter Is the vacuum line routing correct No CORRECT the vacuum line routing Q11 CHECK VACUUM LINES CONNECTIONS Check each vacuum line for a secure connection Also check for blocked Yes GO to Q12 pinched...

Page 322: ...recirculation vacuum solenoid and plug intermittent vacuum line the vacuum line connections Monitor IAA module PID VACPRES for a change in vacuum pressure No REPLACE the heater after the vacuum pump s...

Page 323: ...odule C1945 leave IAA Yes GO to R8 module disconnected With key OFF measure the resistance of the Y LG wire between pin 8 No REPAIR the Y LG wire on in line C2999 and BOB pin 35 Is the resistance less...

Page 324: ...irculation select switch C2998 and ground Is the resistance less than 5 ohms No REPAIR the BK wire R16 CHECK FRESH RECIRCULATION SELECT SWITCH Measure the resistance between the BR W wire terminal and...

Page 325: ...press the button Check circuit X LG BK and circuit W RD LG No INSTALL a new switch Is the resistance less than 3 ohms S5 CHECK CIRCUIT W RD LG FOR POWER Key OFF Yes GO to S6 Disconnect pre heat C262 a...

Page 326: ...anel Refer to the 2001 Ranger Workshop Manual 3 NOTE The evaporator housing nut is located inside the vehicle on the lower bulkhead on the passenger side Remove the evaporator housing nut 4 Position t...

Page 327: ...r core harness clip 2 Disconnect the electrical connector 7 Disconnect the harness clip 8 Position the evaporator housing forward 1 Remove the nuts 2 Position the evaporator housing approximately two...

Page 328: ...plenum from the inside of the vehicle Feed the PTC heater core electrical harness through the bulkhead 13 Remove the PTC heater core cover 1 Remove the screws 2 Remove the cover 14 CAUTION Do not dam...

Page 329: ...Ventilation REMOVAL AND INSTALLATION Continued Installation 1 NOTE Remove the insulation from the electrical harness of the new PTC heater core prior to installation To install reverse the removal pr...

Page 330: ...and Ventilation REMOVAL AND INSTALLATION Continued PTC Heater Core Postal Ranger EV Removal and Installation 1 Disconnect the traction battery auxiliary load high voltage connector Refer to Section 10...

Page 331: ...electrical connector 3 Remove the LH ventilation duct 4 NOTE The PTC heater case is removed for clarity Remove the PTC heater core cover 6 bolts and remove the cover 5 CAUTION Do not damage the insula...

Page 332: ...ng and Ventilation REMOVAL AND INSTALLATION Continued 6 NOTE Remove the insulation from this electrical harness of the new PTC heater core prior to installation To install reverse the removal procedur...

Page 333: ...ND OPERATION A C Inverter Motor Controller 412 03 2 Air Conditioning 412 03 2 Compressor 412 03 2 DIAGNOSIS AND TESTING Air Conditioning 412 03 3 Electrical Schematic 412 03 3 Inspection and Verificat...

Page 334: ...B and this is converted into high voltage alternating Compressor current Six insulated gate bipolar transistors are The compressor for the Electric Ranger is located in incorporated into the A C IMC f...

Page 335: ...C Post Evaporator Sensor Circuit 125 C 257 F or less than 40 C 40 F for Failure more than 30 seconds If this occurs the A C The interface adapter assembly IAA module compressor will be disabled uses t...

Page 336: ...Tool s Pinpoint Tests R 134a Manifold Gauge Set 176 R032A or equivalent Special Tool s R 12 R 134a Air Conditioning Test Fitting Set 104 Pin Breakout Box BOB 418 049 014 00950 or 412 DS028 014 00333 o...

Page 337: ...han 10 000 ohms No REPAIR the DG O wire A6 CHECK CIRCUIT 3029 DG O FOR OPEN Connect 104 Pin Breakout Box BOB to IAA module C1945 leave IAA Yes GO to A7 module disconnected With key OFF measure the res...

Page 338: ...ERATION Is the temperature reading in test step B1 between 0 C 32 F and Yes System OK CHECK wiring 10 C 50 F for intermittent connections No GO to B7 B7 CHECK EVAPORATOR TEMPERATURE SENSOR With key OF...

Page 339: ...isconnected With key OFF disconnect A C IMC C1947 and measure the resistance No REPAIR the wire s in of the Y LG wire between pin 5 on A C IMC C1947 and BOB pin 78 question With key OFF measure the re...

Page 340: ...to D5 Operate the A C system for five minutes and retrieve continuous DTCs No System OK from the IAA module Does DTC B2518 Compressor Overtemperature Fault occur D5 CHECK A C OVERTEMPERATURE SENSOR Wi...

Page 341: ...ct A C overtemperature sensor C1995 and No REPAIR the wire s in measure the resistance of the PK wire between A C overtemperature question sensor C1995 and BOB pin 47 With key OFF measure the resistan...

Page 342: ...FACE ADAPTER ASSEMBLY IAA MODULE Connect the 104 Pin Breakout Box BOB to the IAA module and IAA Yes REPLACE the IAA module module C1945 REFER to Section 412 04 With key ON set the mode select knob to...

Page 343: ...the 12 volt auxiliary battery negative cable With key ON measure the voltage between circuit 3150 DB wire and circuit 3151 W wire on HVPDB A C IMC high voltage C1917 Is the voltage greater than 300 vo...

Page 344: ...l cool position and the blower control knob to HIGH speed position Does the 25A A C high voltage fuse fail again REMOVAL AND INSTALLATION A C Compressor Removal 1 Disconnect the traction battery auxil...

Page 345: ...shown the high voltage electrical connector is behind the A C compressor Disconnect the low and the high voltage electrical connectors at the A C compressor 6 Disconnect the traction battery charger e...

Page 346: ...on WSS M2C31 B This oil is not compatible with any other A C oil If the service compressor has no warning tag label then it has a full production system charge of oil 170 cc and the following steps mu...

Page 347: ...03 15 Air Conditioning REMOVAL AND INSTALLATION Continued A C Inverter Motor Controller Removal 1 Disconnect the traction battery auxiliary load high voltage connector Refer to Section 100 05 2001 Ran...

Page 348: ...A C inverter motor controller IMC electrical connectors One on HVPDB upper rear One on A C IMC 4 Raise and support the vehicle Refer to Section 100 02 5 Disconnect the IMC electrical connector on the...

Page 349: ...Conditioning REMOVAL AND INSTALLATION Continued Installation 1 To install reverse the removal procedure After installation bleed the cooling system For additional information refer to Section 303 03...

Page 350: ...ICATION Ranger EV CONTENTS PAGE SPECIFICATIONS 412 04 2 DESCRIPTION AND OPERATION Control Components 412 04 2 REMOVAL AND INSTALLATION Interface Adapter Assembly IAA Module 412 04 2 Positive Temperatu...

Page 351: ...w voltage conversion vacuum pump operation The IAA module communicates with the traction inverter module TIM and the battery controller module BCM to support the instrument cluster operation and to de...

Page 352: ...ssembly IAA module electrical connector 1 Loosen the connector bolt 2 Remove the harness bracket nut 3 Disconnect the connector 4 Remove the IAA module 1 Remove the nuts 2 Remove the mounting plate 3...

Page 353: ...clamp nut 3 Connect the auxiliary battery ground cable Positive Temperature Coefficient PTC Switching Module Removal NOTE Electric Ranger shown Postal Ranger EV similar 1 Verify that the vehicle is tu...

Page 354: ...efficient PTC switching module 1 Disconnect the electrical connectors 2 Remove the bolts 3 Remove the module Installation 1 To install reverse the removal procedure Variable Blower Controller VBC Remo...

Page 355: ...NSTALLATION Continued 2 Disconnect the auxiliary battery ground cable 3 Disconnect the Variable Blower Controller VBC electrical connector 4 Remove the VBC 1 Remove the mounting screws 5 To install re...

Page 356: ...SCRIPTION AND OPERATION Gauges and Warning Lamps 413 01 2 Indicator Bulbs 413 01 6 DIAGNOSIS AND TESTING Instrument Cluster 413 01 7 Electrical Schematic 413 01 7 Inspection and Verification 413 01 7...

Page 357: ...es economy and transmits the information through the SCP to the IAA module The traction battery state of charge SOC gauge is the equivalent of a fuel gauge on a gasoline powered vehicle F full indicat...

Page 358: ...ant temperature sensor All other temperature information is received through the SCP network If the gauge reading is in the normal or hot region it will display the warmest relative temperature of the...

Page 359: ...tor lamp MIL will illuminate when a diagnostic trouble code DTC has been set in either the IAA module BCM or the TIM The IAA module has two special DTCs to indicate that the BCM or TIM requested the M...

Page 360: ...e is severely limited due to an extremely low SOC or a vehicle malfunction This indicates that the vehicle s performance has been further limited to allow for safe parking of the vehicle before the ve...

Page 361: ...ed to the IAA module damage that could result in a short circuit condition through the SCP network When shifted into the E before the inertia switch is reset and the vehicle is position the vehicle wi...

Page 362: ...the same as the standard gasoline Ranger The bulb replacement also follows the same procedures there are however unique indicators The preceding figure illustrates the name and location of the indica...

Page 363: ...ument Indicator Do Not Operate cluster Speedometer Economy Circuit 570 BK W wire CHECK circuit 570 BK W Gauge Motor Enabled Instrument cluster for open REPAIR if Gauge Traction Battery State necessary...

Page 364: ...Test G Not Operate or Indicates Way IAA module Above the ON Mark Circuit s Instrument cluster Malfunction Indicator Lamp Interface adapter assembly GO to Pinpoint Test H MIL Does Not Operate or IAA mo...

Page 365: ...Circuit s GO to Pinpoint Test T Operate Bulb Instrument cluster Left Turn Indicator Does Not Circuit s GO to Pinpoint Test U Operate Bulb Instrument cluster Right Turn Indicator Does Circuit s GO to...

Page 366: ...ure the voltage between BOB pin 41 and ground No REPLACE the IAA module BOB pin 80 REFER to Section 412 04 Is the voltage greater than 10 volts PINPOINT TEST B SPEEDOMETER DOES NOT OPERATE OR INDICATE...

Page 367: ...ER CONTROL and No REPAIR the GY BK wire set the active command SPDOMETER to 30 between instrument cluster Set the multimeter to the frequency setting and measure the frequency C214 and TIM C4998 betwe...

Page 368: ...disconnect instrument cluster C215 and measure the Yes REPLACE the instrument resistance of the O wire between pin 4 on instrument cluster C215 and cluster BOB pin 21 Is the resistance less than 5 oh...

Page 369: ...Connect 104 Pin Breakout Box BOB to the IAA module and IAA Yes REPLACE the IAA module module C1945 REFER to Section 412 04 With key ON connect a jumper wire between BOB pins 20 and 75 No GO to D5 Doe...

Page 370: ...nomy gauge indicate above the negative mark No GO to E4 E3 CHECK ECONOMY GAUGE FOR CORRECT INDICATION Set the active command ECON G to the following percentages and Yes System OK CHECK wiring verify t...

Page 371: ...SYMPTOM Enter the interface adapter assembly IAA module active command Yes GO to F2 mode DISTANCE TO EMPTY GAUGE and set the active command DTE G to 30 Does the distance to empty DTE gauge indicate gr...

Page 372: ...ent cluster With key ON measure the voltage between pin 12 BK LG wire on No GO to F8 instrument cluster C214 and pin 6 BK W wire on instrument cluster C215 Is the voltage greater than 10 volts F8 CHEC...

Page 373: ...n Breakout Box BOB to IAA module C1945 leave IAA Yes REPAIR the GY R wire module disconnected With key OFF disconnect instrument cluster C214 No REPLACE the instrument With key ON measure the voltage...

Page 374: ...the IAA module and IAA module C1945 With key OFF disconnect instrument cluster C215 and measure the No GO to H9 resistance between BOB pin 31 and ground BOB pin 80 Is the resistance greater than 10 0...

Page 375: ...odule and IAA Yes REPLACE the instrument module C1945 cluster With key OFF disconnect instrument cluster C215 and measure the No GO to J9 resistance between BOB pin 9 and ground BOB pin 80 Is the resi...

Page 376: ...cluster With key OFF disconnect instrument cluster C214 and measure the No GO to K9 resistance between BOB pin 10 and ground BOB pin 80 Is the resistance greater than 10 000 ohms K9 CHECK CIRCUIT 304...

Page 377: ...ire switch C205 and ground Is the voltage greater than 10 volts L9 CHECK INSTRUMENT CLUSTER Connect 104 Pin Breakout Box BOB to the IAA module and IAA Yes REPLACE the instrument module C1945 cluster W...

Page 378: ...to M7 M7 CHECK POWER TO INSTRUMENT CLUSTER With key OFF measure the voltage between pin 1 LB wire pin 12 LB Yes REPLACE the instrument wire on instrument cluster C215 and ground cluster Is the voltage...

Page 379: ...r Yes GO to N5 bulb Is the bulb OK No REPLACE the bulb N5 CHECK CIRCUIT 3400 BR LB FOR OPEN With key OFF disconnect instrument cluster C214 and measure the Yes GO to N6 resistance of the BR LB wire be...

Page 380: ...Yes GO to P5 Is the bulb OK No REPLACE the bulb P5 CHECK CIRCUIT 3043 W PK FOR OPEN With key OFF disconnect instrument cluster C214 and measure the Yes GO to P6 resistance of the W PK wire between pin...

Page 381: ...warning indicator Yes GO to Q5 LED Is the LED OK No REPLACE the bulb Q5 CHECK CIRCUIT 3407 R W FOR OPEN With key OFF disconnect instrument cluster C214 and measure the Yes GO to Q6 resistance of the R...

Page 382: ...bulb R5 CHECK CIRCUIT 3042 PK LG FOR OPEN With key OFF disconnect instrument cluster C215 and measure the Yes GO to R6 resistance of the PK LG wire between pin 7 on instrument cluster C215 and BOB pin...

Page 383: ...E the bulb S5 CHECK RED BRAKE WARNING INDICATOR CONTROL CIRCUIT FOR OPEN With key OFF disconnect instrument cluster C216 and measure the Yes GO to S8 resistance between pin 7 P W wire on instrument cl...

Page 384: ...from the BOB leave BOB Yes GO to S15 connected to IAA module C1945 With key OFF disconnect brake fluid level switch C137 and measure the No REPAIR the T LG wire resistance between BOB pin 39 and grou...

Page 385: ...t cluster C216 and ground Does the voltage vary from 0 to greater than 10 volts U2 CHECK GROUND TO INSTRUMENT CLUSTER With key OFF measure the resistance between pin 2 BK wire on Yes GO to U3 instrume...

Page 386: ...RIFY ANTI LOCK BRAKE SYSTEM ABS WARNING INDICATOR OPERATION With key ON check the anti lock brake system ABS warning indicator Yes System OK CHECK wiring for intermittent connections Does the ABS warn...

Page 387: ...o Section 417 02 of the 2001 Workshop Manual If DTC B1330 REFER to Section 417 02 of the 2001 Workshop Manual If DTC B1342 REPLACE the GEM REFER to Section 419 10 of the 2001 Ranger Workshop Manual CL...

Page 388: ...on No REPLACE the instrument instrument cluster C215 and ground cluster Is the voltage greater than 0 volts Y9 CHECK CIRCUIT 627 BK O FOR SHORT TO POWER With key OFF disconnect GEM C221 Yes REPAIR the...

Page 389: ...e the voltage between pin 4 Y wire on instrument Yes GO to Z7 cluster C216 and ground Is the voltage greater than 10 volts No REPAIR the Y wire Z7 CHECK CIRCUIT 871 Y FOR OPEN With key OFF disconnect...

Page 390: ...stallation 1 Disconnect the auxiliary battery ground cable 2 Remove the eight instrument panel screws 3 Remove the bolt disconnect the gear indicator cable and position aside 4 NOTE Only four connecto...

Page 391: ...cal connector 6 Disconnect the heater control electrical and vacuum connectors 7 Remove the bolt 8 NOTE The foam seal around the RH register vent may come off with the instrument panel If this happens...

Page 392: ...37 413 01 37 Instrument Cluster REMOVAL AND INSTALLATION Continued 9 To install reverse the removal procedure Make sure the register vents move properly side to side after installation 2001 Ranger EV...

Page 393: ...AND OPERATION Auxiliary Battery Charging 414 02 2 DIAGNOSIS AND TESTING Auxiliary Battery Charging 414 02 2 Electrical Schematic 414 02 3 Inspection and Verification 414 02 3 Pinpoint Tests 414 02 4...

Page 394: ...de of the traction battery charger The auxiliary is removed by the coolant that is circulated through battery temperature sensor is located next to the the DC DC converter auxiliary battery to monitor...

Page 395: ...elay If the IAA module suspects remain so As the auxiliary voltage continues the DC DC converter is supporting the to decrease the IAA module will continue to auxiliary battery voltage too high more t...

Page 396: ...E A1 CHECK FOR DC DC CONVERTER FAILURE DIAGNOSTIC TROUBLE CODE DTC Carry out on demand self test for the interface adapter assembly IAA Yes GO to Pinpoint Test C module and check for DTC C1775 DC DC C...

Page 397: ...13 8 No GO to C3 volts C3 CHECK AUXILIARY CONTACTOR RELAY STATUS With key ON monitor the IAA module PID AUX HVC Yes GO to C4 Does the AUX HVC PID indicate CLOSED No CARRY OUT pinpoint test for IAA DTC...

Page 398: ...battery negative cable With key ON measure the voltage between circuit 3117 DB wire and circuit 3118 W wire on HVPDB DC DC converter C1914F Is the voltage greater than 300 volts C10 CHECK HIGH VOLTAGE...

Page 399: ...ID VBATIAA turn the ignition key No GO to D2 to the ON position Does the VBATIAA PID increase to approximately 13 7 volts D2 CHECK DC DC CONVERTER With key OFF disconnect auxiliary battery temperature...

Page 400: ...ions With key ON monitor IAA module PIDs EXT UT2 and VBATIAA No REPLACE the auxiliary and compare the readings to the values below battery temperature sensor Temperature 0 C 32 F 14 1 14 7 volts 5 C 4...

Page 401: ...is hot or if the pump is running Turn the radiator pressure relief cap to the first stop to relieve any remaining pressure 3 Remove the high voltage power distribution Box HVPDB cover 1 Remove the scr...

Page 402: ...es at the DC DC converter 6 Remove the hold down bolts and remove the converter Installation 1 NOTE There are two locating tabs on the lower back side of the DC DC converter These tabs locate and hold...

Page 403: ...ss bar and install the ground strap nut 2 Position the cable and install the nuts 3 Connect the electrical connector 3 Connect the DC DC converter coolant lines 4 Install the HVPDB cover Install the s...

Page 404: ...wer Off EPO Interlock System 414 03A 18 Electrical Schematic 414 03A 18 Inspection and Verification 414 03A 18 Pinpoint Tests 414 03A 19 Symptom Chart 414 03A 19 Main Precharge Contactor Relay Control...

Page 405: ...es 414 03A 109 High Voltage Power Distribution Box HVPDB 414 03A 111 High Voltage Wiring 414 03A 117 High Voltage Wiring Sensory Lead Harness 10B694 414 03A 112 Traction Battery 414 03A 120 Traction B...

Page 406: ...d Two Pin High Voltage 5 44 5 Bolts Connector Nuts Grille Screws 1 5 13 5 76 Pin Connector Bolt 4 8 43 Ground Strap Bolt 12 107 Harness Bracket Bolt 5 4 48 General Specifications High Voltage Fuse Bol...

Page 407: ...interrupt lays across the bottom of the supporting tray The high voltage to the vehicle upper levels have individual heating elements Emergency Power Off EPO Interlock System attached to each module T...

Page 408: ...to the ON position and monitors its status through a feedback line from the contactor box The IAA module sets DTC C1862 if it detects the auxiliary contactor open when it should be closed and closed w...

Page 409: ...ON monitor IAA module PID AUXHVB Yes GO to A3 Does the AUXHVB PID indicate AVAILA No If AUXHVB PID indicates UNAVAI RETRIEVE DTCs from the battery control module BCM REFER to Section 100 07 If AUXHVB...

Page 410: ...CK CIRCUIT 3998 GY BETWEEN IAA MODULE AND TRACTION BATTERY SUPPORT TRAY FOR SHORT TO POWER With key OFF disconnect traction battery support tray in line C1939 Yes REPAIR the GY wire between the IAA mo...

Page 411: ...CHECK AUXILIARY CONTACTOR RELAY STATUS SIGNAL OPEN FAULT Connect 104 Pin Breakout Box BOB to IAA module and IAA module Yes System OK CHECK wiring C1945 for intermittent connections Enter IAA module a...

Page 412: ...the wire s in question WARNING The traction battery contains high voltage components and wiring High voltage insulated safety gloves and face shield must be worn when performing the following steps F...

Page 413: ...The TIM when the ignition key is turned to the ON receives high voltage power when the position The TIM sets DTC C1862 if the contactor box main contactor closes The TIM precharge sequence fails If t...

Page 414: ...ut Box BOB Overlay 418 F220 Continued PINPOINT TEST A DTC B1676 BATTERY PACK VOLTAGE OUT OF RANGE TEST STEP ACTION TO TAKE A1 CHECK FOR INTERFACE ADAPTER ASSEMBLY IAA MODULE AND BATTERY CONTROL MODULE...

Page 415: ...ith key ON monitor TIM PID BAT PV Yes System OK CHECK wiring for intermittent connections Turn the ignition key to the START position No If less than 50 volts GO to Does the BAT PV PID indicate betwee...

Page 416: ...an 5 ohms A10 CHECK CIRCUIT 3986 DG BETWEEN CONTACTOR BOX AND TRACTION BATTERY SUPPORT TRAY FOR SHORT TO GROUND With key OFF measure the resistance between BOB pin 23 and ground Yes GO to A11 BOB pin...

Page 417: ...RT TRAY FOR OPEN With key OFF disconnect TIM C4998 and measure the resistance of the Yes GO to B7 T wire between pin 18 on TIM C4998 and BOB pin 22 Is the resistance less than 5 ohms No REPAIR the T w...

Page 418: ...OK CHECK wiring and monitor TIM PID BAT PV for intermittent connections Does the voltage for the BAT PV PID decrease No GO to B12 B12 CHECK MAIN AND PRECHARGE CONTACTOR RELAY OUTPUTS Connect 104 Pin B...

Page 419: ...uck closed Additionally the BCM sets DTC C1862 if the traction inverter module TIM detects a welded main contactor relay and sends the BCM a disable charging message The BCM also sets DTC C1862 before...

Page 420: ...do so Remove the traction battery No GO to A4 WARNING The traction battery contains high voltage components and wiring High voltage insulated safety gloves and face shield must be worn when performin...

Page 421: ...With key OFF disconnect contactor box C1982 and measure the Yes REPLACE the contactor resistance of the W wire between pin 3 on contactor box C1982 and box BOB pin B7 Is the resistance less than 5 oh...

Page 422: ...BCM TIM Breakout Box BOB Adapter Cable Tool 418 F207 418 F212 Continued PINPOINT TEST A DTC B2517 EMERGENCY POWER OFF SYSTEM FAULTED TEST STEP ACTION TO TAKE A1 CHECK FUSE Check 15A fuse 7 in the elec...

Page 423: ...between the LB W wire terminal and O wire Yes REPAIR the O wire terminal on the inertia switch with the inertia switch in the deactivated between the inertia switch depressed position and in line C19...

Page 424: ...ion battery support tray in line C1939F and traction battery support tray C3994M With key OFF measure the voltage between BOB pin 47 and ground No REPAIR circuit 974 O BOB pin 65 wire between in line...

Page 425: ...iagnostic Trouble Code DTC Definition Manual Cell 16 Traction Battery System for The following DTC relates to the main and schematic and connector information auxiliary current sensors in the contacto...

Page 426: ...HECK STATUS OF CONTACTOR BOX AUXILIARY CURRENT SENSOR With key ON monitor battery control module BCM PID AUX SEN Yes GO to A2 Does the AUX SEN PID indicate between 0 5 and 4 5 volts No GO to A4 A2 CHE...

Page 427: ...measure the resistance between BOB pin A17 and ground Yes GO to A7 BOB pin A33 Is the resistance greater than 10 000 ohms No REPAIR the LB wire A7 CHECK CIRCUIT 3705 LB FOR SHORT TO POWER With key ON...

Page 428: ...line C1935M Connect Traction Battery Low Voltage Service Cord to traction battery support tray in line C1939F and in line C1939M Connect 104 Pin Breakout Box BOB to BCM and BCM C1986 C1987 using the...

Page 429: ...eakage schematic and connector information detection Inspection and Verification DTC C1839 Leakage Fault Refer to Section 100 07 Current leakage is a low level of impedance between vehicle chassis and...

Page 430: ...Auxiliary Interlock Tool 418 F208 Special Tool s Traction Battery High Voltage Service Cord 418 F218 104 Pin Breakout Box BOB 418 049 014 00950 or Traction Battery Low Voltage Service Cord 418 F219 eq...

Page 431: ...rning may result in severe personal injury or death Connect Traction Battery Low Voltage Service Cord to traction battery support tray in line C1939F and in line C1939M With key OFF disconnect BCM hig...

Page 432: ...IN TRACTION BATTERY CHARGER POSITIVE BUS With key ON enter BCM active command mode CONTACTOR Yes GO to A59 OUTPUT CONTROL monitor BCM PID LKRESB and set the active command CHARGER to CLOSE Wait approx...

Page 433: ...s A1 and A2 If all PIDs still indicate NO CHECK the traction battery support tray for excessive moisture or water build up If OK REPLACE the BCM A13 CHECK FOR CURRENT LEAKAGE IN A C COMPRESSOR With ke...

Page 434: ...RESSOR With key OFF disconnect A C inverter motor controller IMC Yes GO to A19 high voltage C1902 to A C compressor With key ON monitor BCM PID LEAKRES No REPLACE the A C Wait approximately 50 seconds...

Page 435: ...ase cables from the Yes GO to A26 leakage is in TIM and reconnect the traction battery high voltage two pin C3994 TIM or high voltage cables to TIM With key ON monitor BCM PID LEAKRES No REPLACE the W...

Page 436: ...s warning may result in severe personal injury or death With key OFF disconnect contactor box C1864 With key ON monitor BCM PID LEAKRES Wait approximately 50 seconds Does the LEAKRES PID indicate less...

Page 437: ...TIM MOTOR TRANSAXLE OR IN THE AUXILIARY NEGATIVE BUS FOR THE HIGH VOLTAGE AUXILIARY LOAD COMPONENTS With key OFF disconnect high voltage auxiliary load in line C1935 on Yes GO to A36 leakage is in th...

Page 438: ...ts and wiring High voltage insulated safety gloves and face shield must be worn when performing the following steps Failure to follow this warning may result in severe personal injury or death Connect...

Page 439: ...th key OFF disconnect PTC switching module high voltage C1912 Yes GO to A46 With key ON monitor BCM PID LKRESB No REPLACE the PTC heater Wait approximately 50 seconds REFER to Section 412 02 Does the...

Page 440: ...battery high voltage two pin Yes GO to A52 leakage is in C3994 and the traction motor three phase cables from the TIM and TIM or high voltage cables reconnect the traction battery high voltage two pi...

Page 441: ...tion Battery Low Voltage Service Cord to traction battery No GO to A56 leakage is in support tray in line C1939F and in line C1939M battery heater harness WARNING The traction battery contains high vo...

Page 442: ...mately 50 seconds Does the LKRESB PID indicate less than 50 000 ohms A60 CHECK FOR CURRENT LEAKAGE IN AUXILIARY LOAD POSITIVE BUS CONTACTOR BOX OR HVPDB With key OFF disconnect high voltage auxiliary...

Page 443: ...Yes REPLACE the HVPDB HVPDB cover and disconnect HVPDB C1914 to DC DC converter Reinstall the HVPDB cover No REPLACE the DC DC With key ON monitor BCM PID LKRESB converter REFER to Section Wait approx...

Page 444: ...BOO TIM PID indicate OFF with the brake pedal not No GO to A2 depressed and ON with the brake pedal depressed A2 CHECK FUSE AND POWER TO BRAKE PEDAL POSITION BPP SWITCH With key OFF check 10A fuse 13...

Page 445: ...n B21 Is the resistance less than 5 ohms A8 CHECK CIRCUIT 3600 R W FOR SHORT TO POWER Connect 104 Pin Breakout Box BOB to TIM C4998 C4999 using the Yes REPAIR the R W wire BCM TIM BOB Adapter Cable an...

Page 446: ...s B6 CHECK CIRCUIT 3603 R FOR SHORT TO GROUND With key OFF measure the resistance between BOB pin B23 and ground Yes REPLACE the TIM REFER BOB pin A29 to Section 303 14 Is the resistance greater than...

Page 447: ...er The battery control module BCM sets DTC A charger undercurrent fault occurs if the C1863 if the on plug circuit indicates the BCM commands maximum power output from vehicle is plugged into a power...

Page 448: ...ontrol module BCM Upper battery module heater s Lower battery heater DTC C1838 Charging System Charger charging fault GO to Pinpoint Test C Fault Charger over temperature fault Charger latchup fault C...

Page 449: ...t N Traction battery charger Battery control module BCM DTC C1859 PRNDL Input 2 Circuit s GO to Pinpoint Test P Circuit Failure Battery control module BCM DTC C1861 PRNDL Input 4 Circuit s GO to Pinpo...

Page 450: ...o follow this warning may result in severe personal injury or death Connect 104 Pin Breakout Box BOB to BCM C1986 C1987 using the BCM TIM BOB Adapter Cable and Overlay leave the BCM disconnected Measu...

Page 451: ...Low Voltage Service Cord to traction battery Yes REPAIR the BR W wire support tray in line C1939F and in line C1939M 1 DG wire 2 R W With key OFF disconnect high voltage auxiliary load in line C1935...

Page 452: ...DISCONNECT PCS from BCM vehicle GO to B2 Does DTC C1838 Charging System Fault occur B2 CHECK STATUS OF AUXILIARY CURRENT NOTE The amperage for the AUX CNT PID should increase by more Yes GO to B3 tha...

Page 453: ...859 each upper battery module heater the resistance should be between 28 and 32 ohms REPLACE the battery module heater s in question With key OFF disconnect upper battery heater C1861 and measure the...

Page 454: ...es GO to B14 support tray in line C1935F and in line C1935M Connect Traction Battery Low Voltage Service Cord to traction battery No GO to B13 support tray in line C1939F and in line C1939M Connect 10...

Page 455: ...e vehicle is connected to the power control station PCS and Yes DISCONNECT the PCS the START button has been depressed to begin charging from the vehicle GO to D2 NOTE Wait approximately up to five mi...

Page 456: ...Is the resistance less than 5 ohms D6 CHECK CIRCUIT 3827 GY W INSIDE OF TRACTION BATTERY SUPPORT TRAY FOR SHORT TO GROUND With key OFF measure the resistance between BOB pin 57 and ground Yes REPLACE...

Page 457: ...traction battery Yes GO to F5 and connect Traction Battery High Voltage Lockout and Diagnostic Tool to the traction battery high voltage two pin C3994M No REPAIR the LG BK wire WARNING The traction ba...

Page 458: ...gloves and face shield must be worn when performing the following steps Failure to follow this warning may result in severe personal injury or death Disconnect HVPDB traction battery charger high volt...

Page 459: ...GER fuse Measure the resistance of the 25A CHARGER fuse No REPLACE the contactor Is the resistance greater than 1 000 ohms box H7 CHECK CHARGER CONTACTOR RELAY CONTROL CLOSE SIGNAL Reconnect contactor...

Page 460: ...he resistance of the DB LG wire between pin 3 question on traction battery charger C1993 and BOB pin 63 With key OFF measure the resistance of the PK wire between pin 3 on traction battery charger C19...

Page 461: ...Traction Battery High Voltage Yes GO to K2 Lockout and Diagnostic Tool to the traction battery high voltage two pin C3994M No REPLACE high voltage harness 14A280 WD WARNING The traction battery contai...

Page 462: ...ort tray in line C1939 and Yes GO to N4 connect 104 Pin Breakout Box BOB to in line C1939M using Traction Battery Low Voltage Service Cord do not connect Traction Battery Low Voltage Service Cord to i...

Page 463: ...Traction Battery High Voltage Lockout and Diagnostic Tool to the traction battery high voltage two pin C3994M No REPAIR the BR Y wire WARNING The traction battery contains high voltage components and...

Page 464: ...the DB wire between pin 17 on BCM C1987 and BOB pin 40 Is the resistance less than 5 ohms P4 CHECK FOR INTERMITTENT CONCERN S With key OFF reconnect DTR sensor C4996 and BCM C1987 Yes REPLACE the BCM...

Page 465: ...e charger inlet before performing this test step With key ON monitor BCM PID CHGCORD Does the CHGCORD PID indicate IN No System OK CHECK wiring for intermittent connections R2 CHECK CHARGER INLET CONN...

Page 466: ...OF BATTERY PACK TEMPERATURE FAULT With key ON monitor battery control module BCM PIDs HIGHTMP Yes If PID HIGHTMP indicates and FAN DIS YES ALLOW vehicle to cool Monitor BCM PIDs TMPSEN1 TMPSEN2 TMPSE...

Page 467: ...ing the No GO to T4 power off may allow the PCS to clear the fault Turn the PCS power back on and plug the vehicle back in Is the Service light illuminated T4 CHECK READY AND CHARGING LIGHTS EVI MANUF...

Page 468: ...Circuit s Traction battery cooling fan relay Traction battery cooling fan Battery control module BCM Special Tool s Pinpoint Tests Traction Battery High Voltage Service Cord 418 F218 Special Tool s T...

Page 469: ...K POWER TO TRACTION BATTERY COOLING FAN Disconnect BOB from in line C1939M remove the traction battery and Yes REMOVE the jumper wire connect Traction Battery High Voltage Lockout and Diagnostic Tool...

Page 470: ...oling fan Enter BCM active command mode FAN SPEED CONTROL set active No REPLACE the BCM command FAN SPEED to 50 and measure the frequency between pin A O LB wire on traction battery cooling fan C1984...

Page 471: ...gh voltage insulated safety gloves and face shield must be worn when performing the following steps Failure to follow this warning may result in severe personal injury or death Connect Traction Batter...

Page 472: ...8 volt traction battery modules through voltage sense lines The Press 7 PIDS button and highlight BAT_MV BCM can sense the battery module voltages if they are within the range of 3 and 14 volts Hit S...

Page 473: ...detects the wrong hardware lead acid Electrical Schematic BCM in a NiMH battery pack has been installed into the battery pack Refer to Electrical and Vacuum Troubleshooting Manual Cell 16 Traction Bat...

Page 474: ...ut Box BOB Adapter Cable High Voltage Insulated Safety Gloves 100 F036 or 418 F212 equivalent BCM TIM Breakout Box BOB Overlay 418 F220 Face Shield 100 F035 or equivalent Continued PINPOINT TEST A DTC...

Page 475: ...7 B2 CHECK BATTERY MODULE FAULT STATUS With key ON monitor BCM PIDs BTM 1FT thru BTM39FT Yes GO to B3 Do any of the battery module fault PIDs indicate YES No GO to B6 B3 CHECK VOLTAGE SENSE LINE CIRCU...

Page 476: ...11 12 circuit 3082 BK LG between in line C1879M label G and pin 23 on BCM C1865 12 13 circuit 3083 Y W between in line C1874M label J and pin 24 on BCM C1865 13 14 circuit 3084 BK PIK between in line...

Page 477: ...CM C1866 37 38 circuit 3209 W BK between in line C1886M label U and pin 28 on BCM C1866 38 39 circuit 3210 LG W between in line C1887M label V and pin 38 on BCM C1866 39 circuit 3211 W LB between in l...

Page 478: ...8 19 between circuit 3090 P on in line C1869F label F and battery module 18 post 19 20 between circuit 3091 LB BK on in line C1868F label M and battery module 19 post 20 21 between circuit 3092 GY O o...

Page 479: ...tion high voltage two pin C3994M Connect Traction Battery High Voltage Service Cord to traction battery No ENTER the indicated data support tray in line C1935F and in line C1935M REPLACE the battery m...

Page 480: ...T 3215 PK BK BETWEEN BCM AND IN LINE C1882M FOR OPEN With key OFF disconnect BCM high voltage C1865 and in line C1882 Yes GO to B10 label R With key OFF measure the resistance of the PK BK wire betwee...

Page 481: ...olt monitor BCM PID BAT MV set the NGS Setup to AUTO and dial battery module s and the active command BATTERY through all 39 battery modules to INSTALL an 8 volt battery determine the 12 volt battery...

Page 482: ...or Auxiliary battery indicator Electrical hazard warning indicator may or may not illuminate Do all the instrument cluster indicators listed above illuminate No REFER to the Powertrain Diagnostic Rout...

Page 483: ...iliary load systems operate GO to A2 With key ON operate the heater and air conditioner if equipped If some of the high voltage Do all the high voltage auxiliary load systems operate auxiliary load sy...

Page 484: ...he R wire on contactor box C3985 and chassis ground Is the voltage greater than 10 volts GENERAL PROCEDURES Module Charging Special Tool s 8 Volt Battery Charger 418 F214 1 CAUTION Do not use any char...

Page 485: ...tenance mode 6 If the green and red lights flash sequentially the charger to module polarity is incorrect and must be corrected before module charging can begin Traction Battery Module Replacement Spe...

Page 486: ...ery modules need to be replaced do not replace the traction battery cover or install the traction battery at the end of the procedure Repeat the battery module removal and installation process until a...

Page 487: ...ts 2 Remove the cover 9 Check the specific battery module number procedure for specific removal information The battery modules are grouped as follows 1 7 17 18 19 21 8 11 34 39 12 15 and 28 31 16 and...

Page 488: ...ent Data Form The form is located on the Electric Ranger Service Card that is inside the traction battery support tray If more than 5 modules are to be replaced refer to Traction Battery Temperature S...

Page 489: ...battery module or damage to both may occur If the battery module that was removed is equipped with a temperature sensor remove the sensor Pull the bottom of the temperature sensor from the battery mod...

Page 490: ...on Battery High Voltage Service Cord to the traction battery high voltage auxiliary load connector on the traction battery 26 Connect the Traction Battery Low Voltage Service Cord to the 76 pin low vo...

Page 491: ...arger inlet connector 1 Press and hold the release button 2 Lift and disconnect the PCS from the charger inlet connector 31 NOTE Electric Ranger shown Postal Ranger EV similar Close the charge inlet a...

Page 492: ...ll new module number decals on the replacement battery module positive terminal side 39 NOTE When viewing a heater element with the adhesive side on the back the elements with the male electrical conn...

Page 493: ...close the caps 42 Install the separator plates above the battery module s that were installed 43 Enter the indicated data on the Dealer Battery Return Form that is packaged with the new battery modul...

Page 494: ...25 27 and 22 24 Refer to the specific Traction Battery Module procedure 50 Disconnect the Traction Battery High Voltage Service Cord from the high voltage auxiliary load connector on the vehicle 51 D...

Page 495: ...m the 76 pin low voltage connector on the vehicle 54 Apply Locktite 242 threadlock and sealer to the 22 traction battery cover bolts 55 Install the traction battery cover Install the 22 bolts 56 Remov...

Page 496: ...414 03A 93 414 03A 93 High Voltage Traction Battery GENERAL PROCEDURES Continued Traction Battery Tray Repair Battery Tray 2001 Ranger EV 01 2001...

Page 497: ...of the composite material 2 A crack in the composite material less than 25 mm 1 in in length can also be repaired A crack is damage that passes all the way through the outer layer of the composite mat...

Page 498: ...y GENERAL PROCEDURES Continued 4 To repair cracks less than 25 mm 1 in in length clean the area surrounding the damage prior to repair After cleaning grind a 20 degree bevel extending 40 to 50 mm 1 57...

Page 499: ...the composite member as illustrated 6 Allow the patched area to cure for at least 1 5 to 2 hours at 24 C 75 F Curing will take longer at colder temperatures A heat lamp placed no less than 45 cm 18 in...

Page 500: ...he composite material to excessive heat Once the adhesive softens the part can be removed and discarded 2 Scrape and sand off all of the remaining adhesive The surface must be clean and roughly sanded...

Page 501: ...on the battery tray by pealing back the white strip to expose the adhesive Start at one end of the seal to maintain a good fit 6 Press down continuously along the entire length of the seal to ensure a...

Page 502: ...ecautions may result in severe personal injury or death Observe the EV specific precautions Refer to Section 100 00 1 Set up the buffer zone 2 Test and wear the insulated rubber gloves 3 Wear the face...

Page 503: ...emoval procedure Fill the area around the high voltage jumper nuts with Nyogel Apply Locktite 242 to the 22 traction battery cover bolts After installation connect the New Generation STAR NGS Tester T...

Page 504: ...ry load high voltage connector Refer to Section 100 05 2 Remove the grille 1 Remove the four screws 2 Remove the grille 3 NOTE The low voltage connector is located at the rear of the charger inlet Dis...

Page 505: ...NSTALLATION Continued 5 Remove the two charge bracket bolts 6 Remove the charge inlet 1 Loosen the two charge inlet bracket bolts 2 Slide the charge inlet from behind the bolts and remove Installation...

Page 506: ...03 High Voltage Traction Battery REMOVAL AND INSTALLATION Continued Contactor Box Special Tool s Battery Terminal Cap Opener 418 F215 Removal 1 Remove the traction battery Refer to Traction Battery 20...

Page 507: ...olts The buffer zone must be set up and insulated rubber gloves and a face shield must be worn Failure to follow these precautions may result in severe personal injury or death Observe the EV specific...

Page 508: ...Pull the connectors off the contactor box 7 Disconnect one HVJ from module 17 8 CAUTION Disconnect only one HVJ at a time Disconnect the HVJs from the contactor box Use the Battery Terminal Cap Opene...

Page 509: ...nclip the contactor box harness from the separator plate 2 Remove the contactor box Installation 1 To install reverse the removal procedure 1 Fill the high voltage jumper connectors with Nyogel after...

Page 510: ...Traction Battery REMOVAL AND INSTALLATION Continued Contactor Box Fuses Removal 1 Remove the traction battery Refer to Traction Battery 2 Remove the traction battery cover 1 Remove the 22 bolts 2 Rem...

Page 511: ...precautions may result in severe personal injury or death Observe the EV specific precautions Refer to Section 100 00 1 Set up the buffer zone 2 Test and wear the insulated rubber gloves 3 Wear the fa...

Page 512: ...the removal procedure Apply Locktite 242 to the 22 traction battery cover bolts HVPDB Fuses Removal 1 Disconnect the traction battery auxiliary load high voltage connector Refer to Section 100 05 2 Re...

Page 513: ...DB fuse safety cover 1 Remove the two screws 2 Remove the cover 4 Use a fuse puller to remove the necessary fuse 1 10A Power Steering Fuse 2 25A Positive Temperature Coefficient PTC Heater Fuse 3 25A...

Page 514: ...ALLATION Continued High Voltage Power Distribution Box HVPDB Removal 1 Remove the positive temperature coefficient PTC module Refer to Section 412 04 2 Disconnect the power steering pump electrical co...

Page 515: ...on with three clips Remove the HVPDB 1 Remove the bolts 2 Remove the HVPDB Installation 1 To install reverse the removal procedure High Voltage Wiring Sensory Lead Harness 10B694 Removal 1 Remove the...

Page 516: ...njury or death Observe the EV specific precautions Refer to Section 100 00 1 Set up the buffer zone 2 Test and wear the insulated rubber gloves 3 Wear the face shield 4 Disconnect the high voltage sen...

Page 517: ...zip ties are removed from the traction battery Unclip the low and high voltage wiring harnesses from each other and from the separator plate Cut the zip tie 8 NOTE There are 20 sense lead wiring conn...

Page 518: ...REMOVAL AND INSTALLATION Continued 11 Unclip and disconnect the sense lead wiring 12 Unclip and disconnect the sense lead wiring 13 Unclip and disconnect the sense lead wiring 14 Cut the two zip ties...

Page 519: ...nued 15 Disconnect the multi pin connectors from the battery control module BCM Loosen the two bolts 16 Remove the high voltage sense lead harness Installation 1 To install reverse the removal procedu...

Page 520: ...414 03A 117 414 03A 117 High Voltage Traction Battery REMOVAL AND INSTALLATION Continued High Voltage Wiring Special Tool s Battery Terminal Cap Opener 418 F215 2001 Ranger EV 01 2001...

Page 521: ...4 03A 118 414 03A 118 High Voltage Traction Battery REMOVAL AND INSTALLATION Continued High Voltage Jumper Routing Removal 1 Remove the traction battery Refer to Traction Battery 2001 Ranger EV 01 200...

Page 522: ...lt in severe personal injury or death Observe the EV specific precautions Refer to Section 100 00 1 Set up the buffer zone 2 Test and wear the insulated rubber gloves 3 Wear the face shield 4 Refer to...

Page 523: ...he battery module route the sense lead wiring under the HVJ cable Refill the HVJ caps with Nyogel after tightening the nuts Apply Locktite 242 to the 22 traction battery cover bolts Traction Battery R...

Page 524: ...utions may result in severe personal injury or death Observe the EV specific precautions Refer to Section 100 00 1 Set up the buffer zone 2 Test and wear the insulated rubber gloves 3 Wear the face sh...

Page 525: ...that the safety locks on the lift are engaged 9 Adjust the lift table so it is parallel with the battery pack Turn the adjustment screw at the front of the lift table to vary the angle of the lift ta...

Page 526: ...ssure equalizes and both gauges reach 60 psi 13 NOTE There are three mounting bolts on both the left and right sides of the traction battery Remove the six mounting bolts from the battery pack 14 Lowe...

Page 527: ...vehicle and battery pack are aligned during battery pack installation Lift the battery pack up into the mounting position 5 NOTE The LH front bolt must be installed first in order to properly align t...

Page 528: ...ector 1 Position the connector 2 Tighten the bolt 9 Connect the traction battery auxiliary load high voltage connector Refer to Section 100 05 10 Connect the traction battery two pin high voltage conn...

Page 529: ...inued 3 Remove the harness bracket Remove the bolt 4 Remove the A C inverter motor controller IMC bracket 1 Remove the bolts 2 Remove the bracket 5 Remove the ground strap bolt 6 Remove the traction b...

Page 530: ...414 03A 127 414 03A 127 High Voltage Traction Battery REMOVAL AND INSTALLATION Continued Installation 1 To install reverse the removal procedure 2001 Ranger EV 01 2001...

Page 531: ...ilation Fan Removal 1 Remove the traction battery Refer to Traction Battery 2 Remove the traction battery cover 1 Remove the 22 bolts 2 Remove the cover 3 Remove the traction battery cooling fan 1 Dis...

Page 532: ...414 03A 129 414 03A 129 High Voltage Traction Battery REMOVAL AND INSTALLATION Continued Installation 1 To install reverse the removal procedure 2001 Ranger EV 01 2001...

Page 533: ...and the battery module must be removed in order to replace the heating element Refer to the specific traction battery module procedure in this section Modules 1 4 20 and 21 are equipped with LH heate...

Page 534: ...action Battery High Voltage Fuse 250A Special Tool s Battery Terminal Cap Opener 418 F215 Removal 1 Remove the traction battery Refer to Traction Battery 2 WARNING The nominal voltage of the traction...

Page 535: ...ove the nut 2 Move the fuse up and out of the traction battery pack 5 WARNING Do not allow the HVJs to touch each other once they are removed from the high voltage fuse The HVJs contain high DC voltag...

Page 536: ...Fill the area around the high voltage fuse bolts with Nyogel Apply Locktite 242 to the 22 traction battery cover bolts Traction Battery Module Modules 1 7 Removal 1 The battery modules are located on...

Page 537: ...faulty battery module s Refer to Battery Control Module BCM Installation 1 The battery module replacement procedure also contains the battery module installation Traction Battery Module Modules 19 21...

Page 538: ...lure to follow these precautions may result in severe personal injury or death Observe the EV specific precautions Refer to Section 100 00 1 Set up the buffer zone 2 Test and wear the insulated rubber...

Page 539: ...ting Tool to install the battery modules Install and tighten new battery module nuts using the Battery Post Torque Wrench Install the separator plates Connect the heating element connectors Clip the c...

Page 540: ...emove battery modules 1 7 Unclip and disconnect the heating element electrical connectors Remove the separator plates Remove and discard the high voltage jumper retaining nuts Use the Battery Module L...

Page 541: ...tor Box Traction Battery Module Modules 12 15 28 31 Removal 1 The battery modules are located in the lower center section of the traction battery and have no other battery modules above them Replace t...

Page 542: ...ilure to follow these precautions may result in severe personal injury or death Observe the EV specific precautions Refer to Section 100 00 1 Set up the buffer zone 2 Test and wear the insulated rubbe...

Page 543: ...fting Tool to install the battery modules Install and tighten new battery module nuts using the Battery Post Torque Wrench Install the separator plates Connect the heating element connectors Clip the...

Page 544: ...ace shield 3 Remove battery modules 17 21 Unclip and disconnect the heating element electrical connectors Remove the separator plates Remove and discard the high voltage jumper retaining nuts Use the...

Page 545: ...dules17 18 2 The 2 temperature sensor is located on the negative side of the 6 traction battery module To remove the temperature sensor remove traction battery module 6 Refer to Traction Battery Modul...

Page 546: ...dule or damage to both may occur Remove the temperature sensor Pull the bottom of the temperature sensor from the battery module and remove the sensor Installation 1 Apply a thin coat of thermal greas...

Page 547: ...ltage Traction Battery DISASSEMBLY AND ASSEMBLY Traction Battery Temperature Sensor Special Tool s Battery Terminal Cap Opener 418 F215 Battery Module Lifting Tool 418 F206 Battery Post Torque Wrench...

Page 548: ...414 03A 145 414 03A 145 High Voltage Traction Battery DISASSEMBLY AND ASSEMBLY Continued Traction Battery LH View 2001 Ranger EV 01 2001...

Page 549: ...er Level Heating Elements 1 Battery Control Module BCM 7 Separator Plate 2 Contactor Box Harness 8 Low Voltage Harness 3 High Voltage Sensor Lead Harness 10B694 9 Traction Battery Cooling Fan Relay 4...

Page 550: ...414 03A 147 414 03A 147 High Voltage Traction Battery DISASSEMBLY AND ASSEMBLY Continued Traction Battery RH View 2001 Ranger EV 01 2001...

Page 551: ...6 Pin Connector 13 Low Voltage Harness 10B691 8 Battery Control Module BCM 14 Battery Module Continued Disassembly 1 Remove the traction battery Refer to Traction Battery 2 Remove the traction battery...

Page 552: ...low and high voltage wiring harnesses from each other and from the separator plate Cut the zip tie 6 Unclip the low and high voltage wiring harnesses from each other and from the separator plate Cut...

Page 553: ...tery DISASSEMBLY AND ASSEMBLY Continued 8 Unclip and disconnect the sense lead wiring 9 Unclip and disconnect the sense lead wiring 10 Unclip and disconnect the sense lead wiring 11 Unclip and disconn...

Page 554: ...voltage harness 14 NOTE The battery control module BCM is held in position with strips of VelcroTM Remove the BCM 1 Loosen the four bolts and disconnect the four multi pin connectors from the BCM 2 R...

Page 555: ...om contacting one another Disconnect the HVJs from the contactor box one at a time Use the Battery Terminal Cap Opener to open the battery module caps Remove the two bolts Wrap the HVJs with orange el...

Page 556: ...Unclip the heating element connector 2 Unclip the temperature sensor connector 3 Unclip and disconnect the traction battery high voltage two pin connector 4 Remove the contactor box 22 Unclip the low...

Page 557: ...e temperature sensor 26 Disconnect the temperature sensor 27 NOTE The low voltage harness remains connected to the traction battery at the 76 pin connector Remove the low voltage harness from the trac...

Page 558: ...ator plates 31 Remove all of the upper level battery module HVJs and discard the nuts Use the Battery Terminal Cap Opener to open the battery module caps 32 Use Battery Module Lifting Tool to remove a...

Page 559: ...overheat the sensor or the battery module or damage to both may occur Remove the temperature sensors that are attached to the two upper battery modules Pull the bottom of the temperature sensor from t...

Page 560: ...Use Battery Module Lifting Tool to remove all of the lower level battery modules 38 Remove the cross bar blower bracket 1 Remove the two nuts 2 Remove the cross bar blower bracket 39 Remove the lower...

Page 561: ...t in the bottom of the battery tray and apply the battery module numbers to the blanket as illustrated 2 NOTE This step only applies to initial traction battery build up These components were not sepa...

Page 562: ...t gun to warm the temperature sensor prior to installation 6 Apply a thin layer of thermal grease to the back of the thermistor 7 CAUTION Do not use excessive force to install the temperature sensor o...

Page 563: ...nstalled with the terminals oriented as illustrated Install the 27 lower level battery modules Label the battery modules as illustrated NOTE The high voltage jumper HVJ retaining nuts are hand tighten...

Page 564: ...414 03A 161 414 03A 161 High Voltage Traction Battery DISASSEMBLY AND ASSEMBLY Continued 10 Install the W HVJ Install the 39 nut 2001 Ranger EV 01 2001...

Page 565: ...414 03A 162 414 03A 162 High Voltage Traction Battery DISASSEMBLY AND ASSEMBLY Continued 11 Install the V HVJ 1 Install the 39 nut 2 Install the 38 nut 2001 Ranger EV 01 2001...

Page 566: ...Voltage Traction Battery DISASSEMBLY AND ASSEMBLY Continued 12 Install the U HVJ 1 Install the 35 nut 2 Install the 36 nut 3 Install the 37 nut 4 Install the 38 nut 5 Install the 36 nut 6 Install the...

Page 567: ...Voltage Traction Battery DISASSEMBLY AND ASSEMBLY Continued 13 Install the T HVJ 1 Install the 32 nut 2 Install the 33 nut 3 Install the 33 nut 4 Install the 34 nut 5 Install the 34 nut 6 Install the...

Page 568: ...ASSEMBLY Continued 14 Install the G HVJ 1 Install the 8 nut 2 Install the 9 nut 3 Install the 11 nut 4 Install the 12 nut 5 Install the 9 nut 6 Install the 10 nut 7 Install the 8 nut The remaining en...

Page 569: ...Voltage Traction Battery DISASSEMBLY AND ASSEMBLY Continued 15 Install the S HVJ 1 Install the 31 nut 2 Install the 32 nut 3 Install the 29 nut 4 Install the 30 nut 5 Install the 28 nut 6 Install the...

Page 570: ...167 414 03A 167 High Voltage Traction Battery DISASSEMBLY AND ASSEMBLY Continued 16 Install the R HVJ 1 Install the 10 nut 2 Install the 11 nut 3 Install the 13 nut 4 Install the 14 nut 2001 Ranger EV...

Page 571: ...414 03A 168 414 03A 168 High Voltage Traction Battery DISASSEMBLY AND ASSEMBLY Continued 17 Install the K HVJ 1 Install the 14 nut 2 Install the 15 nut 2001 Ranger EV 01 2001...

Page 572: ...Voltage Traction Battery DISASSEMBLY AND ASSEMBLY Continued 18 Install the J HVJ 1 Install the 30 nut 2 Install the 31 nut 3 Install the 15 nut 4 Install the 16 nut 5 Install the 12 nut 6 Install the...

Page 573: ...Voltage Traction Battery DISASSEMBLY AND ASSEMBLY Continued 19 Install the L HVJ 1 Install the 27 nut 2 Install the 28 nut 3 Install the 16 nut The remaining end is not connected at this time Close th...

Page 574: ...Voltage Traction Battery DISASSEMBLY AND ASSEMBLY Continued 20 Install the N HVJ 1 Install the 26 nut 2 Install the 27 nut 3 Install the 24 nut 4 Install the 25 nut 5 Install the 26 nut 6 Install the...

Page 575: ...414 03A 172 414 03A 172 High Voltage Traction Battery DISASSEMBLY AND ASSEMBLY Continued 21 Install the E HVJ 1 Install the 22 nut 2 Install the 23 nut 2001 Ranger EV 01 2001...

Page 576: ...414 03A 173 414 03A 173 High Voltage Traction Battery DISASSEMBLY AND ASSEMBLY Continued 22 Install the P HVJ 1 Install the 23 nut 2 Install the 24 nut 2001 Ranger EV 01 2001...

Page 577: ...Battery DISASSEMBLY AND ASSEMBLY Continued 23 Install the M HJV Install the 22 nut The remaining end is not connected at this time Close the cap 24 Using the Battery Post Torque Wrench tighten the HVJ...

Page 578: ...the inside of the battery tray Install the 76 pin connector Clip the bottom of the connector into the tray first then the top 27 NOTE This step only applies to initial traction battery build up These...

Page 579: ...ese strips are for holding the contactor box in position Install the rear separator plates 30 Use a heat gun to warm the temperature sensor prior to installation 31 Apply a thin coat of thermal grease...

Page 580: ...ules 1 Apply the heating element to battery module 21 on the side facing out and install the battery module 2 Apply the heating element to battery module 20 on the side facing battery module 21 and in...

Page 581: ...the battery module 18 female connector to the battery module 17 male connector 36 Install the upper rear battery modules 1 Apply the heating element to battery module 1 on the side facing out and inst...

Page 582: ...le 3 Apply the heating element to battery module 4 on the side facing battery module 3 and install the battery module 4 Apply the heating element to battery module 5 on the side facing out and install...

Page 583: ...Traction Battery DISASSEMBLY AND ASSEMBLY Continued 38 Install the D HVJ 1 Install the 6 nut 2 Install the 7 nut 39 Install the B HVJ 1 Install the 2 nut 2 Install the 3 nut 3 Install the 4 nut 4 Inst...

Page 584: ...Traction Battery DISASSEMBLY AND ASSEMBLY Continued 40 Install the A HVJ 1 Install the 3 nut 2 Install the 4 nut 3 Install the 1 nut 4 Install the 2 nut 41 Install the L HVJ 1 Install the 5 nut 2 Inst...

Page 585: ...nued 42 Connect the remaining G HVJ end from the lower level battery module to the 7 battery module terminal Install the nut 43 NOTE The remaining end of the H HVJ is not connected at this time Connec...

Page 586: ...d around the rear of the battery modules Install the F HVJ 1 Install the 20 nut 2 Install the 21 nut 3 Install the 17 nut 4 Install the 18 nut 5 Install the 19 nut 6 Install the 18 nut 45 Connect the...

Page 587: ...battery Do not touch the contactor box HVJs or allow them to touch each other Connect the remaining L HVJ end from the lower level battery module Install the nut 47 Using the Battery Post Torque Wrenc...

Page 588: ...actor box HVJs with orange electrical tape to prevent contact or shorting 51 NOTE The HVJ wiring that runs between the battery modules must fit into the separators Install the front battery module sep...

Page 589: ...Battery DISASSEMBLY AND ASSEMBLY Continued 54 Install the two pin connector in the tray 1 Position the connector 2 Install the four nuts 55 Mount the fuse 1 Position the fuse bracket on the left rear...

Page 590: ...s part of the 76 pin harness 1 Position the harness with the two BCM connectors at the front of the pack 2 Push the four harness clips into the separator plate 3 Clip the two harness side clips onto t...

Page 591: ...low voltage harness 59 Connect the low voltage harness to the contactor box 1 Clip the two harness clips to the contactor box 2 Connect the two pin auxiliary connector 3 Connect the temperature sensor...

Page 592: ...connectors Connect the 17 to the brown brown and white connector Connect the 26 lead to the green red connector 62 Connect the heating element connector Clip the connector on the low voltage harness c...

Page 593: ...ASSEMBLY Continued 64 Clip the three high voltage harness clips onto the separator plate 65 Clip the three high voltage harness clips onto the separator plate 66 Connect the J and S high voltage conn...

Page 594: ...ter harness connectors onto the high voltage harness 68 Connect the K and L sense lead connectors 69 Connect the T B and H sense lead connectors 1 Connect the T B and H connectors 2 Clip the H connect...

Page 595: ...High Voltage Traction Battery DISASSEMBLY AND ASSEMBLY Continued 70 Connect the G sense lead connector 71 Clip the G sense lead harness into the separator plate 72 Connect the D sense lead connector...

Page 596: ...ASSEMBLY AND ASSEMBLY Continued 73 Connect the C sense lead connector 74 Clip the heater connector into the high voltage harness 75 Clip the two heating element connectors into the high voltage harnes...

Page 597: ...tery DISASSEMBLY AND ASSEMBLY Continued 76 Connect the A sense lead and clip it into the separator plate 77 Connect the V sense lead connector Clip the sensor lead onto the separator plate 78 Connect...

Page 598: ...ND ASSEMBLY Continued 79 Connect the temperature sensor to the 2 battery module 80 Connect the heater harness connector to the contactor box 81 Connect the heating element connector to the heater harn...

Page 599: ...ors to the harness and clip them into the separator plate 83 Connect the heating element connector to the harness 84 Position the heater harness down the center of the battery around the LH front batt...

Page 600: ...across the separator plate and zip tie them into place 87 NOTE The battery module is held into place with strips of VelcroTM Install the BCM 1 Position the BCM 2 Connect the two upper high voltage con...

Page 601: ...per harness into the separator plate 90 Connect the P and M sense lead connectors Clip the P sense lead connector into the high voltage harness 91 Connect the E F and N sense lead connectors Clip the...

Page 602: ...92 Connect the heating element electrical connector and clip it into the BCM harness 93 Position the contactor box harness Clip the contactor box harness into the four high voltage harness clips 94 Cl...

Page 603: ...s to the HVJ 1 Position the bracket 2 Install the screw 3 Connect the harness to the jumper 97 Connect the HVJs to the contactor box The traction battery is now energized 1 Position the HVJs 2 Install...

Page 604: ...26 Symptom Chart 414 03B 26 Emergency Power Off EPO Interlock System 414 03B 18 Electrical Schematic 414 03B 18 Inspection and Verification 414 03B 18 Pinpoint Tests 414 03B 19 Symptom Chart 414 03B 1...

Page 605: ...trol Module BCM 414 03B 94 Charge Inlet 414 03B 96 Contactor Box 414 03B 99 Contactor Box Fuses 414 03B 103 Flow Through Blower 414 03B 124 HVPDB Fuses 414 03B 105 High Voltage Power Distribution Box...

Page 606: ...attery Hold Down 14 10 Bolts Recirculating Blower 6 53 Nuts Battery Hold Down 5 44 Strap Bolts Traction Battery Charger 22 16 Bolts Charger Inlet Bracket 7 62 5 Bolts Traction Battery Cover 17 12 5 Bo...

Page 607: ...ver Module IOM operation The BCM and the IOM are located in the The IOM is a module that monitors the traction front end of the pack The contactor box is in the battery temperature during charging usi...

Page 608: ...3 degrees Fahrenheit NOTE Most all concerns with the IOM are sensor The BCM will suspend traction battery charging if related any BCM temperature sensor exceeds 45 degrees Emergency Power Off EPO Inte...

Page 609: ...ey is turned to the ON position and monitors its status through a feedback line from the contactor box The IAA module sets DTC C1862 if it detects the auxiliary contactor relay open when it should be...

Page 610: ...o Emergency Power Off EPO Interlock System in this section A3 CHECK AUXILIARY CONTACTOR RELAY STATUS With key ON monitor IAA module PID AUX HVC Yes System OK CHECK wiring for intermittent connections...

Page 611: ...age between BOB pin 42 and ground No REMOVE the traction BOB pin 80 battery and REPAIR the GY Is the voltage greater than 0 volts wire between the contactor box and in line C1939F A10 CHECK AUXILIARY...

Page 612: ...m OK CHECK wiring C1945 for intermittent connections Enter IAA module active command mode AUXILIARY SYSTEM No GO to A15 CONTROL set the active command AUX CONT to CLOSE and measure the voltage between...

Page 613: ...g 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...

Page 614: ...gnition key is turned to the START position illuminate The TIM also performs a test to with the gear selector in the P Park or N determine if the main and or precharge Neutral position The TIM sets DT...

Page 615: ...t Non SCP occur A2 CHECK GROUND TO CONTACTOR BOX With key OFF disconnect traction battery support tray in line C1939 and Yes GO to A3 connect 104 Pin Breakout Box BOB to traction battery support tray...

Page 616: ...23 Is the resistance less than 5 ohms No REPAIR the DG wire A8 CHECK CIRCUIT 3986 DG BETWEEN TIM AND TRACTION BATTERY SUPPORT TRAY FOR SHORT TO GROUND With key OFF measure the resistance between BOB...

Page 617: ...RACTION INVERTER MODULE TIM PRECHARGE FAULT With key ON monitor TIM PID PRECH F Yes GO to B3 Does the PRECH F PID indicate YES No GO to B11 B3 CHECK STATUS OF TIM PRECHARGE BUS VOLTAGE With key ON mon...

Page 618: ...key OFF measure the resistance between BOB pin 22 and ground Yes REPLACE the contactor BOB pin 65 box Is the resistance greater than 10 000 ohms No REPAIR the T wire B10 CHECK TRACTION BATTERY VOLTAGE...

Page 619: ...tom Chart Symptom Chart Condition Possible Sources Action DTC C1862 Contactor Circuit Circuit GO to Pinpoint Test A Failure Contactor box Battery control module BCM Special Tool s Pinpoint Tests Tract...

Page 620: ...towards the front of the vehicle and the high voltage positive output pin is the pin towards the rear of the vehicle Measure the voltage between the high voltage positive post on the contactor box an...

Page 621: ...wer off EPO occurs when the contactor box outputs an EPO signal through the EPO circuit to the battery control module BCM interface adapter assembly IAA module and positive temperature coefficient PTC...

Page 622: ...than 10 volts A4 CHECK EPO DISABLE SIGNAL TO TRACTION BATTERY SUPPORT TRAY Disconnect BOB and reconnect IAA module C1945 Yes REPAIR circuit 3006 P LG wire between the IAA module and in line C1939M Wit...

Page 623: ...Yes REPLACE the contactor Lockout and Diagnostic Tool to the traction battery high voltage two pin box C3994M Connect Traction Battery High Voltage Service Cord to high voltage No REPAIR the R wire b...

Page 624: ...C1935M between the contactor box and traction battery support tray C3994M WARNING The traction battery contains high voltage components and wiring High voltage insulated safety gloves and face shield...

Page 625: ...nt sensor if the current estimate from the traction inverter module TIM is 50 amps greater than the current reading from the main current sensor Symptom Chart Symptom Chart Condition Possible Sources...

Page 626: ...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 Connect 104 Pin Breakout Box BOB to BCM C1986 C1987...

Page 627: ...und Yes GO to A11 BOB pin A33 Is the resistance greater than 10 000 ohms No REPAIR the DB wire A11 CHECK CIRCUIT 3706 DB FOR SHORT TO POWER With key ON measure the voltage between BOB pin A15 and grou...

Page 628: ...FOR SHORT TO GROUND With key OFF measure the resistance between BOB pin B22 and ground Yes REPLACE the contactor BOB pin A33 box Is the resistance greater than 10 000 ohms No REPAIR the LB BK wire El...

Page 629: ...nterlock Tool 418 F208 Special Tool s Traction Battery High Voltage Service Cord 418 F218 104 Pin Breakout Box BOB 418 049 014 00950 or Traction Battery Low Voltage Service Cord 418 F219 equivalent Hi...

Page 630: ...low this warning may result in severe personal injury or death Connect Traction Battery Low Voltage Service Cord to traction battery support tray in line C1939F and in line C1939M With key OFF disconn...

Page 631: ...T LEAKAGE IN TRACTION BATTERY CHARGER POSITIVE BUS With key ON enter BCM active command mode CONTACTOR Yes GO to A50 OUTPUT CONTROL monitor BCM PID LKRESB and set the active command CHARGER to CLOSE W...

Page 632: ...T test steps A1 and A2 If all PIDs still indicate NO CHECK the traction battery support tray for excessive moisture or water build up If OK REPLACE the BCM A13 CHECK FOR CURRENT LEAKAGE IN A C COMPRES...

Page 633: ...E IN A C COMPRESSOR With key OFF disconnect A C inverter motor controller IMC Yes GO to A19 high voltage C1902 to A C compressor With key ON monitor BCM PID LEAKRES No REPLACE the A C Wait approximate...

Page 634: ...t the traction motor three phase cables from the Yes GO to A26 leakage is in TIM and reconnect the traction battery high voltage two pin C3994 TIM or high voltage cables to TIM With key ON monitor BCM...

Page 635: ...d Yes REPLACE high voltage battery module harness 10B694 and or the high voltage harness 14A280 in question NOTE If there is no continuity between the indicated battery module and No GO to A31 chassis...

Page 636: ...otor transaxle REFER to Does the LKRESB or LKRESB PID indicate less than 50 000 Section 303 01 ohms A35 CHECK FOR CURRENT LEAKAGE IN TIM OR HIGH VOLTAGE CABLES LEADING TO TIM With key OFF check the hi...

Page 637: ...R to Section Wait approximately 50 seconds 414 02 Does the LKRESB PID indicate less than 50 000 ohms A42 CHECK FOR CURRENT LEAKAGE IN TRACTION BATTERY CHARGER With key OFF remove the HVPDB cover and d...

Page 638: ...voltage positive or negative cables are touching chassis ground harness 14B322 Are any of the cables touching chassis ground No REPLACE the TIM REFER to Section 303 14 A47 CHECK FOR CURRENT LEAKAGE I...

Page 639: ...ait approximately 50 seconds Does the LKRESB PID indicate less than 50 000 ohms A51 CHECK FOR CURRENT LEAKAGE IN AUXILIARY LOAD POSITIVE BUS CONTACTOR BOX OR HVPDB With key OFF disconnect high voltage...

Page 640: ...bution box Yes REPLACE the HVPDB HVPDB cover and disconnect HVPDB C1914 to DC DC converter Reinstall the HVPDB cover No REPLACE the DC DC With key ON monitor BCM PID LKRESB converter REFER to Section...

Page 641: ...Does the BOO TIM PID indicate OFF with the brake pedal not No GO to A2 depressed and ON with the brake pedal depressed A2 CHECK FUSE AND POWER TO BRAKE PEDAL POSITION BPP SWITCH With key OFF check 10...

Page 642: ...and BOB pin B21 Is the resistance less than 5 ohms A8 CHECK CIRCUIT 3600 R W FOR SHORT TO POWER Connect 104 Pin Breakout Box BOB to TIM C4998 C4999 using the Yes REPAIR the R W wire BCM TIM BOB Adapt...

Page 643: ...to B6 BCM TIM BOB Adapter Cable and Overlay leave the TIM disconnected With key OFF measure the resistance of the R wire between master No REPAIR the R wire cylinder brake pressure sensor C1940 and BO...

Page 644: ...control module BCM sets DTC charger C1859 during the BCM on demand self test if it detects the PRNDE TR2 signal is not A charger undercurrent fault occurs if the grounded An open or short in the TR2...

Page 645: ...e capacity fault Charger mode feedback fault IOM to BCM diagnostic input stuck high fault IOM to BCM diagnostic input stuck low fault Charger Charging After Being Contactor box GO to Pinpoint Test D D...

Page 646: ...GO to Pinpoint Test Q Input Stuck Low Fault Independent observer module IOM DTC C1859 PRNDL Input 2 Circuit s GO to Pinpoint Test R Circuit Failure Battery control module BCM DTC C1861 PRNDL Input 4 C...

Page 647: ...Sensor 1 With key OFF disconnect battery temperature sensor 1 C1813 and measure the resistance of the BR wire between BOB pin A40 and temperature sensor 1 C1813 With key OFF measure the resistance of...

Page 648: ...in question Battery Temperature Sensor 1 No GO to A5 BOB pins A9 and A33 Battery Temperature Sensor 2 BOB pins A22 and A33 Battery Temperature Sensor 3 BOB pins A25 and A33 Battery Temperature Sensor...

Page 649: ...ger Latchup Fault CHG MFF Charger Mode Feedback Fault CHG OAF Charger Over Amp Hours Fault CHG OCF Charger Over Current Fault CHG OTF Charger Over Temperature Fault CHG OVF Charger Over Voltage Fault...

Page 650: ...out the following steps Failure to follow this warning may result in severe personal injury or death Connect 104 Pin Breakout Box BOB to traction battery support tray in line C1939F using Traction Ba...

Page 651: ...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 BCM C1987 and measure the...

Page 652: ...e C1923F Is the voltage greater than 300 volts H3 CHECK HVPDB CIRCUITS 3134 O AND 3133 W OUTSIDE OF TRACTION BATTERY SUPPORT TRAY FOR OPEN S With key OFF disconnect high voltage auxiliary load in line...

Page 653: ...using the BCM TIM BOB Adapter Cable and Overlay Enter BCM active command mode CONTACTOR OUTPUT CONTROL set the active command CHARGER to CLOSE and measure the voltage between BOB pin B9 and ground BOB...

Page 654: ...OB pins 50 63 and Yes GO to H14 ground BOB pin 65 Are the resistances greater than 10 000 ohms No REPAIR the wire s in question H14 CHECK CIRCUITS 3401 DB LG AND 3985 PK INSIDE OF TRACTION BATTERY SUP...

Page 655: ...ETWEEN IN LINE C1885F AND BATTERY MODULE 25 FOR SHORTED RESISTOR Remove the traction battery and connect Traction Battery High Voltage Yes GO to K2 Lockout and Diagnostic Tool to the traction battery...

Page 656: ...CS OPERATION Carry out the Power Control Station PCS Operation Verification Test Yes GO to M2 Refer to Pinpoint Test S Is the PCS OK No PERFORM the required action as indicated in Pinpoint Test S M2 C...

Page 657: ...ction 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 BCM C1986 a...

Page 658: ...e must be disconnected and reconnected power reset to clear the latched fault from the BCM after the concern is repaired If the power reset is not performed the BCM will not allow charging NOTE If oth...

Page 659: ...sensors No REPAIR the wire s in question IOM Battery Temperature Sensor 1 With key OFF disconnect IOM battery temperature sensor 1 C1803 and measure the resistance of the LB wire between pin 35 on IO...

Page 660: ...ure sensor s in question P9 CHECK ON PLUG DETECT CIRCUIT 3404 Y FOR OPEN Connect 104 Pin Breakout Box BOB to BCM C1986 C1987 using the Yes GO to P10 BCM TIM BOB Adapter Cable and Overlay leave the BCM...

Page 661: ...an the No REPLACE the BCM rest of the battery modules in the battery pack PINPOINT TEST Q IOM TO BCM DIAGNOSTIC INPUT STUCK LOW FAULT TEST STEP ACTION TO TAKE Q1 CHECK BATTERY CONTROL MODULE BCM TO IN...

Page 662: ...ox BOB to in line C1939M using Traction Battery Low Voltage Service Cord do not connect Traction Battery Low Voltage Service Cord to in line C1939F With key OFF disconnect digital transmission range D...

Page 663: ...94M No REPAIR the Y 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 step...

Page 664: ...94M Connect 104 Pin Breakout Box BOB to traction battery support tray No REPAIR the Y wire inside in line C1939F using Traction Battery Low Voltage Service Cord do not the traction battery support con...

Page 665: ...panel turning the No GO to U4 power off may allow the PCS to clear the fault Turn the PCS power back on and plug the vehicle back in Is the Service light illuminated U4 CHECK READY AND CHARGING LIGHTS...

Page 666: ...flow thru fan or recirculation fan fault occurs A flow thru fan fault occurs if the BCM does not receive a feedback signal when the flow thru fan is enabled or if it receives a feedback signal after i...

Page 667: ...ic Tool wire between C1939F and to the traction battery high voltage two pin C3994M the traction battery fan relay connectors No REPAIR the BK wire WARNING The traction battery contains high voltage c...

Page 668: ...fan C3994M No GO to A8 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...

Page 669: ...nd BCM C1986 C1987 using the BCM TIM BOB Adapter Cable and Overlay Enter BCM active command mode BCM PACKETED COMMANDS set active command FAN FL to ENABLE and measure the voltage between BOB pin B6 an...

Page 670: ...the traction battery high voltage two pin fan C3994M No GO to A19 WARNING The traction battery contains high voltage components and wiring High voltage insulated safety gloves and face shield must be...

Page 671: ...personal injury or death Connect Traction Battery Low Voltage Service Cord to traction battery support tray in line C1939F and in line C1939M Connect Traction Battery High Voltage Service Cord to tra...

Page 672: ...de DIAGNOSIS AND TESTING Continued Traction Battery System Battery Module Diagnostic Test The Battery Module Diagnostic Test is the method used to analyze electric vehicle traction battery modules All...

Page 673: ...h voltage sense lines The BCM can sense the battery module voltages if Press 7 PIDS button and highlight BAT_MV they are within the range of 3 and 16 8 volts Hit START button The BCM sets DTC P1794 if...

Page 674: ...modules module voltage is lower than the average module voltage by more than one volt that are much weaker than the rest at the end of charge Electrical Schematic Refer to Electrical and Vacuum Troubl...

Page 675: ...IT SHUTDOWN FAULT TEST STEP ACTION TO TAKE A1 CHECK FOR OTHER TRACTION INVERTER MODULE TIM DIAGNOSTIC TROUBLE CODES DTCs NOTE DTCs must be retrieved from the interface adapter assembly IAA Yes REFER t...

Page 676: ...BCM AND IN LINE CONNECTOR FOR OPEN Remove the traction battery and connect Traction Battery High Voltage Yes GO to B5 Lockout and Diagnostic Tool to the traction battery high voltage two pin C3994M No...

Page 677: ...3085 O LG between in line C1756M label G and pin 33 on BCM C1866 15 16 circuit 3086 W P between in line C1757M label H and pin 23 on BCM C1866 16 17 circuit 3087 DG P between in line C1758M label J an...

Page 678: ...l E and battery module 9 post 10 11 between circuit 3081 W R on in line C1755F label F and battery module 10 post 11 12 between circuit 3082 BK LG on in line C1754F label E and battery module 11 post...

Page 679: ...Ds BAT MC CHG CYC and LOWVOLT and enter the values on the Dealer Battery Return Form that is packaged with the new battery module Fill out all the required data on the Dealer Battery Return Form and r...

Page 680: ...d BCM high voltage C1865 and C1866 Carry out the on demand self test for the BCM No System OK Does DTC C1676 Battery Pack Voltage Out of Range occur PINPOINT TEST C DTC C1864 BATTERY MODULE FAULT TEST...

Page 681: ...ic Tool to the traction battery high voltage two pin connector C3994M Carry out the Diagnostic Process Refer to Section 100 07 Do any DTCs occur No GO to E2 E2 CHECK INSTRUMENT CLUSTER INDICATORS With...

Page 682: ...tem does not operate for intermittent connections With key ON measure the voltage of the 12 volt auxiliary battery The No If none of the high voltage voltage should be greater than 13 volts auxiliary...

Page 683: ...death Connect Traction Battery High Voltage Service Cord to high voltage auxiliary load in line C1935F on the traction battery support tray and in line C1935M NOTE Contactor box C3985 is mounted on t...

Page 684: ...de RESET HISTORICAL DATA and set the active command RESET to the battery module s that were replaced 3 NOTE If more than two battery modules need to be replaced do not replace the traction battery cov...

Page 685: ...nd wear the insulated rubber gloves 3 Wear the face shield 5 NOTE The Traction Battery High Voltage Lockout and Diagnostic Tool connects to the two pin high voltage connector located at the rear of th...

Page 686: ...sembly 9 Replace the battery module s that were removed with the in line bypass battery module s and install the nuts 10 Replace any components that were removed to gain access to the battery module s...

Page 687: ...nnector on the traction battery 14 Connect the Traction Battery Low Voltage Service Cord to the 76 pin low voltage connector on the traction battery Loosely install the bolt 15 Connect the Traction Ba...

Page 688: ...ector 19 Close the charge inlet access door 20 Enter the indicated data on the Dealer Battery Return Form that is packaged with the new battery module 21 Remove the In Line Bypass Battery Module s and...

Page 689: ...Test Refer to Diagnosis and Testing for Traction Battery System in this section 25 Disconnect the Traction Battery High Voltage Service Cord from the auxiliary load high voltage connector on the vehic...

Page 690: ...e Cord from the 76 pin low voltage connector on the vehicle 29 Apply Locktite 242 threadlock and sealer to the 22 traction battery cover bolts 30 Install the traction battery cover Install the 22 bolt...

Page 691: ...414 03B 88 414 03B 88 High Voltage Traction Battery Nickel Metal Hydride GENERAL PROCEDURES Continued Traction Battery Tray Repair Battery Tray 2001 Ranger EV 01 2001...

Page 692: ...split can be found on the radii or in smooth high gloss areas 2 NOTE A crack in the composite enclosure is more significant than a resin split and requires repair or replacement of the battery tray A...

Page 693: ...etal Hydride GENERAL PROCEDURES Continued 4 To repair cracks less than 25 mm 1 in in length clean the area surrounding the damage prior to repair After cleaning grind a 20 degree bevel extending 40 to...

Page 694: ...er as illustrated 6 Allow the patched area to cure for at least 1 5 to 2 hours at 24 C 75 F Curing will take longer at colder temperatures A heat lamp placed no less than 45 cm 18 in from the repair f...

Page 695: ...area 6 Position a new bracket The adhesive should be 1 2 mm 04 08 in thick for correct bonding Do not squeeze out excessive amounts of the adhesive or the bond may fail 7 Allow the adhesive to cure f...

Page 696: ...Turn the charger on A flashing green light on the charger will indicate that the charger is operating and that the module is being charged During the charging cycle the charger will produce approxima...

Page 697: ...inal voltage of the traction battery is 300 volts The buffer zone must be set up and insulated rubber gloves and a face shield must be worn Failure to follow these precautions may result in severe per...

Page 698: ...Do not overtighten the BCM multi pin connectors Damage to the connectors may occur if overtightened To install reverse the removal procedure Apply Locktite 242 to the 22 traction battery cover bolts...

Page 699: ...gh Voltage Traction Battery Nickel Metal Hydride REMOVAL AND INSTALLATION Continued Charge Inlet Removal 1 Disconnect the traction battery auxiliary load high voltage connector Refer to Section 100 05...

Page 700: ...the grille 1 Remove the four screws 2 Remove the grille 3 NOTE The low voltage connector is located at the rear of the charger inlet Disconnect the low voltage electrical connector 4 Disconnect the tr...

Page 701: ...OVAL AND INSTALLATION Continued 5 Remove the two charge bracket bolts 6 Remove the charge inlet 1 Loosen the two charge inlet bracket bolts 2 Slide the charge inlet from behind the bolts and remove In...

Page 702: ...tage Traction Battery Nickel Metal Hydride REMOVAL AND INSTALLATION Continued Contactor Box Special Tool s Battery Terminal Cap Opener 418 F215 Removal 1 Remove the traction battery Refer to Traction...

Page 703: ...up and insulated rubber gloves and a face shield must be worn Failure to follow these precautions may result in severe personal injury or death Observe the EV specific precautions Refer to Section 100...

Page 704: ...ND INSTALLATION Continued 6 Remove the two pin high voltage connector nuts 7 Disconnect the high voltage interlock electrical connector 8 Disconnect the low voltage electrical connector 9 Unclip the t...

Page 705: ...inued 10 Open the clips that secure the contactor box harness to the high voltage harness 11 Cut the two zip ties securing the contactor box harness 12 Disconnect the contactor box harness 13 NOTE The...

Page 706: ...stallation 1 To install reverse the removal procedure Fill the high voltage jumper connectors with Nyogel after final tightening of the nuts bolts Apply Locktite 242 to the 22 traction battery cover b...

Page 707: ...fer zone must be set up and insulated rubber gloves and a face shield must be worn Failure to follow these precautions may result in severe personal injury or death Observe the EV specific precautions...

Page 708: ...ler to remove the necessary fuse 1 25A Charger Fuse 2 40A Auxiliary Fuse Installation 1 To install reverse the removal procedure Apply Locktite 242 to the 22 traction battery cover bolts HVPDB Fuses R...

Page 709: ...er 1 Remove the four screws 2 Remove the cover 3 Remove the HVPDB fuse safety cover 1 Remove the two screws 2 Remove the cover 4 Use a fuse puller to remove the necessary fuse 1 10A Power Steering Fus...

Page 710: ...AL AND INSTALLATION Continued High Voltage Power Distribution Box HVPDB Removal 1 Remove the positive temperature coefficient PTC module Refer to Section 412 04 2 Disconnect the power steering pump el...

Page 711: ...d in position with three clips Remove the HVPDB 1 Remove the bolts 2 Remove the HVPDB Installation 1 To install reverse the removal procedure High Voltage Wiring Sensor Lead Harness 10B694 Removal 1 R...

Page 712: ...ailure to follow these precautions may result in severe personal injury or death Observe the EV specific precautions Refer to Section 100 00 1 Set up the buffer zone 2 Test and wear the insulated rubb...

Page 713: ...Unclip and disconnect the sense lead located above battery module 1 8 Unclip and disconnect the sense lead located above battery module 24 9 Unclip and disconnect the sense leads located in front of t...

Page 714: ...sense leads located above the recirculating blower cover 12 Unclip and disconnect the sense lead located above battery module 19 13 Unclip and disconnect the sense lead located between the battery con...

Page 715: ...battery modules 11 and 10 16 Remove the six high voltage harness pushpins and remove the harness 17 Disconnect the high voltage sense lead harness from the battery control module BCM 1 Loosen the bolt...

Page 716: ...4 03B 113 414 03B 113 High Voltage Traction Battery Nickel Metal Hydride REMOVAL AND INSTALLATION Continued High Voltage Wiring Special Tool s Battery Terminal Cap Opener 418 F215 2001 Ranger EV 01 20...

Page 717: ...414 03B 114 414 03B 114 High Voltage Traction Battery Nickel Metal Hydride REMOVAL AND INSTALLATION Continued High Voltage Jumper Routing 2001 Ranger EV 01 2001...

Page 718: ...be worn Failure to follow these precautions may result in severe personal injury or death Observe the EV specific precautions Refer to Section 100 00 1 Set up the buffer zone 2 Test and wear the insul...

Page 719: ...the battery module caps Remove and discard the two nuts Installation 1 To install reverse the removal procedure Refill the HVJ caps with Nyogel after tightening the nuts Apply Locktite 242 to the 22 t...

Page 720: ...nd insulated rubber gloves and a face shield must be worn Failure to follow these precautions may result in severe personal injury or death Observe the EV specific precautions Refer to Section 100 00...

Page 721: ...vehicle 8 Completely lower the lift table and then lower the vehicle until the battery pack is within 25 5 cm 10 in of the lift table Verify that the safety locks on the lift are engaged 9 Adjust the...

Page 722: ...r for more than 60 psi NOTE The lift table is designed to only lift the battery pack assembly It will not lift the entire vehicle Continue to lift the battery pack until the lift table system pressure...

Page 723: ...pport the vehicle Refer to Section 100 02 2 Position the lift table and battery pack under the vehicle Connect the lift table to the shop air supply 3 With the assistance of a second person carefully...

Page 724: ...shop air source 7 Raise the vehicle and roll the lift table from under the vehicle 8 NOTE The bolt will break if the specified torque is exceeded If this happens pull the connector off the bolt stem a...

Page 725: ...ND INSTALLATION Continued 2 Disconnect the traction battery charger electrical connectors 3 Remove the harness bracket Remove the bolt 4 Remove the A C inverter motor controller IMC bracket 1 Remove t...

Page 726: ...ge Traction Battery Nickel Metal Hydride REMOVAL AND INSTALLATION Continued 6 Remove the traction battery charger 1 Remove the four bolts 2 Remove the charger Installation 1 To install reverse removal...

Page 727: ...LLATION Continued Flow Through Blower Removal 1 Remove the traction battery Refer to Traction Battery 2 Remove the traction battery cover 1 Remove the 22 bolts 2 Remove the cover 3 Remove the blower c...

Page 728: ...ctrical connector 5 CAUTION The flow through blower is very fragile and can easily be damaged if mishandled Remove the flow through blower 1 Remove the nuts 2 Remove the blower 6 Remove the flow throu...

Page 729: ...26 414 03B 126 High Voltage Traction Battery Nickel Metal Hydride REMOVAL AND INSTALLATION Continued Recirculating Blower Removal 1 Remove the traction battery Refer to Traction Battery 2001 Ranger EV...

Page 730: ...AND INSTALLATION Continued 2 Remove the traction battery cover 1 Remove the 22 bolts 2 Remove the cover 3 Disconnect the recirculating blower electrical connector and cut the zip tie 4 Remove the com...

Page 731: ...LLATION Continued 6 Remove the low voltage harness push pin 7 Remove the battery hold down bracket 1 Remove bolts 2 Remove the bracket 8 Remove the battery hold down bracket 1 Remove the bolts 2 Remov...

Page 732: ...ove the blower cover 1 Remove the bolts 2 Remove the cover 11 NOTE Note the location of the P clip that retains the recirculating blower harness Remove the recirculating blower 1 Remove the bolts 2 Re...

Page 733: ...414 03B 130 414 03B 130 High Voltage Traction Battery Nickel Metal Hydride REMOVAL AND INSTALLATION Continued 2001 Ranger EV 01 2001...

Page 734: ...Refer to Traction Battery 2 WARNING The nominal voltage of the traction battery is 300 volts The buffer zone must be set up and insulated rubber gloves and a face shield must be worn Failure to follow...

Page 735: ...clamp bolt 5 WARNING Do not allow the HVJs to touch each other once they are removed from the high voltage fuse The HVJs contain high DC voltage and may cause severe personal injury or death Remove th...

Page 736: ...WARNING The nominal voltage of the traction battery is 300 volts The buffer zone must be set up and insulated rubber gloves and a face shield must be worn Failure to follow these precautions may resul...

Page 737: ...and 18 There is also one mounted in the cover of the recirculating blower NOTE The traction battery module procedure found in the General Procedures section does not have to be followed for thermisto...

Page 738: ...layer of thermal grease to the thermistor 2 Install the thermistor 1 Install the thermistor 2 Install the clips 3 NOTE If replacing module 12 thermistors route both of the wires to the inboard side o...

Page 739: ...ON Continued 5 Install the module Refer to the appropriate procedure 6 Install the traction battery cover Install the 22 bolts Traction Battery Module Modules 2 6 Special Tool s Battery Post Torque Wr...

Page 740: ...e To replace a faulty module follow the Traction Battery Module Replacement located in the General Procedures section of this manual Refer to Traction Battery Module Replacement to begin module replac...

Page 741: ...ed 5 Disconnect the high voltage interlock electrical connector 6 Disconnect the low voltage electrical connector 7 Position the contactor box towards the front of the traction battery 8 Remove the co...

Page 742: ...r module hold down bracket 1 Remove the bolts 2 Remove the hold down 10 Unclip the battery hold down tie bar 1 Remove the pushpins 2 Unclip the cover 11 Remove the battery hold down strap bolt and pul...

Page 743: ...nnect the 2 two thermistor electrical connectors Disconnect the HVJ cables and discard the nuts 15 Using the special tool remove the module Installation 1 NOTE The arrow on the battery hold down tie b...

Page 744: ...414 03B 141 414 03B 141 High Voltage Traction Battery Nickel Metal Hydride REMOVAL AND INSTALLATION Continued 2001 Ranger EV 01 2001...

Page 745: ...n Battery Nickel Metal Hydride REMOVAL AND INSTALLATION Continued Traction Battery Module Modules 1 7 8 9 25 Special Tool s Battery Post Torque Wrench 307 026 Battery Terminal Cap Opener 418 F215 Batt...

Page 746: ...odules listed Do not start with this procedure Refer to Traction Battery Module Replacement to begin module replacement 2 CAUTION Disconnect only one HVJ at a time Disconnect the HVJs from the contact...

Page 747: ...ed 5 Disconnect the high voltage interlock electrical connector 6 Disconnect the low voltage electrical connector 7 Position the contactor box towards the front of the traction battery 8 Remove the co...

Page 748: ...STALLATION Continued 9 Unclip the battery hold down tie bar cover 1 Remove the pushpins 2 Unclip the cover 10 Remove the battery hold down strap bolt and pull the straps back 11 Disconnect the 6 HVJ R...

Page 749: ...he low and high voltage harness push pins 14 Unclip the battery hold down tie bar cover 1 Unclip the sense lead connectors from the cover 2 Unclip the cover 15 Remove the battery hold down strap bolt...

Page 750: ...t the HVJ cables and discard the nuts 18 Using the special tool remove the module Installation 1 NOTE The arrow on the battery hold down tie bars must be pointed towards the front of the traction batt...

Page 751: ...414 03B 148 414 03B 148 High Voltage Traction Battery Nickel Metal Hydride REMOVAL AND INSTALLATION Continued 2001 Ranger EV 01 2001...

Page 752: ...cial Tool s Battery Post Torque Wrench 307 026 Battery Terminal Cap Opener 418 F215 Battery Handles 414 F001 Removal 1 This procedure contains steps specific to the modules listed Do not start with th...

Page 753: ...connect the sensor lead electrical connectors 2 Unclip the cover 4 Unclip the battery hold down tie bar cover 1 Unclip and disconnect the sensor lead electrical connector 2 Unclip the relay 3 Unclip t...

Page 754: ...ry hold down strap bolt and pull the straps back off the battery hold down tie bar 8 Remove the battery hold down tie bar 9 NOTE If removing module 12 disconnect the two thermistors Disconnect the nec...

Page 755: ...ALLATION Continued Installation 1 NOTE The arrow on the battery hold down tie bars must be pointed towards the front of the traction battery To install reverse the removal procedure Fill the high volt...

Page 756: ...Battery Post Torque Wrench 307 026 Battery Terminal Cap Opener 418 F215 Battery Handles 414 F001 Removal Modules 13 15 1 This procedure contains steps specific to the modules listed Do not start with...

Page 757: ...1 Unclip and disconnect the sensor lead electrical connector 2 Unclip the relay 3 Unclip the cover 4 Remove the battery hold down strap bolt and pull the straps back off the battery hold down tie bar...

Page 758: ...TALLATION Continued 7 Remove the battery hold down bracket 1 Remove the bolts 2 Remove the bracket 8 Remove the battery hold down bracket 1 Remove the bolts 2 Remove the bracket Module 15 9 Remove the...

Page 759: ...sconnect the HVJ cables and discard the nuts 11 Using the special tool remove the module Installation 1 NOTE The arrow on the battery hold down tie bars must be pointed towards the front of the tracti...

Page 760: ...414 03B 157 414 03B 157 High Voltage Traction Battery Nickel Metal Hydride REMOVAL AND INSTALLATION Continued 2001 Ranger EV 01 2001...

Page 761: ...le Modules 17 18 21 Special Tool s Battery Post Torque Wrench 307 026 Battery Terminal Cap Opener 418 F215 Battery Handles 414 F001 Removal 1 This procedure contains steps specific to the modules list...

Page 762: ...emove the blower cover 1 Remove the four bolts two each side 2 Remove the blower cover 3 Disconnect the blower electrical connector 4 Remove the flow through blower 1 Remove the nuts 2 Remove the blow...

Page 763: ...d 6 Disconnect the low voltage connector 1 Loosen the bolts 2 Disconnect the connectors 7 Remove the battery control module BCM 1 Remove the bolts 2 Remove the BCM 8 Position the IOM 1 Remove the bolt...

Page 764: ...or bracket bolt 2 Remove the bracket mounting bolts 3 Remove the bracket 11 Disconnect the harness connectors 1 Disconnect the sense lead connectors 2 Unclip and disconnect the thermistor 12 Remove th...

Page 765: ...n strap bolt and pull the straps back off the battery hold down tie bar 15 Remove the battery hold down tie bar 16 NOTE If removing module 18 disconnect the two thermistor electrical connectors Discon...

Page 766: ...ALLATION Continued Installation 1 NOTE The arrow on the battery hold down tie bars must be pointed towards the front of the traction battery To install reverse the removal procedure Fill the high volt...

Page 767: ...414 03B 164 414 03B 164 High Voltage Traction Battery Nickel Metal Hydride REMOVAL AND INSTALLATION Continued 2001 Ranger EV 01 2001...

Page 768: ...n Battery Nickel Metal Hydride REMOVAL AND INSTALLATION Continued Traction Battery Module Modules 16 19 20 22 Special Tool s Battery Post Torque Wrench 307 026 Battery Terminal Cap Opener 418 F215 Bat...

Page 769: ...nect the high voltage connector 1 Loosen the bolts 2 Disconnect the connectors 2 Disconnect the low voltage connector 1 Loosen the bolts 2 Disconnect the connectors 3 Remove the battery control module...

Page 770: ...BCM IOM bracket 1 Remove the 4 pin auxiliary connector bracket bolt 2 Remove the bracket mounting bolts 3 Remove the bracket 7 Disconnect the harness connectors 1 Disconnect the sense lead connectors...

Page 771: ...ION Continued 9 Unclip the battery hold down tie bar cover 10 Remove the battery hold down strap bolt and pull the straps back off the battery hold down tie bar 11 Remove the battery hold down tie bar...

Page 772: ...t the HVJ cables and discard the nuts 14 Using the special tool remove the module Installation 1 NOTE The arrow on the battery hold down tie bars must be pointed towards the front of the traction batt...

Page 773: ...414 03B 170 414 03B 170 High Voltage Traction Battery Nickel Metal Hydride REMOVAL AND INSTALLATION Continued 2001 Ranger EV 01 2001...

Page 774: ...Nickel Metal Hydride REMOVAL AND INSTALLATION Continued Independent Observer Module IOM Removal 1 Remove the traction battery Refer to Traction Battery 2 Remove the traction battery cover 1 Remove th...

Page 775: ...ce shield must be worn Failure to follow these precautions may result in severe personal injury or death Observe the EV specific precautions Refer to Section 100 00 1 Set up the buffer zone 2 Test and...

Page 776: ...414 03B 173 414 03B 173 High Voltage Traction Battery Nickel Metal Hydride REMOVAL AND INSTALLATION Continued Installation 1 To install reverse the removal procedure 2001 Ranger EV 01 2001...

Page 777: ...14 03B 174 High Voltage Traction Battery Nickel Metal Hydride DISASSEMBLY AND ASSEMBLY Traction Battery Special Tool s Battery Terminal Cap Opener 418 F215 Battery Post Torque Wrench 307 026 2001 Rang...

Page 778: ...414 03B 175 414 03B 175 High Voltage Traction Battery Nickel Metal Hydride DISASSEMBLY AND ASSEMBLY Continued Traction Battery 2001 Ranger EV 01 2001...

Page 779: ...r to Traction Battery 2 Remove the traction battery cover 1 Remove the 22 bolts 2 Remove the cover 3 WARNING The nominal voltage of the traction battery is 300 volts The buffer zone must be set up and...

Page 780: ...BLY AND ASSEMBLY Continued 5 Wrap the HVJ ends with orange electrical tape 6 Remove the two pin high voltage connector nuts 7 Disconnect the high voltage interlock electrical connector 8 Unclip the th...

Page 781: ...tinued 9 Open the clips that secure the contactor box harness to the high voltage harness 10 Cut the two zip ties securing the contactor box harness 11 Disconnect the contactor box harness 12 NOTE The...

Page 782: ...age connector 1 Loosen the bolts 2 Disconnect the connectors 14 Disconnect the low voltage connector 1 Loosen the bolts 2 Disconnect the connectors 15 Disconnect the independent observer module IOM el...

Page 783: ...BLY AND ASSEMBLY Continued 17 Disconnect the sense leads 18 Disconnect the sense leads and unclip the relay 19 Remove the high voltage harness push pins 20 Remove the high voltage harness 1 Disconnect...

Page 784: ...stor electrical connectors and unclip the relay 22 Disconnect the low voltage harness 1 Disconnect the blower electrical connectors 2 Disconnect the thermistor electrical connectors 3 Unclip the relay...

Page 785: ...s 1 Remove the bolts 2 Remove the bars 26 Remove the BCM IOM mounting bracket 1 Remove the 4 pin auxiliary mounting bolt 2 Remove the bolts 3 Remove the bracket 27 Remove the flow through blower 1 Rem...

Page 786: ...Remove the battery hold down 1 Remove the bolts 2 Remove the hold down 31 Remove the recirculating blower cover 1 Remove the bolts 2 Remove the cover 32 NOTE The P clip that retains the blower harness...

Page 787: ...al Hydride DISASSEMBLY AND ASSEMBLY Continued 33 Remove the rear battery hold down 1 Remove the bolts 2 Remove the hold down 34 Unclip the battery hold down tie bar covers 35 Remove the hold down stra...

Page 788: ...SASSEMBLY AND ASSEMBLY Continued 37 Remove the battery hold down 1 Remove the bolt 2 Remove the hold down 38 Remove the battery hold down 1 Remove the bolt 2 Remove the hold down 39 Remove the mid wal...

Page 789: ...AND ASSEMBLY Continued 41 Remove the hold down strap bolt 42 Remove the hold down tie bar 43 Remove the front battery hold down 1 Remove the bolts 2 Remove the hold down 44 Remove all of the HVJs and...

Page 790: ...e the clips 2 Remove the thermistor Assembly 1 NOTE The battery supports are all the same NOTE The battery supports must be pressed against the bottom of the traction battery tray Install the rear bat...

Page 791: ...must be pressed against the bottom of the traction battery tray Install the front battery supports 4 Install the mid wall 5 CAUTION Do not cover the module vents with the decals NOTE All of the module...

Page 792: ...tors 8 Install the thermistors on modules 3 12 and 18 1 Install the thermistor 2 Install the clips 9 NOTE On the module 12 thermistors route both of the wires to the in board side of the module Route...

Page 793: ...n battery case Match the numbers of the modules to the numbers in the bottom of the traction battery case 12 NOTE Install the P clip in the same position that was noted during disassembly Position the...

Page 794: ...olts 16 Install the recirculating blower cover and battery hold down bolts 17 Install the front battery hold down 1 Install the hold down 2 Install the bolt 18 NOTE The front battery hold down tie bar...

Page 795: ...EMBLY Continued 19 Install the front hold down strap bolt 20 Clip the front battery hold down tie bar cover into place 21 Install the rear battery hold down tie bars with the arrows pointing towards t...

Page 796: ...Y Continued 23 Clip the rear battery hold down tie bar covers into place 24 Install the B HVJ 2 to 3 4 to 5 and loosely install new nuts 25 Install the D HVJ 5 to 6 6 to 7 and 8 to 9 and loosely insta...

Page 797: ...ed 27 Install the E HVJ 11 to 12 9 to 10 7 to 8 and loosely install new nuts 28 Install the N HVJ 25 to contactor box and loosely install a new nut 29 Install the M HVJ 24 to 25 23 to 24 and loosely i...

Page 798: ...ntinued 31 Install the G HVJ 13 to 14 14 to 15 and loosely install new nuts 32 Install the H HVJ 15 to 16 and loosely install new nuts 33 Install the L HVJ 22 to 23 19 to 20 and loosely install new nu...

Page 799: ...ride DISASSEMBLY AND ASSEMBLY Continued 35 Install the K HVJ 17 to 18 21 to 22 and loosely install new nuts 36 Install the A HVJ 1 to contactor box and loosely install a new nut 37 Tighten the HVJ nut...

Page 800: ...al Hydride DISASSEMBLY AND ASSEMBLY Continued 38 Install the flow through blower 39 Install the flow through blower cover 40 Install the BCM IOM bracket 1 Position the bracket 2 Install the bolts 3 In...

Page 801: ...D ASSEMBLY Continued 41 NOTE The high voltage fuse is held in place by the composite bar bolt Install the composite bars 1 Position the bars 2 Install the bolts 42 Position the low voltage harness and...

Page 802: ...ness 1 Connect the blower electrical connector 2 Connect the thermistor electrical connector 3 Clip the relay into place 45 Connect the thermistors and clip the relay into the battery hold down tie ba...

Page 803: ...Battery Nickel Metal Hydride DISASSEMBLY AND ASSEMBLY Continued 47 Install the high voltage harness push pins 48 Connect the sense leads and clip the relay into the battery hold down tie bar cover 49...

Page 804: ...raction Battery Nickel Metal Hydride DISASSEMBLY AND ASSEMBLY Continued 50 Install the IOM and install the bolts 51 Connect the IOM electrical connector and tighten the bolt 52 Position the BCM and in...

Page 805: ...ISASSEMBLY AND ASSEMBLY Continued 53 Connect the low voltage BCM connector and tighten the bolts 54 Connect the high voltage BCM connector and tighten the bolts 55 NOTE The contactor box is held in pl...

Page 806: ...attery Nickel Metal Hydride DISASSEMBLY AND ASSEMBLY Continued 56 Connect the contactor box harness 57 Instal two new zip ties to secure the high voltage harness 58 Clip the contactor box harness to t...

Page 807: ...LY AND ASSEMBLY Continued 59 Clip the thermistors into the contactor box harness and install a zip tie to secure the thermistor wires 60 Connect the high voltage interlock electrical connector 61 Posi...

Page 808: ...minal on the contactor box the HVJ from module 1 connects to the terminal on the contactor box Connect the HVJ ends to the contactor box and install the nuts Fill the area around the nuts with Nyogel...

Page 809: ...VEHICLE APPLICATION Ranger EV CONTENTS PAGE DESCRIPTION AND OPERATION Module Communication 418 00 2 DIAGNOSIS AND TESTING Communications Network 418 00 3 Electrical Schematic 418 00 3 Inspection and...

Page 810: ...also operates a number of instrument cluster communication network the NGS tester must ask gauges and warning lamps Refer to Section for all information the modules cannot initiate 412 04 communicati...

Page 811: ...Troubleshooting Manual Cell 14 Multiplex Communication Network for schematic and connector information System Precheck PINPOINT TEST PC DATA LINK DIAGNOSTICS NETWORK TEST TEST STEP ACTION TO TAKE PC1...

Page 812: ...it Link ISO link modules No Module Network Wire or connection in SCP GO to Pinpoint Test F Communication SCP Link link circuit SCP link modules No Module Network Data link connector DLC GO to Pinpoint...

Page 813: ...re between pin 16 in line C1946F on in line C134F and pin 7 on DLC C209 Are the connectors OK and is the resistance less than 5 ohms No REPAIR the connectors and or the LB W wire between in line C134F...

Page 814: ...evere personal injury or death Remove the traction battery NOTE There are two power feeds to the BCM with the same circuit No REPAIR the connectors number wire color circuit 787 PK BK wire When perfor...

Page 815: ...ule C1945 and rerun DATA Yes System OK LINK DIAGNOSTICS Network Test Does the IAA module respond to NGS Tester No REPLACE the IAA module REFER to Section 412 04 C4 CHECK CIRCUITS 914 T O AND 915 PK LB...

Page 816: ...4 D4 CHECK CIRCUITS 914 T O AND 915 PK LB BETWEEN IN LINE C3999F AND DLC C209 FOR OPEN S With key OFF disconnect in line C3999 and inspect C3999M and Yes REPAIR the wire in C3999F for damage question...

Page 817: ...LOCK BRAKE CONTROL MODULE C1942 FOR THE SOURCE OF THE CONCERN With key OFF disconnect in line C1941 and inspect pin 7 for damage Yes GO to E5 Run DATA LINK DIAGNOSTICS Network Test No REPAIR the conne...

Page 818: ...2 04 F3 CHECK THE TRACTION INVERTER MODULE TIM FOR THE SOURCE OF THE CONCERN With key OFF disconnect TIM C4998 and inspect pins 5 and 15 for Yes GO to F4 damage Run DATA LINK DIAGNOSTICS Network Test...

Page 819: ...DLC C209 and With key OFF measure the resistance between BOB pin 28 and ground S2992 and or the PK LB BOB pin 80 wire between DLC C209 and S2990 for an open Are the resistances greater than 10 000 ohm...

Page 820: ......

Page 821: ......

Page 822: ......

Page 823: ......

Page 824: ...specific section or cell in all Wiring Diagrams is numbered by cell and starts with page 1 For ex ample HOW TO USE THIS MANUAL is CELL 2 and begins with page 2 1 D CONNECTOR FACES CELL 150 will contai...

Page 825: ...1 Circuit Protection 11 1 Component Location Views 151 13 Component Testing Exterior Rear View Mirror Switch 149 10 Ignition Switch 149 4 Introduction 149 1 Left Right Door Lock Switch 149 7 Main Lig...

Page 826: ...28 Fuse 2 13 8 Fuse 4 13 15 13 31 Fuse 5 13 11 13 27 Fuse 7 13 14 13 30 Fuse 8 13 15 13 31 Fuse 9 13 12 13 28 Fuse 10 13 8 13 23 Fuse 11 13 10 13 25 Fuse 12 13 8 Fuse 13 13 11 13 27 Fuse 14 13 8 13 2...

Page 827: ...air work with tested effective tech niques Following them will help assure re liability There are numerous variations in proce dures techniques tools and parts for serv icing vehicles as well as in th...

Page 828: ...2001 RANGER ELECTRIC VEHICLE 1 4 TABLE OF CONTENTS INDEX...

Page 829: ...ges will be shown at the end of each cell Component connector face information specific to a certain cell is found at the end of that cell A Con nector Face Reference List is provided to locate con ne...

Page 830: ...hot metal parts such as the radiator exhaust manifold tail pipe catalytic converter and muffler D Do not allow flame or sparks near the battery Gases are always present in and around the battery cell...

Page 831: ...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 Te...

Page 832: ...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...

Page 833: ...Female Half Displaced Tab Seal Seal Male Half Intermittent Contact Type A Type B Intermittent Contact 2001 ELECTRIC RANGER VEHICLE 2 5 HOW TO USE THIS MANUAL TROUBLESHOOTING WIRING HARNESS AND CONNECT...

Page 834: ...ation 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 anothe...

Page 835: ...LE LINK 63 RD 981 RD WH SOLID WIRES STRIPED WIRES FUSE CURRENT RATING CIRCUIT BREAKER CURRENT RATING MAXI FUSE or FUSIBLE LINK CARTRIDGE CURRENT RATING WIRE SIZE AND COLOR S100 SPLICE OR CRIMP TERMINA...

Page 836: ...RE COVERED BY A SHIELD FIELD COIL C105F C105M C100F C100M M MOTOR HEATING ELEMENT THERMISTOR RHEOSTAT OR POTENTIOMETER SOLENOID SWITCH GANGED SWITCHES CONTACTS MOVE AT THE SAME TIME DIODES CURRENT FLO...

Page 837: ...09 C219 570 BK WH 649 BK OG 10 649 BK OG 21 S205 INSTRUMENT CLUSTER PAGES 61 2 61 7 AIRBAG SLIDING CONTACT PAGE 44 1 DATA LINK CONNECTOR DLC PAGES 14 1 14 5 AIR BAG DIAGNOSTIC MONITOR PAGE 46 1 TO C13...

Page 838: ...0 BK WH TRACTION INVERTER MODULE TIM PAGE 26 3 3233 BK LB 39 C4998 29 FROM S205 PAGE 10 1 C1939 3233 3233 3233 3233 3233 3233 C3999 C201 C136 570 BK WH 570 BK WH 570 BK WH S1962 BK LB LB WH BK LB BK L...

Page 839: ...09 BLOWER SWITCH PAGES 53 3 54 3 A C HEATER CONTROL ASSEMBLY PAGE 54 4 CIGAR LIGHTER PAGE 44 1 POWER POINT PAGE 44 1 TO S131 PAGE 10 4 C233 ALL LOCK RELAY PAGE 110 1 C235 RADIO PAGE 130 1 C136 2 S2998...

Page 840: ...AGE 54 6 S131 S1965 E FROM C124 PAGE 10 6 C B FROM C135 PAGE 10 5 FROM C136 PAGE 10 3 All wires are 57 BK unless otherwise noted S1996 BATTERY CONTROL MODULE PAGE 16 5 C1801 33 C1986 RECIRCU LATING FA...

Page 841: ...CUUM SOLENOID PAGES 53 3 54 3 TO S131 PAGE 10 4 2 INSTRUMENT CLUSTER PAGES 61 4 61 5 C135 4 16 C2999 C234 HEATER CONTROL ASSEMBLY PAGE 53 4 C234 WITHOUT A C WITH A C 4 POWER STEERING ASSEMBLY PAGE 43...

Page 842: ...CUUM PUMP PAGE 139 1 TO S117 PAGE 10 7 C148 22 C1992 C1999 C1998 POSITIVE TEMPERATURE COEFFICIENT PTC SWITCHING MODULE PAGES 53 5 54 5 COOLANT PUMP PAGE 33 1 S123 S1999 E TO S1965 PAGE 10 4 C181 9 11...

Page 843: ...RONT PARK TURN LAMP PAGE 92 2 CHARGER INLET PAGE 18 3 FROM S123 PAGE 10 6 C147 RIGHT FRONT PARK TURN LAMP PAGE 92 2 C182 G105 C164 WINDSHIELD WASHER PUMP MOTOR PAGE 81 2 RIGHT FRONT SIDE MARKER LAMP P...

Page 844: ...N LIGHT SWITCH PAGE 13 13 DATA LINK CONNECTOR DLC PAGE 14 1 S300 S244 D TO S131 PAGE 10 4 5 C210 C136 C200 G200 4 C212 C208 FLASHER PAGE 90 1 C201 80 81 87 570 BK WH 570 BK WH 570 BK WH 570 BK WH G199...

Page 845: ...GHT REAR TURN LAMP PAGE 90 3 RIGHT LICENSE LAMP PAGE 92 1 OIL PRESSURE SWITCH PAGE 26 2 C404 RIGHT BACKUP LAMP PAGE 93 1 C412 G4999 C4992 OIL PUMP PAGE 26 2 LEFT LICENSE LAMP PAGE 92 1 C400 LEFT REAR...

Page 846: ...IRROR SWITCH PAGE 124 1 MASTER WINDOW CONTROL SWITCH PAGE 100 2 C502 2 LEFT DOOR AJAR SWITCH PAGE 59 2 C506 S500 All wires are 57 BK unless otherwise noted EXCEPT POSTAL H TO C200 PAGE 10 8 RIGHT DOOR...

Page 847: ...erwise noted G S1996 BATTERY CONTROL MODULE BCM PAGE 19 2 C1801 33 C1986 RECIRCU LATING FAN PAGE 19 2 C1802 FLOW THRU FAN PAGE 19 2 NiMH LEAD ACID C1810 INDEPENDENT OBSERVER MODULE IOM PAGE 19 3 S1972...

Page 848: ...E 85 2 C155 C183 RIGHT FRONT SIDE MARKER LAMP PAGE 92 4 S180 RIGHT FRONT PARK TURN LAMP PAGE 92 4 C182 C137 CHARGER INLET PAGE 18 3 E FROM C124 PAGE 10 6 BRAKE FLUID LEVEL SWITCH PAGE 61 8 C1969 C5000...

Page 849: ...AGE 10 12 C131 WINDSHIELD WIPER MOTOR PAGE 81 3 A C2099 DATA LINK PAGE 14 5 4 C209 DATA LINK CONNECTOR DLC PAGE 14 5 4 C2994 RECIRCULATION VACUUM SOLENOID PAGE 54 3 C2999 C212 SHIFT LOCK ACTUATOR PAGE...

Page 850: ...res are 57 BK unless otherwise noted R H TURN HAZARD RELAY PAGE 90 6 2 L H TURN HAZARD RELAY PAGE 90 6 2 P REAR HAZARD ONLY RELAY PAGE 90 8 1 LEFT HI BEAM PAGE 85 2 1 Q RIGHT HI BEAM PAGE 85 2 1 R REP...

Page 851: ...S214 B TO S131 PAGE 10 12 C233 2 C234 A C HEATER CONTROL ASSEMBLY PAGE 54 4 4 1 C262 PREHEAT SWITCH PAGE 53 6 C2998 FRESH RECIRCULATION SELECT SWITCH PAGE 54 4 3 L C135 3 POWER STEERING ASSEMBLY PAGE...

Page 852: ...STER PAGES 61 9 61 10 S244 16 C903 GRUMMAN HEADLINER HARNESS PAGE 90 10 P H C216 C261 MAIN LIGHT SWITCH PAGE 13 29 1 C257 HAZARD SWITCH PAGE 90 8 4 C227 CIGAR LIGHTER PAGE 44 1 2 C214 C210 BRAKE PEDAL...

Page 853: ...C180 LEFT FRONT PARK TURN LAMP PAGE 92 4 S181 B C181 C147 C1968 COOLING FAN PAGE 33 1 C164 WINDSHIELD WASHER PUMP MOTOR PAGE 81 2 6 LEFT FRONT SIDE MARKER LAMP PAGE 92 4 LEFT HEADLAMP PAGE 85 2 3 BACK...

Page 854: ...1 87 570 BK WH 570 BK WH 570 BK WH 570 BK WH G1998 G1997 INTERFACE ADAPTER ASSEMBLY IAA MODULE AUXILIARY BATTERY C1945 S1969 DC DC CONVERTER PAGE 12 1 G1999 DC DC CONVERTER GROUND STRAP OIL PUMP PAGE...

Page 855: ...lso be determined by following the color code shown in the chart 20 AMPERE RATING GOOD FUSE BLOWN FUSE MAXI FUSE CARTRIDGE SIDE VIEW TOP VIEW BLOWN GOOD Maxi fuse cartridges have a transparent col ore...

Page 856: ...Module TIM 25 10 7 5 Generic Electronic Module GEM 26 15 Digital Transmission Range DTR Sensor Backup Lights DRL Module 27 10 Battery Saver Relay 28 7 5 Generic Electronic Module GEM 29 10 Radio 30 N...

Page 857: ...UIT PROTECTION 23 24 22 21 27 28 26 25 55 56 B A 53 52 54 49 50 B A 31 32 30 29 35 36 34 33 51 43 44 42 41 39 40 38 37 48 B A 47 B A 46 45 3 4 2 1 5 6 7 9 10 8 11 12 14 15 13 16 17 19 20 18 ELECTRIC V...

Page 858: ...T USED 1 Maxi 50 Ignition Switch 2 Maxi 40 I P Fuse Panel 3 Maxi 30 Anti Lock Brake Control Module 4 NOT USED 5 NOT USED 6 Maxi 60 Anti Lock Brake Control Module 7 Maxi 50 Fan Speed Relays Cooling Fan...

Page 859: ...ELECTRIC VEHICLE 11 5 FUSE PANEL CIRCUIT PROTECTION ELECTRIC VEHICLE POWER DISTRIBUTION BOX EVPDB 38 36 37 35 34 33 29 30 31 32 27 23 24 25 26 28 18 19 20 21 22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16...

Page 860: ...ssembly IAA Module 14 Mini 20 Battery Charger 15 NOT USED 16 Mini 20 Park Lamps 17 NOT USED 18 Maxi 20 Main Light Switch Multifunction Switch 19 Maxi 20 Oil Pump Relay Oil Pump 20 Maxi 20 Coolant Pump...

Page 861: ...icient PTC Switching Module 4 10A Power Steering Assembly 10 AMP 25 AMP 25 AMP 10 AMP PWR STR DC DC 1 2 3 4 HIGH VOLTAGE POWER DISTRIBUTION BOX HVPDB AC PTC 40A AUXILIARY FUSE 10A HEATER FUSE 25A CHAR...

Page 862: ...CTRIC VEHICLE 11 8 FUSE PANEL CIRCUIT PROTECTION OIL PUMP RELAY ALL LOCK RELAY DOOR AJAR RELAY BATTERY SAVER RELAY INTERIOR LAMP RELAY I P RELAY CENTER BOX ALL UNLOCK RELAY ONE TOUCH DOWN RELAY MODULE...

Page 863: ...L PUMP RELAY POWER STEERING RELAY WIPER PARK RELAY PREHEAT IGNITION RELAY PREHEAT INVERTER RELAY REAR HAZARD ONLY RELAY RH TURN HAZARD RELAY LH TURN HAZARD RELAY ECONO MODE RELAY RIGHT HIGH BEAM RELAY...

Page 864: ...2001 RANGER ELECTRIC VEHICLE 11 10 FUSE PANEL CIRCUIT PROTECTION...

Page 865: ...38 BK OG MEGA FUSE POWER DISTRIBUTION PAGE 13 1 2037 RD AUXILIARY BATTERY AUXILIARY BATTERY NEGATIVE 57 BK DC DC CONVERTER For diagnostic information refer to Section 414 02 of the Workshop Manual Re...

Page 866: ...2001 RANGER ELECTRIC VEHICLE 12 2 AUXILIARY BATTERY CHARGING SYSTEM...

Page 867: ...STA A4 1 P1 GND P2 C213 37 YE 37 YE 37 YE 297 BK LG NOT USED 1050 LG VT 32 RD LB 687 GY YE 687 GY YE NOT USED NOT USED C213 16 30A 12 10A 26 15A 22 15A 25 10A 24 7 5A 10 7 5A 14 10A 2 7 5A 11 7 5A 15...

Page 868: ...C136 85 86 87 30 3 5 2 1 S1977 FAN LO SPEED RELAY FAN HI SPEED RELAY 50 RD 50 RD 50 RD 50 RD C1954 C1955 69 101 3828 OG BK 260 RD OG 261 OG BK 3829 LB BK INTERFACE ADAPTER ASSEMBLY IAA MODULE PAGE 33...

Page 869: ...1 HORN PAGE 44 1 POWER POINT PAGE 44 1 C235 1048 LB WH C249 INERTIA SWITCH PAGE 20 1 C136 190 WH OG C1982 CONTACTOR BOX PAGES 16 11 18 2 C1939 1049 BN PK 1048 LB WH 190 WH OG 17 C1945 INTERFACE ADAPT...

Page 870: ...1 566 DG C1991 TRACTION BATTERY CHARGER PAGE 18 1 C124 88 BK WH C134 ELECTRIC VEHICLE POWER DISTRIBUTION BOX EVPDB ELECTRIC VEHICLE POWER DISTRIBUTION BOX EVPDB TO ELECTRIC VEHICLE POWER DISTRIBUTION...

Page 871: ...E BK S1995 E C1983 C1983 554 YE BK 196 DB OG S230 MAIN LIGHT SWITCH PAGE 13 13 6 196 C205 196 DB OG 196 DB OG 196 DB OG C208 87 86 554 YE BK FLOW THRU FAN RELAY PAGE 19 2 S1995 C1983 554 YE BK 86 RECI...

Page 872: ...1 INTERFACE ADAPTER ASSEMBLY IAA MODULE PAGE 33 1 C161 C1998 19 C1945 3229 WH RD BLOWER MOTOR RELAY ELECTRIC VEHICLE POWER DISTRIBUTION BOX EVPDB C124 85 86 87 30 262 BN PK S1970 262 BN PK 87A C4998...

Page 873: ...WINDSHIELD WIPER RELAY 63 RD 63 RD INTERVAL WIPER WASHER PAGE 81 1 671 LB 28 BK PK 2 1 WINDSHIELD WIPER MOTOR PAGE 81 1 HOT IN ACC OR RUN C131 647 GY LB 647 GY LB WINDSHIELD WIPER SPEED RELAY 2 1 3 5...

Page 874: ...TRONIC MODULE TIM PAGE 59 1 17 RADIO PAGE 130 1 364 BK LG C221 TRACTION INVERTER MODULE TIM PAGE 26 1 I P FUSE PANEL 1002 BK PK 10 8 HOT IN RUN HOT IN START C228 24 7 5A 1001 WH YE C4999 33 WH PK C201...

Page 875: ...UN C226 29 10A 1001 WH YE C228 797 LG VT 8 OG YE DIGITAL TRANSMISSION RANGE DTR SENSOR PAGE 26 3 9 C4996 298 VT OG C201 26 15A 86 85 30 87A 383 RD WH 8 OG YE C208 C211 87 FLASHER C211 57 BK 44 LB 385...

Page 876: ...YE 10 584 YE INSTRUMENT CLUSTER PAGE 61 3 C2990 INTERFACE ADAPTER ASSEMBLY IAA MODULE PAGE 16 4 97 295 LB PK C1945 C136 S1959 295 LB PK CONTACTOR BOX PAGES 16 11 21 1 13 BATTERY CONTROL MODULE PAGE 16...

Page 877: ...MES 10 LG RD C134 S1967 I P FUSE PANEL DATA LINK CONNECTOR DLC PAGE 14 1 16 693 OG C209 10 LG RD 2 1 3 5 10 LG RD 10 LG RD S2995 10 LG RD 1 3 C210 10 LG RD 10 LG RD BRAKE PEDAL POSITION BPP SWITCH PAG...

Page 878: ...C205 5 MAIN LIGHT SWITCH PAGE 13 13 792 TN YE 792 TN YE 705 LG OG 1 INSTRUMENT ILLUMINATION DIMMING MODULE PAGE 71 1 1005 VT OG BATTERY SAVER RELAY I P RELAY CENTER BOX 5 C204 705 7 GENERIC ELECTRONI...

Page 879: ...23 15A HOT AT ALL TIMES I P FUSE PANEL PAGE 13 12 C205 C205 HEAD PARK OFF 5 7 HEAD PARK OFF 6 3 2 MAIN LIGHT SWITCH SEE PAGE 149 2 FOR SWITCH TESTING HEAD PARK OFF 4 ILLUMINATION 8 9 19 LB RD S208 C2...

Page 880: ...RUMENT ILLUMINATION DIMMING MODULE PAGE 71 1 A 7 FROM C205 PAGE 13 13 14 1011 TN OG 7 5A I P FUSE PANEL S2900 BN 14 BN 14 BN 14 BN 14 BN C201 C134 C3999 14 BN EXTERIOR LAMPS PAGE 92 1 S1004 14 BN 14 B...

Page 881: ...LO HI 6 2 HEAD PARK OFF MAIN LIGHT SWITCH PAGE 13 13 SEE PAGE 149 2 FOR SWITCH TESTING C208 15 RD YE 15 RD YE C205 C254 C254 C208 33 15A 4 10A 8 10A 632 GY OG 13 RD BK I P FUSE PANEL 1056 DB LG 1055...

Page 882: ...ART RUN OFF LOCK ACC ACC 12 A1 A2 A3 STA A4 1 P1 GND P2 C213 37 YE 37 YE 37 YE 297 BK LG NOT USED 1050 LG VT 32 RD LB 687 GY YE 687 GY YE NOT USED NOT USED C213 16 30A 20 10A 26 15A 22 15A 24 7 5A 10...

Page 883: ...FILL CONNECTOR 1 EVAC FILL CONNECTOR 2 50 RD C136 85 86 87 30 3 5 2 1 S1977 FAN LO SPEED RELAY FAN HI SPEED RELAY 50 RD 50 RD 50 RD 50 RD C1954 C1955 69 101 3828 OG BK 260 RD OG 261 OG BK 3829 LB BK I...

Page 884: ...LB WH C249 INERTIA SWITCH PAGE 20 1 C136 190 WH OG C1982 CONTACTOR BOX PAGES 16 11 18 2 C1939 1048 LB WH 190 WH OG 17 C1945 INTERFACE ADAPTER ASSEMBLY IAA MODULE PAGE 16 5 75 76 931 OG ELECTRIC VEHIC...

Page 885: ...AGE 16 1 566 DG C1991 TRACTION BATTERY CHARGER PAGE 18 1 C124 88 BK WH C134 ELECTRIC VEHICLE POWER DISTRIBUTION BOX EVPDB ELECTRIC VEHICLE POWER DISTRIBUTION BOX EVPDB TO ELECTRIC VEHICLE POWER DISTRI...

Page 886: ...39 554 YE BK S1995 E C1983 C1983 554 YE BK 196 DB OG MAIN LIGHT SWITCH PAGE 13 29 4 C261 87 86 554 YE BK FLOW THRU FAN RELAY PAGE 19 2 S1995 C1983 554 YE BK 86 RECIRCULATING FAN RELAY PAGE 19 2 C2038...

Page 887: ...CE ADAPTER ASSEMBLY IAA MODULE PAGE 33 1 C161 C1998 19 C1945 3229 WH RD BLOWER MOTOR RELAY ELECTRIC VE HICLE POWER DISTRIBUTION BOX EVPDB C124 85 86 87 30 262 BN PK S1970 262 BN PK 87A C4998 19 20A 37...

Page 888: ...R PAGE 81 3 671 LB 28 BK PK 4 5 WINDSHIELD WIPER MOTOR PAGE 81 3 HOT IN ACC OR RUN C131 647 GY LB 647 GY LB WINDSHIELD WIPER SPEED RELAY 1 2 3 5 686 TN RD 941 BK WH 686 TN RD C136 C224 C164 WINDSHIELD...

Page 889: ...CTUATOR PAGE 37 1 ANTI LOCK BRAKE CONTROL MODULE PAGE 42 1 20 14 10A GENERIC ELECTRONIC MODULE GEM PAGE 59 3 C221 TRACTION INVERTER MODULE TIM PAGE 26 1 I P FUSE PANEL 1002 BK PK HOT IN RUN HOT IN STA...

Page 890: ...I P FUSE PANEL HOT IN RUN C226 29 10A 1001 WH YE C270 797 LG VT DIGITAL TRANSMISSION RANGE DTR SENSOR PAGE 26 3 9 C4996 26 15A C3999 298 VT OG 298 VT OG D FROM I P FUSE PANEL PAGE 13 17 1052 TN BK S17...

Page 891: ...N START OR RUN 19 15A C216 295 LB PK TRACTION INVERTER MODULE TIM PAGE 26 1 20 C4998 S4994 640 RD YE 640 RD YE 640 RD YE 640 RD YE 10 584 YE INSTRUMENT CLUSTER PAGE 61 8 C2990 640 RD YE GENERIC ELECTR...

Page 892: ...OWER STEERING ASSEMBLY PAGE 43 2 E S175 295 LB PK 295 LB PK C1939 S1959 295 LB PK 13 CONTACTOR BOX PAGES 16 11 21 1 295 LB PK 295 LB PK 14 BATTERY CONTROL MODULE PAGE 16 2 X 295 LB PK FROM I P FUSE 19...

Page 893: ...LG RD 1 2 3 5 10 LG RD 10 LG RD S2995 10 LG RD 10 LG RD ELECTRIC VEHICLE POWER DISTRIBUTION BOX EVPDB STOP LAMP RELAY C4998 P BK C136 P YE LG C3998 3235 YE LG 6 TRACTION INVERTER MODULE TIM PAGE 26 4...

Page 894: ...B 742 LB 742 LB 742 LB C216 C215 9 1 10 12 C3998 S2900 S4993 276 BN 276 BN C4998 276 BN TRACTION INVERTER MODULE TIM PAGE 26 1 POSTAL 195 TN WH 5 MAIN LIGHT SWITCH PAGE 13 29 C260 S291 195 TN WH J GRU...

Page 895: ...4 4 5 MAIN LIGHT SWITCH SEE PAGE 149 3 FOR SWITCH TESTING HEAD PARK OFF 1 ILLUMINATION 6 6 19 LB RD C903 GRUMMAN HEADLINER HARNESS PAGE 89 3 BK S244 57 53 BK LB 13 RD BK 14 BN SEE GROUNDS PAGE 10 16 G...

Page 896: ...MODULE GEM PAGE 59 4 18 C224 14 BN G 7 FROM C260 PAGE 13 29 14 1011 TN OG 7 5A I P FUSE PANEL S2993 BN 14 BN 14 BN C134 EXTERIOR LAMPS PAGE 92 1 14 BN POSTAL 14 BN E C903 GRUMMAN HEADLINER HARNESS PAG...

Page 897: ...PAGE 13 29 SEE PAGE 149 3 FOR SWITCH TESTING 13 RD BK 13 RD BK C261 4 10A 8 10A I P FUSE PANEL 1056 DB LG WH LG LEFT HIGH BEAM RELAY PAGE 85 2 RIGHT HIGH BEAM RELAY PAGE 85 2 POSTAL S173 1055 3 3 33 1...

Page 898: ...140 BK 3141 WH PWR STR 10A J 3131 RD INTERLOCK SWITCH CLOSED WITH COVER ON 3008 RD 3009 DG C1895 POWER STEERING ASSEMBLY PAGE 43 1 INTERLOCK C1932 DC DC 10A 3117 DB 3118 WH C1914 EMERGENCY POWER OFF E...

Page 899: ...3133 WH I 3131 RD 3131 RD J K C3985 C1935 3132 YE 3134 OG 3132 YE 3132 YE 3133 WH 3131 RD 3180 OG 3180 OG 3181 OG 3181 OG C3994 TRACTION INVERTER MODULE TIM PAGE 26 4 TO HIGH VOLTAGE POWER DISTRIBUTIO...

Page 900: ...2001 RANGER ELECTRIC VEHICLE 13 34 POWER DISTRIBUTION HIGH VOLTAGE...

Page 901: ...ODULE 28 27 C1945 TRACTION INVERTER MODULE TIM PAGE 16 3 5 15 C4998 S1958 S1957 S2990 S2992 C3999 915 PK LB 914 TN OG 915 PK LB 914 TN OG 915 PK LB 914 TN OG C201 915 PK LB 914 TN OG C136 915 PK LB 91...

Page 902: ...250 5 GENERIC ELECTRONIC MODULE GEM PAGE 59 1 C221 3 23 C134 70 LB WH 70 LB WH 70 LB WH S205 70 LB WH 7 DATA LINK CONNECTOR DLC C209 Refer to Location Index Cell 152 for Component Connector Splice and...

Page 903: ...C1939 C1987 INTERFACE ADAPTER ASSEMBLY IAA MODULE 28 27 C1945 TRACTION INVERTER MODULE TIM PAGE 16 3 5 15 C4998 S1958 S1957 S2990 S2992 C3999 915 PK LB 914 915 PK LB 914 915 PK LB 914 C136 915 PK LB...

Page 904: ...LG OG 1 TRACTION BATTERY CHARGER PAGE 16 4 5 BATTERY CONTROL MODULE BCM PAGE 16 4 4 TRACTION BATTERY CHARGER PAGE 16 4 8 BATTERY CONTROL MODULE BCM PAGE 16 4 3035 LG OG C124 3035 LG OG S177 3035 LG OG...

Page 905: ...1 C221 70 LB WH 70 LB WH C154 70 LB WH S2050 C1941 C1946 70 LB WH 7 I P FUSE PANEL PAGE 13 27 693 OG 693 OG S172 16 5 7 5A HOT AT ALL TIMES C209 693 OG C2099 DATA LINK CONNECTOR DLC 570 BK WH S205 5...

Page 906: ...2001 RANGER ELECTRIC VEHICLE 14 6 MULTIPLEX COMMUNICATION NETWORK...

Page 907: ...PK 295 C124 295 LB PK 295 LB PK C1986 12V START OR RUN STEERING WHEEL SENSOR PAGE 43 1 295 LB PK 295 LB PK 295 LB PK 14 SOLID STATE BATTERY CONTROL MODULE BCM C1939 295 LB PK 295 LB PK POWER STEERING...

Page 908: ...R ASSEMBLY IAA MODULE C1945 YA BK C135 Y WH 4 PREHEAT INVERTER RELAY PAGE 53 6 RELAY MODULE 295 LB PK S1998 19 15A HOT IN START OR RUN I P FUSE PANEL PAGE 13 25 295 C136 295 LB PK S1959 295 LB PK C193...

Page 909: ...3501 DB 3501 DB 3501 DB 3404 YE C135 C136 3404 YE 3404 YE 3404 YE C1969 CHARGER INLET PAGE 18 3 S1960 C1939 3404 YE 3404 YE 3503 YE 3501 DB 3503 YE 3501 DB 12 18 17 21 20 C1987 M 914 TN OG 914 TN OG 9...

Page 910: ...1987 3137 GY YE 9 7 20 12 3136 WH 3138 LB BK 1 23 3602 TN YE 15 15 3706 DB 1 4 3003 VT WH 3001 PK OG 3007 VT YE 2 31 10 3 3000 VT 3006 VT LG 18 2 14 9 S1997 12 7 11 6 5 35 5 13 8 14 2 C1986 C1982 3993...

Page 911: ...8 PAGE 16 2 915 PK LB C1945 SOLID STATE SOLID STATE 33 4 3 28 27 91 INTERFACE ADAPTER ASSEMBLY IAA MODULE POSITIVE TEMPERATURE COEFFICIENT PTC SWITCHING MODULE PAGES 53 5 54 5 C1999 N 3006 VT LG 3006...

Page 912: ...GE 16 7 C1982 3403 OG 3403 OG 3403 OG 3403 OG 3403 OG S1956 30 9K RESISTOR 30 9K RESISTOR 30 9K RESISTOR 30 9K RESISTOR 30 9K RESISTOR 312V 3403 OG 3403 OG 3403 OG 3403 OG 3403 OG 3214 LB 3214 LB 3212...

Page 913: ...O BATTERY 32 PAGE 16 8 3403 OG 30 9K RESISTOR 3403 OG BATTERY MODULE 34 30 9K RESISTOR 3403 OG BATTERY MODULE 35 30 9K RESISTOR 3403 OG BATTERY MODULE 36 30 9K RESISTOR 3403 OG 3403 OG 3403 OG OG 3403...

Page 914: ...0 9K RESISTOR 3403 OG 3077 OG LB F TO BATTERY 28 PAGE 16 9 3403 OG 30 9K RESISTOR 3403 OG BATTERY MODULE 30 30 9K RESISTOR 3403 OG BATTERY MODULE 31 30 9K RESISTOR 3403 OG BATTERY MODULE 32 30 9K RESI...

Page 915: ...11 30 9K RESISTOR 3403 OG 3082 BK LG H TO BATTERY 24 PAGE 16 10 3403 OG 30 9K RESISTOR 3403 OG BATTERY MODULE 26 30 9K RESISTOR 3403 OG BATTERY MODULE 27 30 9K RESISTOR 3403 OG BATTERY MODULE 28 30 9K...

Page 916: ...8 DB OG BATTERY MODULE 16 30 9K RESISTOR 3403 OG 3087 DG VT 3403 OG 30 9K RESISTOR 3403 OG BATTERY MODULE 22 30 9K RESISTOR 3403 OG BATTERY MODULE 23 30 9K RESISTOR 3403 OG BATTERY MODULE 24 30 9K RES...

Page 917: ...2001 RANGER ELECTRIC VEHICLE 16 11 TRACTION BATTERY SYSTEM To Traction Battery To Traction Inverter Module TIM To High Voltage Power Distribution Box HVPDB CONTACTOR BOX Y O W R...

Page 918: ...TTERY MODULE 25 J TO BATTERY 24 PAGE 16 16 C1982 3403 OG 3403 OG 3403 OG S1956 30 9K RESISTOR 30 9K RESISTOR 30 9K RESISTOR 312V 3403 OG 3403 OG 3403 OG 3214 LB 3214 LB 3212 DB 3212 DB 3097 RD LG 3097...

Page 919: ...G 3403 OG 3076 YE WH 9 3075 YE BATTERY MODULE 3 30 9K RESISTOR 3403 OG 3074 BK OG BATTERY MODULE 2 30 9K RESISTOR 3403 OG 3073 RD WH BATTERY MODULE 1 30 9K RESISTOR 3403 OG 3072 PK YE K TO S1955 PAGE...

Page 920: ...3403 OG 3403 OG 30 9K RESISTOR 30 9K RESISTOR 3403 OG 3403 OG 3081 WH RD 22 3080 RD LB BATTERY MODULE 8 30 9K RESISTOR 3403 OG 3079 WH PK BATTERY MODULE 7 30 9K RESISTOR 3403 OG 3078 LB OG BATTERY MOD...

Page 921: ...9K RESISTOR 30 9K RESISTOR 3403 OG 3403 OG 3086 WH VT 6 3085 OG LG BATTERY MODULE 13 30 9K RESISTOR 3403 OG 3084 BK PK BATTERY MODULE 12 30 9K RESISTOR 3403 OG 3083 DG LG BATTERY MODULE 11 30 9K RESI...

Page 922: ...3 OG 30 9K RESISTOR 3403 OG BATTERY MODULE 22 30 9K RESISTOR 3403 OG BATTERY MODULE 23 30 9K RESISTOR 3403 OG BATTERY MODULE 24 30 9K RESISTOR 3403 OG 3403 OG 3403 OG OG 3403 OG T 3403 OG 3403 OG 3403...

Page 923: ...3826 WH 3826 WH 3990 3990 3990 SOLID STATE 12 3 3404 YE 3404 YE 3404 YE 3404 YE 3404 YE 3404 YE A FROM C1969 PAGES 18 3 18 4 3404 YE 18 13 3503 YE 3503 YE 3503 YE 3503 YE 3503 YE C4998 17 20 3501 DB...

Page 924: ...0 WH OG C B A D E C1982 12V 21 3709 RD UPPER BATTERY HEATER C1859 C1861 57 BK S1954 LOWER BATTERY HEATER C1863 C1862 57 BK 1201 DB WH 1161 DB OG C1864 3996 RD YE 3705 LB 3001 VT OG 3000 VT 3007 VT YE...

Page 925: ...12 3404 YE 3404 YE A TO S1960 PAGE 18 1 C1969 3984 RD C124 3984 RD C1993 5 6 0V C1991 240VAC 240VAC C1938 WH 3172 OG TRACTION BATTERY CHARGER 57 BK S1999 57 BK G103 SEE GROUNDS PAGES 10 4 10 6 10 12 3...

Page 926: ...AGE 18 1 C1969 3984 RD 3984 RD C1939 3984 RD C1993 5 6 0V C1991 240VAC 240VAC C1938 WH 3172 OG TRACTION BATTERY CHARGER 57 BK S1999 57 BK G103 SEE GROUNDS PAGES 10 4 10 6 10 12 3171 WH 3170 OG C1923 H...

Page 927: ...BCM PAGE 19 1 40 C1986 1163 BN 9 3703 BN WH C1988 UPPER FRONT PACK TEMPERATURE SENSOR 1 C1989 UPPER REAR PACK TEMPERATURE SENSOR 2 C1981 LOWER FRONT PACK TEMPERATURE SENSOR 3 C1985 LOWER REAR PACK TE...

Page 928: ...RATURE SENSOR 1 IOM 2 1 22 35 4003 WH C1804 4002 LG BATTERY TEMPERATURE SENSOR 2 IOM 2 1 23 36 4005 BN C1805 4004 VT BATTERY TEMPERATURE SENSOR 3 IOM 2 1 24 37 4008 RD BK 32 C1986 36 BATTERY CONTROL M...

Page 929: ...397 WH RD E G C D A TRACTION BATTERY COOLING FAN B FROM C1983 THIS PAGE C1984 57 BK 3852 BK LG 3396 YE LG 3395 OG LB 3397 WH RD C1984 S131 C1939 57 BK 57 BK 57 BK S1996 A FROM C1983 THIS PAGE C1987 38...

Page 930: ...1983 RECIRCULATING FAN RELAY C2038 C2038 554 YE BK 554 YE BK 554 YE BK 554 YE BK 3850 LG VT 3852 BK LG 10 BATTERY CONTROL MODULE BCM 23 FLOW THRU FAN C1802 3851 YE RD C1986 3395 OG LB 2 3 C1802 1 RECI...

Page 931: ...ERATURE SENSOR 1 IOM 2 1 22 35 4003 WH C1804 4002 LG BATTERY TEMPERATURE SENSOR 2 IOM 2 1 23 36 4005 BN C1805 4004 VT BATTERY TEMPERATURE SENSOR 3 IOM 2 1 24 37 4008 RD BK 32 C1986 36 BATTERY CONTROL...

Page 932: ...2001 RANGER ELECTRIC VEHICLE 19 4 TRACTION BATTERY COOLING VENTILATION...

Page 933: ...974 OG C1939 C1980 C134 C3994 C4998 3410 YE 3997 DG C1980 C134 C1939 C201 C3998 3997 DG 3997 DG 3997 DG 3997 DG 3410 YE 6 16 TRACTION BATTERY SUPPORT TRAY PAGE 13 33 TRACTION INVERTER MODULE TIM 35 1...

Page 934: ...3985 C1935 C1931 3131 RD 3131 RD C1888 C1895 POWER STEERING CONTROLLER ASSEMBLY PAGE 43 1 3008 RD HIGH VOLTAGE POWER DISTRIBUTION BOX HVPDB PAGE 13 32 INTERLOCK Refer to Location Index Cell 152 for Co...

Page 935: ...he Workshop Manual HOT IN START OR RUN S1959 295 LB PK 295 LB PK 13 17 22 10A HOT AT ALL TIMES 190 WH OG 190 WH OG 12V START OR RUN 12V C1939 C1982 I P FUSE PANEL PAGES 13 10 13 25 ELECTRIC VEHICLE PO...

Page 936: ...NTERFACE ADAPTER ASSEMBLY IAA MODULE 12V START OR RUN C1945 S1962 570 BK WH G101 SEE GROUNDS PAGE 10 2 57 BK 8 57 BK S131 57 BK G103 SEE GROUNDS PAGE 10 4 C1939 C1982 CONTACTOR BOX PAGE 16 11 SOLID ST...

Page 937: ...C1945 S1962 570 BK WH G101 SEE GROUNDS PAGE 10 2 57 BK 8 57 BK S131 57 BK G105 SEE GROUNDS PAGES 10 11 10 12 C1939 C1982 CONTACTOR BOX PAGE 16 11 SOLID STATE 11 18 18 8 TRACTION INVERTER MODULE TIM 3...

Page 938: ...2001 RANGER ELECTRIC VEHICLE 21 4 CONTACTOR BOX RELAY CONTROL...

Page 939: ...15 16 3601 WH RD 3600 RD WH 3603 RD 3836 YE LB 3837 GY YE 3835 YE WH 3010 TN 3011 BK OG 3012 WH 3013 GY BK 3014 BK WH 3015 WH RD 3601 WH RD 3600 RD WH 3603 RD 3601 WH RD 3600 RD WH 3603 RD 3601 WH RD...

Page 940: ...CH 12 3605 DB WH C4999 C4997 C4997 OIL PUMP 40 36 26 30 2 11 31 BK VT 3700 LB RD 3701 DB WH 3707 OG 3708 BN 3757 3659 9 4 1 8 5 2 TRACTION INVERTER MODULE TIM S4997 57 BK C4998 SEE GROUNDS PAGES 10 9...

Page 941: ...3 9 13 24 BATTERY CONTROL MODULE BCM PAGE 18 1 C3999 298 VT OG 298 VT OG 9 11 3501 DB 3501 DB 3501 DB 3501 DB 3503 YE C1939 3503 YE 3503 YE C136 C201 C3998 3503 YE 3503 YE S4996 S4995 3501 DB 3501 DB...

Page 942: ...80 OG HIGH VOLTAGE POWER DISTRIBUTION PAGE 13 33 3181 OG 3018 WH 3016 LG BK 3019 GY BK SIEMANS INTERACTIVE AUTOMOTIVE DIAGNOSTIC INTERFACE SYSTEM SIADIS C409 16 3986 DG 3986 DG 3986 DG 3986 DG 3986 DG...

Page 943: ...C1966 COOLANT TEMPERATURE SENSOR 69 50 RD S1977 50 50 RD 87 30 85 86 C1954 C1954 3828 OG BK FAN LOW SPEED RELAY 3 5 2 C1955 RD 50 RD 50 C1955 3829 LB BK C1945 INTERFACE ADAPTER ASSEMBLY IAA MODULE FAN...

Page 944: ...2001 RANGER ELECTRIC VEHICLE 33 2 COOLING SYSTEM...

Page 945: ...locations SHIFT LOCK ACTUATOR G200 C212 C212 57 BK 57 BK 810 RD LG 810 RD LG SEE TURN STOP HAZARD LAMPS PAGES 90 4 90 9 For diagnostic information refer to Section 307 05 of the Workshop Manual 12V BP...

Page 946: ...2001 RANGER ELECTRIC VEHICLE 37 2 SHIFT LOCK...

Page 947: ...K BK 519 LG BK 518 LG RD 523 RD PK C4995 C4994 6 60A HOT AT ALL TIMES 534 YE LG 3 30A HOT AT ALL TIMES 14 10A HOT IN RUN 483 RD 601 LB VT ELECTRIC VEHICLE POWER DISTRIBUTION BOX EVPDB PAGES 13 2 13 17...

Page 948: ...LB 491 OG LB 491 OG LB C4999 ABS MOTOR ABS INDICATOR TRACTION INVERTER MODULE TIM INSTRUMENT CLUSTER PAGES 61 4 61 9 C3998 C201 224 TN WH 603 DG 603 DG S2996 ANTI LOCK BRAKE CONTROL MODULE 16 C154 60...

Page 949: ...ELAY 10 LG RD 10 LG RD 10 LG RD 3235 BK LB 511 LG C136 3235 YE LG C201 3235 YE LG C3998 6 TRACTION INVERTER MODULE TIM 3235 YE LG C4998 C210 10 LG RD ANTI LOCK BRAKE CONTROL MODULE SHIFT LOCK ACTUATOR...

Page 950: ...2001 RANGER ELECTRIC VEHICLE 42 4 ANTI LOCK BRAKE SYSTEM ABS...

Page 951: ...57 BK 3023 BK OG 3022 RD YE G103 C221 SEE GROUNDS PAGES 10 4 10 6 10 12 SEE POWER DISTRIBUTION PAGES 13 10 13 25 13 26 295 LB PK 295 LB PK 679 GY BK C201 C3999 14 INSTRUMENT CLUSTER PAGE 61 2 679 GY B...

Page 952: ...N HOT AT ALL TIMES S1959 295 LB PK 295 LB PK S175 F WH 27 10A I P FUSE PANEL PAGE 13 28 S292 792 TN YE 792 TN YE 3 5 1 2 POWER STEERING RELAY RELAY MODULE SEE POWER DISTRIBUTION PAGE 13 28 SEE POWER D...

Page 953: ...K WH SEE GROUNDS PAGES 10 1 10 2 G101 AIR BAG SLIDING CONTACT PAGE 46 1 57 BK 1049 BN BK C135 C235 C235 POWER POINT 17 10A HOT AT ALL TIMES I P FUSE PANEL PAGES 13 9 13 24 40 LB WH C226 CIGAR LIGHTER...

Page 954: ...2001 RANGER ELECTRIC VEHICLE 44 2 HORN CIGAR LIGHTER...

Page 955: ...PK WH 619 PK WH C135 S156 19 183 TN YE C221 GENERIC ELECTRONIC MODULE GEM PAGE 59 1 28 20 INSTRUMENT CLUSTER PAGE 61 4 608 BK YE 5 70 LB WH MULTIPLEX COMMUNICATION NETWORK PAGE 14 2 10 21 649 BK OG 64...

Page 956: ...Power Hot in Run NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED Warning Indicators Ground NOT USED NOT USED NOT USED Crash Sensors Generic Electronic Module GEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14...

Page 957: ...262 BN PK 262 BN PK BLOWER MOTOR RELAY 3020 LB 181 BN OG C161 C161 BLOWER MOTOR 758 PK WH S1971 57 BK 57 BK G105 VARIABLE BLOWER CONTROLLER VBC 85 86 87 30 87A 2 3 1 5 4 C1971 515 OG RD 361 RD 148 YE...

Page 958: ...38 RD WH 436 RD LG 245 NR LG 246 VT 437 YE LG 438 RD WH 436 RD LG 6 7 51 72 85 C240 INTERFACE ADAPTER ASSEMBLY IAA MODULE 3050 WH OG 3060 GY RD C2997 IN CAR TEMPERATURE SENSOR 49 79 77 96 3062 BK WH 3...

Page 959: ...34 BLOWER SWITCH 3068 BN PK 3067 LB RD 3066 OG YE C136 C2999 3052 YE LG 3052 YE LG 3068 BN PK 3067 LB RD 3066 OG YE C2999 S214 57 BK G103 SEE GROUNDS PAGES 10 4 10 5 RECIRCULATION VACUUM SOLENOID C299...

Page 960: ...LLUMINATION PAGE 71 2 3054 BK LG 3053 BN WH SOLID STATE C2998 INTERFACE ADAPTER ASSEMBLY IAA MODULE 3056 TN LG C1945 58 3056 TN LG HEATER CONTROL ASSEMBLY G103 SEE GROUNDS PAGES 10 4 10 5 C234 FLOOR D...

Page 961: ...03 3036 YE WH 3036 YE WH 3036 YE WH C136 C2999 57 BK 57 BK SEE GROUNDS PAGES 10 4 10 6 Refer to Location Index Cell 152 for Component Connector Splice and Ground descriptions and locations 2 9 3 OG WH...

Page 962: ...NSTRUMENT ILLUMINATION PAGE 71 4 C136 19 LB RD PREHEAT SWITCH C262 C262 57 BK PREHEAT INVERTER RELAY W RD LG 1 2 3 5 RELAY MODULE 931 OG S147 C135 931 OG 931 OG SEE GROUNDS PAGES 10 12 10 15 B SEE POW...

Page 963: ...ER DASH FAN SWITCH POSTAL HOT AT ALL TIMES 29 10A I P FUSE PANEL PAGE 13 24 C270 797 LG VT C270 C271 S RD R LG DASH FAN Refer to Location Index Cell 152 for Component Connector Splice Ground and Base...

Page 964: ...2001 RANGER ELECTRIC VEHICLE 53 8 HEATER...

Page 965: ...G C161 C161 BLOWER MOTOR 758 PK WH S1971 57 BK 57 BK G105 VARIABLE BLOWER CONTROLLER VBC 85 86 87 30 87A SENSE LINE LOW 2 12V 3 SENSE LINE HIGH 1 5 4 C1971 515 OG RD 361 RD 148 YE RD 5 SENSE LINE LOW...

Page 966: ...YE LG 438 RD WH 436 RD LG 245 BN LG 246 PK 437 YE LG 438 RD WH 436 RD LG 6 7 51 72 85 C240 INTERFACE ADAPTER ASSEMBLY IAA MODULE 3050 WH OG 3060 GY RD C2997 IN CAR TEMPERATURE SENSOR 49 79 77 96 3062...

Page 967: ...068 BN PK 3067 LB RD 3066 OG YE C136 C2999 3052 YE LG 3052 YE LG 3068 BN PK 3067 LB RD 3066 OG YE C2999 S214 57 BK G103 SEE GROUNDS PAGES 10 4 10 5 10 12 10 13 RECIRCULATION VACUUM SOLENOID C2994 C299...

Page 968: ...CONTROL ASSEMBLY S209 2 57 BK 0V MODE SELECT SWITCH 19 LB RD INSTRUMENT ILLUMINATION PAGES 71 2 71 5 C233 S2998 57 BK 0V FLOOR DEFROST DEFROST FLOOR PANEL FLOOR A C 3 4 C233 G103 SEE GROUNDS PAGES 10...

Page 969: ...7 GY WH C134 C2999 3037 GY WH 3037 GY WH S1999 G103 3036 YE WH 3036 YE WH 3036 YE WH C136 C2999 57 BK 57 BK SEE GROUNDS PAGES 10 4 10 6 10 12 3260 OG WH 3260 OG WH 3261 PK YE 3261 PK YE 3038 OG 3038 O...

Page 970: ...OG 3220 PK 3029 DG OG 3031 BK PK 3030 DG OG 3220 PK C1972 EVAPORATOR TEMPERATURE SENSOR INTERFACE ADAPTER ASSEMBLY IAA MODULE 93 C1945 3063 TN OG 3051 BK YE A C OVERTEMPERATURE SENSOR 3221 BN LB 3221...

Page 971: ...3151 WH A B C WARNING This system contains high voltage components and wiring Do not attempt any service procedures without direction from the workshop manual Failure to follow this warning may result...

Page 972: ...2001 RANGER ELECTRIC VEHICLE 54 8 AIR CONDITIONER HEATER...

Page 973: ...RELAY PAGE 13 12 I P RELAY CENTER BOX HOT AT ALL TIMES C224 12V 12V ACC OR RUN 12V RUN 5 2 1 3 1005 VT OG 12V 15 IGNITION ACC OR RUN 17 IGNITION ACC OR RUN 1 BATT 8 BATTERY SAVER RELAY CONTROL 705 LG...

Page 974: ...1 I P RELAY CENTER BOX C224 7 INTERIOR LAMP RELAY CONTROL 14 BN 671 LB MODE SELECT SWITCH INPUT 765 YE BK C219 2 COIL 761 GY RD PASSENGER DOOR AJAR INPUT SEE GROUNDS PAGE 10 10 WASHER PUMP RELAY CONTR...

Page 975: ...2 RELAY MODULE HOT AT ALL TIMES C224 12V 12V ACC OR RUN 3 2 1 5 1005 VT OG 15 IGNITION ACC OR RUN 17 IGNITION ACC OR RUN 1 BATT 8 POWER STEERING RELAY CONTROL 705 LG OG VSS OUTPUT 14 2 SELF TEST ISO...

Page 976: ...646 YE WH 4 5 WIPER HI LO RELAY CONTROL WIPER RUN PARK RELAY CONTROL POSTAL VSS OUTPUT 14 679 GY BK VEHICLE SPEED SENSOR VSS PAGE 64 2 686 TN RD 10 4 MAIN LIGHT SWITCH PAGE 13 29 SEE POWER DISTRIBUTIO...

Page 977: ...itch Internal Delay Wash Input One Touch Down Sense High NOT USED 1 2 3 4 5 6 7 8 9 10 11 C221 PIN CIRCUIT CIRCUIT FUNCTION GENERIC ELECTRONIC MODULE GEM 9 8 7 6 5 4 3 10 12 11 2 1 19 18 17 16 15 14 1...

Page 978: ...l NOT USED GEM Battery Saver Output Module One Touch Down Relay Output NOT USED Wiper Pump Relay Control 1 2 3 4 5 6 7 8 9 10 C224 PIN CIRCUIT CIRCUIT FUNCTION GENERIC ELECTRONIC MODULE GEM 9 8 7 6 5...

Page 979: ...LB 742 LB 12V 12V 12V ECONOMY MODE INDICATOR 5 5 MALFUNCTION INDICATOR LAMP MIL POWER RESET INDICATOR CHARGE INDICATOR AUXILIARY BATTERY INDICATOR POWER LIMIT WARNING INDICATOR LOW OIL PRESSURE INDICA...

Page 980: ...LID STATE INSTRUMENT CLUSTER INTERFACE ADAPTER ASSEMBLY IAA C134 C FROM S2900 PAGE 61 1 C134 3049 BK LG 3049 BK LG 3049 BK LG 3049 BK LG TO INSTRUMENT CLUSTER PAGE 61 3 570 BK WH G101 SEE GROUNDS PAGE...

Page 981: ...G 512 T LG SOLID STATE INSTRUMENT CLUSTER INTERFACE ADAPTER ASSEMBLY IAA MODULE E D FROM INSTRUMENT CLUSTER PAGE 61 1 C216 C134 FROM INSTRUMENT CLUSTER PAGE 61 2 162 LG RD C202 C201 S2989 162 LG RD C1...

Page 982: ...EAM INDICATOR LEFT TURN SIGNAL RIGHT TURN SIGNAL 3 LG WH 2 WH LB INSTRUMENT CLUSTER TURN STOP HAZARD LAMPS PAGE 90 2 AIR BAG DIAGNOSTIC MONITOR PAGE 46 1 20 3 10 6 1 5 8 GENERAL ELECTRONIC MODULE GEM...

Page 983: ...or Splice and Ground descriptions and locations B FROM C214 PAGE 61 2 GENERIC ELECTRONIC MODULE GEM PAGE 59 2 14 POWER STEERING ASSEMBLY PAGE 43 1 15 TRACTION INVERTER MODULE TIM 7 19 LB RD C214 19 LB...

Page 984: ...MIL POWER RESET INDICATOR CHARGE INDICATOR AUXILIARY BATTERY INDICATOR POWER LIMIT WARNING INDICATOR LOW OIL PRESSURE INDICATOR H TO INSTRUMENT CLUSTER PAGE 61 8 10 8 2 7 1 3 2 1 12 742 LB 3044 LB 304...

Page 985: ...SOLID STATE INSTRUMENT CLUSTER INTERFACE ADAPTER ASSEMBLY IAA C134 G FROM S2900 PAGE 61 6 C134 3049 BK LG 3049 BK LG 3049 BK LG 3049 BK LG TO INSTRUMENT CLUSTER PAGE 61 8 570 BK WH G101 SEE GROUNDS P...

Page 986: ...61 9 9 7 7 4 3407 RD WH 3042 PK LG C216 C1945 13 11 39 C215 C136 C214 3407 RD WH 3042 PK LG 512 T LG SOLID STATE INSTRUMENT CLUSTER INTERFACE ADAPTER ASSEMBLY IAA MODULE K H FROM INSTRUMENT CLUSTER PA...

Page 987: ...R SAFETY BELT INDICATOR ABS INDICATOR HI BEAM INDICATOR LEFT TURN SIGNAL RIGHT TURN SIGNAL 3 LG WH 2 WH LB INSTRUMENT CLUSTER TURN STOP HAZARD LAMPS PAGE 90 6 3 10 6 1 5 8 ANTI LOCK BRAKES PAGE 42 2 5...

Page 988: ...152 for Component Connector Splice and Ground descriptions and locations J FROM C214 PAGE 61 7 GENERIC ELECTRONIC MODULE GEM PAGE 59 4 14 POWER STEERING ASSEMBLY PAGE 43 1 15 TRACTION INVERTER MODULE...

Page 989: ...14 SEE POWER DISTRIBUTION PAGES 13 13 13 14 PARK HEAD C205 14 BN DOME 1 3 4 2 A 705 LG OG COURTESY LAMPS PAGE 89 1 COURTESY LAMPS PAGE 89 1 1011 TN OG C204 55 BK PK 19 LB RD C204 TO S208 PAGE 71 2 IN...

Page 990: ...71 1 B C TO C205 PAGE 71 1 TO C228 PAGE 71 1 19 LB RD 19 LB RD 19 LB RD 19 LB RD 6 3 16 C219 19 LB RD S214 C233 C2998 C214 C215 C219 SEE GROUNDS PAGES 10 1 10 2 SEE GROUNDS PAGES 10 3 10 4 G103 57 BK...

Page 991: ...WITCH PAGE 13 29 HEAD PARK OFF 1 ILLUMINATION 6 6 19 LB RD BK S244 57 SEE GROUNDS PAGE 10 8 G200 BK 57 TO S208 PAGE 71 5 B 1011 TN OG Z FROM I P FUSE 7 THIS PAGE 195 TN WH 195 TN WH C260 S291 SEE POWE...

Page 992: ...LAMP FROM S208 PAGE 71 5 19 LB RD S923 C905 SEE GROUNDS PAGE 10 16 BK C905 57 G200 BK 57 19 LB RD S924 15 7 5A HOT IN START OR RUN 7 7 5A HOT IN HEAD OR PARK I P FUSE PANEL PAGES 13 25 13 30 17 INSTR...

Page 993: ...E 54 4 TO S924 PAGE 71 4 B FROM C261 PAGE 71 3 TO ECONOMY MODE RELAY PAGE 71 4 19 LB RD 19 LB RD 19 LB RD 19 LB RD 6 3 16 C219 19 LB RD S214 C233 C2998 C214 C215 C219 SEE GROUNDS PAGES 10 1 10 2 SEE G...

Page 994: ...2001 RANGER ELECTRIC VEHICLE 71 6 INSTRUMENT ILLUMINATION...

Page 995: ...YE WH C136 671 LB 646 YE WH C224 2 4 GENERIC ELECTRONIC MODULE GEM PAGE 59 2 671 LB 63 RD 63 RD WINDSHIELD WIPER SPEED RELAY 4 5 3 ELECTRIC VEHICLE POWER DISTRIBUTION BOX EVPDB PAGE 13 7 2 1 56 DB OG...

Page 996: ...4 57 BK S117 686 TN RD 10 GENERIC ELECTRONIC MODULE GEM PAGE 59 2 57 BK G105 SEE GROUNDS PAGE 10 7 MULTIFUNCTION SWITCH SEE PAGE 149 5 FOR SWITCH TESTING C254 680 LB OG 359 GY RD 684 PK YE C208 GENERI...

Page 997: ...6 YE WH C136 646 YE WH C224 2 4 GENERIC ELECTRONIC MODULE GEM PAGE 59 3 671 LB 63 RD WINDSHIELD WIPER SPEED RELAY 4 5 3 ELECTRIC VEHICLE POWER DISTRIBUTION BOX EVPDB PAGE 13 22 1 2 56 DB OG 58 WH 647...

Page 998: ...CTRONIC MODULE GEM PAGE 59 4 57 BK G1998 SEE GROUNDS PAGE 10 17 MULTIFUNCTION SWITCH C254 680 LB OG 359 GY RD 684 PK YE C208 GENERIC ELECTRONIC MODULE GEM PAGES 59 3 59 4 10 20 9 680 LB OG 359 GY RD 6...

Page 999: ...30A SEE GROUNDS PAGES 10 12 10 13 G105 HOT IN ACC OR RUN 63 RD I P FUSE PANEL PAGE 13 22 S150 63 RD 63 RD SEE POWER DISTRIBUTION PAGE 13 22 671 LB 57 BK 57 BK POSTAL 61 YE RD E TO C131 PAGE 81 3 FROM...

Page 1000: ...2001 RANGER ELECTRIC VEHICLE 81 6 INTERVAL WIPER WASHER...

Page 1001: ...ITCH DIMMER SWITCH 632 GY OG C254 13 RD BK 33 15A I P FUSE PANEL PAGE 13 15 4 10A 8 10A MULTIFUNCTION SWITCH SEE PAGE 149 6 FOR SWITCH TESTING SEE POWER DISTRIBUTION PAGE 13 5 WITH MULTIFUNCTION SWITC...

Page 1002: ...LASH TO PASS SWITCH DIMMER SWITCH MULTI FUNCTION SWITCH S173 13 RD BK 1055 WH LG 1056 DB LG 2 1 3 5 RIGHT HIGH BEAM RELAY AUXILIARY RELAY BOX 2 4 2 1 3 5 LEFT HIGH BEAM RELAY 4 15 RD YE 12 LG BK A FRO...

Page 1003: ...PAGE 71 1 I P RELAY CENTER BOX 55 BK PK C204 57 BK 0V C900 C900 OUTSIDE CARGO HIGH MOUNTED STOPLAMP 55 BK PK 569 DG HIGH MOUNTED STOPLAMP OUTSIDE CARGO LAMP TURN STOP HAZARD LAMPS PAGE 90 4 INTERIOR M...

Page 1004: ...O LAMP SWITCH 27 10A HOT AT ALL TIMES POWER DISTRIBUTION PAGE 13 28 I P FUSE PANEL PAGE 13 28 C904 GRUMMAN HEADLINER HARNESS 792 TN YE C904 T DB U YE Refer to Location Index Cell 152 for Component Con...

Page 1005: ...ction 417 01 of the Workshop Manual 22 15A I P FUSE PANEL PAGE 13 9 21 15A HOT IN RUN HOT AT ALL TIMES FLASHER C211 12V RUN 12V C208 383 RD WH 383 RD WH 8 OG YE 8 OG YE 85 86 C211 C208 A TO C253 PAGE...

Page 1006: ...GE 90 1 B 385 WH RD 44 LB C253 INSTRUMENT CLUSTER PAGE 61 4 C214 C216 C208 S251 3 LG WH 374 DB WH 378 BN YE 2 WH LB S2987 2 WH LB 2 WH LB 12V 12V D TO C136 PAGE 90 3 5 2 C216 0V 8 LEFT TURN INDICATOR...

Page 1007: ...3 LG WH 12V C148 12V C180 E FROM S2987 PAGE 90 2 C136 S155 2 WH LB 2 WH LB 2 WH LB 12V C156 2 WH LB 12V C182 C148 0V G105 S123 57 BK 57 BK 57 BK SEE GROUNDS PAGES 10 6 10 7 C182 0V G105 S117 57 BK 57...

Page 1008: ...999 57 BK S244 G103 57 BK SEE GROUNDS PAGE 10 4 810 RD LG S228 C212 C154 511 LG C201 810 RD LG C3997 810 RD LG 810 RD LG 810 RD LG 810 RD LG C135 511 LG S229 3235 YE LG LEFT REAR PARK STOPLAMP PAGE 92...

Page 1009: ...G YE 85 86 C211 TO S251 PAGE 90 6 Z 57 BK 44 LB G105 SEE GROUNDS PAGES 10 12 10 13 30 87 POSTAL S170 S209 8 OG YE C208 1344 VT LB S171 44 LB 2 WH LB C208 2 WH LB C253 MULTIFUNCTION SWITCH C254 6 1 C25...

Page 1010: ...HAZARD RELAY 1 2 5 3 4 378 BN YE 458 OG BK 3 LG WH A FROM S296 PAGE 90 8 REPEATER ISOLATION RELAY 85 86 87 30 87a RH TURN HAZARD RELAY 1 2 5 3 4 Y 1042 RD OG FROM C208 PAGE 90 5 57 BK 458 OG BK 1042...

Page 1011: ...AGE 92 4 RIGHT FRONT SIDE MARKER LAMP PAGE 92 4 D FROM LH TURN HAZARD RELAY PAGE 90 6 S154 9 LG OG 3 LG W 3 LG WH 3 LG WH C181 C180 E C136 S155 5 OG LB 2 WH LB C182 2 WH LB C183 C181 G1998 S181 57 BK...

Page 1012: ...ASHER RELAY 85 86 C272 57 BK 57 BK 378 BN YE G105 30 87 87A SEE POWER DISTRIBUTION PAGE 13 24 C257 1 S244 S209 C272 SEE GROUNDS PAGES 10 12 10 13 A TO LH TURN HAZARD RELAY PAGE 90 6 B TO RH TURN HAZAR...

Page 1013: ...134 10 LG RD 10 LG RD 10 LG RD 10 LG RD ANTI LOCK BRAKE CONTROL MODULE PAGE 42 3 2 SHIFT LOCK ACTUATOR PAGE 37 1 TRACTION INVERTER MODULE TIM PAGE 42 3 14 C210 C4999 57 BK S244 G200 57 BK SEE GROUNDS...

Page 1014: ...2001 RANGER ELECTRIC VEHICLE 90 10 TURN STOP HAZARD LAMPS...

Page 1015: ...TO S130 PAGE 92 2 C201 C3999 14 BN 14 BN 14 BN S1004 RIGHT REAR PARK STOP LAMP LEFT REAR PARK STOP LAMP LEFT LICENSE LAMP RIGHT LICENSE LAMP TURN STOP HAZARD LAMPS PAGE 90 4 TURN STOP HAZARD LAMPS PAG...

Page 1016: ...V 0V 0V 0V 0V S123 S117 57 BK 57 BK 57 BK 57 BK 57 BK 57 BK 57 BK 57 BK SEE GROUNDS PAGE 10 7 SEE GROUNDS PAGES 10 6 10 7 14 BN 14 BN TURN STOP HAZARD LAMPS PAGE 90 3 3 LG WH TURN STOP HAZARD LAMPS PA...

Page 1017: ...195 TN WH POSTAL 23 15A MAIN LIGHT SWITCH PAGE 13 29 SEE PAGE 149 3 FOR SWITCH TESTING 5 OFF 4 HEAD PARK C260 C260 14 BN SEE POWER DISTRIBUTION PAGE 13 29 S2993 C134 14 BN A TO S130 PAGE 92 4 14 BN 14...

Page 1018: ...180 C182 C183 C181 C183 C180 C182 S181 S180 57 BK 57 BK 57 BK 57 BK 57 BK 57 BK G1998 G105 SEE GROUNDS PAGE 10 12 SEE GROUNDS PAGE 10 17 14 BN TURN STOP HAZARD LAMPS PAGE 90 7 3 LG WH TURN STOP HAZARD...

Page 1019: ...HOT IN RUN I P FUSE PANEL PAGE 13 9 C4996 REVERSE PARK NEUTRAL DRIVE 11 9 C4996 140 BK PK 140 BK PK S403 C401 C405 140 BK PK 140 PK BK LEFT BACKUP LAMP RIGHT BACKUP LAMP 57 BK 57 BK 57 BK S400 SEE GRO...

Page 1020: ...6 140 BK PK 140 BK PK 57 BK SEE GROUNDS PAGE 10 17 DIGITAL TRANSMISSION RANGE DTR SENSOR PAGE 26 3 FOR COMPONENT TESTING SEE WORKSHOP MANUAL SECTION 307 05 POSTAL Refer to Location Index Cell 152 for...

Page 1021: ...GE TO HIGH BEAMS SEE POWER DISTRIBUTION PAGE 13 9 SEE GROUNDS PAGE 10 7 I P FUSE PANEL PAGE 13 9 C150 12V 57 BK HOT IN RUN HOT AT ALL TIMES FROM S122 PAGE 97 2 HEADLAMPS PAGE 85 1 SEE INSTRUMENT CLUST...

Page 1022: ...Cell 152 for Component Connector Splice Ground and Base Part Number descriptions and locations 0V 0V 12V 12V 12V 12V 20A S122 1056 DB LG SEE POWER DISTRIBUTION PAGE 13 13 SEE POWER DISTRIBUTION PAGE 1...

Page 1023: ...12V ACC OR RUN 3 I P RELAY CENTER BOX S217 S226 1007 YE RD 903 RD 991 TN LB 991 TN LB 995 GY C224 903 RD 9 ONE TOUCH DOWN RELAY OUTPUT 11 ONE TOUCH DOWN SENSE HIGH 11 DOWN WINDOW COMMAND INPUT GENERI...

Page 1024: ...502 12V ACC OR RUN UP DOWN UP DOWN 1 4 2 5 MASTER WINDOW CONTROL SWITCH SEE PAGE 149 8 FOR SWITCH TESTING UP DOWN UP DOWN 6 LEFT RIGHT 3 C203 TN LB 991 TN LB 991 C502 C504 M C504 C604 M C604 RD 903 C2...

Page 1025: ...V 12V 12V 4 5 3 1 2 ALL UNLOCK RELAY 0V 5 3 12V 1 2 ALL LOCK RELAY 120 118 PK OG 163 RD OG 120 PK LG 117 PK BK 117 PK BK RIGHT DOOR LOCK ACTUATOR C606 C606 HOT AT ALL TIMES TO C201 PAGE 110 2 I P FUSE...

Page 1026: ...IGHT DOOR LOCK SWITCH SEE PAGE 149 7 FOR SWITCH TESTING 120 PK LG 119 PK YE FROM I P RELAY CENTER BOX PAGE 110 1 LOCK UNLOCK UNLOCK LOCK 1 5 3 12V C603 12V B D C201 120 PK LG 119 PK YE C252 120 PK LG...

Page 1027: ...I P FUSE PANEL PAGE 13 2 32 7 5A UP DOWN MOTOR M M LEFT EXTERIOR REAR VIEW MIRROR 544 VT 543 DG 540 541 DB 542 YE 57 BK LEFT AND RIGHT MIRROR SELEC TOR SWITCH DIRECTIONAL CONTROL SWITCH SEE POWER DIST...

Page 1028: ...2001 RANGER ELECTRIC VEHICLE 124 2 POWER MIRRORS...

Page 1029: ...ALL TIMES 797 LG PK 19 LB RD C252 805 WH LG 811 DG OG 804 OG LG 813 LB WH 802 OG RD 803 BN PK 800 GY LB 801 TN YE INSTRUMENT ILLUMINATION PAGE 71 1 C200 C601 C501 C201 RADIO 694 BK LG 694 BK LG G201 5...

Page 1030: ...2001 RANGER ELECTRIC VEHICLE 130 2 RADIO...

Page 1031: ...ERFACE ADAPTER ASSEMBLY IAA MODULE 4 88 3033 BK LB 3032 DB LG 3034 LG RD C1945 C124 3033 BK LB 3032 DB LG 3034 LG RD C1997 VACUUM PRESSURE SENSOR 3 5 576 DG VACUUM PUMP RELAY ELECTRIC VEHICLE POWER DI...

Page 1032: ...2001 RANGER ELECTRIC VEHICLE 139 2 VACUUM SYSTEM...

Page 1033: ...of the wires that connect to that terminal 2 the wire insulation color and 3 letters or numbers that may be marked on the component 38 BK OG B Circuit number as shown on schematics Terminal as marked...

Page 1034: ...dicate Park Lamp Circuit Off Park Head Open Circuit Closed Circuit Closed Circuit Headlamp Circuit 6 and 2 Off Park Head Open Circuit Open Circuit Closed Circuit TERMINALS 5 9 4 3 8 7 11 10 6 2 HEAD O...

Page 1035: ...260 5 and C260 4 COMPONENT TESTING PROCEDURE TO TEST Connect Self Powered Test Light or Ohmmeter to Terminals Move Switch to These Positions A Good Switch Will Indicate Park Lamp Circuit Off Park Head...

Page 1036: ...c Lock Off Run Start Start Circuit Closed Circuit in RUN position Acc Lock Off Run Start B5 and I1 Closed Circuit in START or RUN position only Acc Lock Off Run Start Closed Circuit in RUN and ACC pos...

Page 1037: ...10 With Wiper Switch OFF Push Washer Switch in Release Washer Switch Closed Circuit 10 COMPONENT TESTING PROCEDURE TO TEST Connect Self Powered Test Light or Ohmmeter to Terminals Move Switch to Thes...

Page 1038: ...Will Indicate Turn Switch Circuit 44 and 3 Turn Left Closed Circuit 44 and 2 Turn Right Closed Circuit Hazard Closed Circuit Passing Beam and Dimmer Switch Circuit 196 and 12 Pull half way up Closed C...

Page 1039: ...wered Test Light or Ohmmeter to Terminals TERMINALS COMPONENT TESTING PROCEDURE TO TEST Move Switch to These Positions A Good Switch Will Indicate SCHEMATIC Lock Closed Circuit Unlock Lock Both Doors...

Page 1040: ...4 2 5 UP DOWN UP DOWN 6 LEFT RIGHT 3 314 TN LB 992 WH BK 991 TN LB 57 BK 400 LB BK 1 2 3 4 5 6 C502 5 and 3 5 and 6 Connect Self Powered Test Light or Ohmmeter to Terminals COMPONENT TESTING PROCEDUR...

Page 1041: ...TN LB 400 LB BK 5 4 3 2 1 C602 Up Switch Circuit Down Switch Circuit 3 and 1 4 and 5 Connect Self Powered Test Light or Ohmmeter to Terminals COMPONENT TESTING PROCEDURE TO TEST Move Switch to These P...

Page 1042: ...Closed Circuit Closed Circuit Down 7 and 1 6 and 8 Left Closed Circuit Closed Circuit Left 7 and 6 1 and 8 Right Closed Circuit Closed Circuit Right 7 and 6 2 and 8 Right Mirror 7 and 2 6 and 8 Up Clo...

Page 1043: ...0 to 87A 85 and 86 From 30 to 87 only COMPONENT TESTING PROCEDURE Connect battery pos and neg to terminals Check continuity from terminals 85 to all others Continuity will be To 86 only 30 to all othe...

Page 1044: ...ELAY CONTACTS CHANGE POSITION WITH CURRENT THROUGH COIL 1 2 3 4 5 3 5 1 2 4 3 to 4 and 3 to 5 1 and 2 From 3 to 5 only COMPONENT TESTING PROCEDURE Connect battery pos and neg to terminals Check contin...

Page 1045: ...D 3033 BK LB 3220 PK 3023 BK OG 3226 BK LG 3227 RD 3228 BN 3800 LG BK 3993 YE RD 29 30 31 32 33 34 35 36 37 38 39 40 41 42 C124F PIN NUMBER CIRCUIT 3261 PK YE 3990 LB RD 3008 VT 3992 BN YE 3038 OG 383...

Page 1046: ...3 BK LB 3220 PK 3023 BK OG 3226 BK LG 3227 RD 3228 BN 3800 LG BK 3993 YE RD 29 30 31 32 33 34 35 36 37 38 39 40 41 42 C124M PIN NUMBER CIRCUIT 3261 PK YE 3990 LB RD 3008 VT 3992 BN YE 3038 OG 3834 LG...

Page 1047: ...ut High Wiper High Low Relay Switched Power Output Low Ground Voltage in Run or Accessory Overload Protected Wiper Run Park Relay Switched Output 57 BK 58 WH 61 YE RD 56 DB OG A B C D C131 PIN CIRCUIT...

Page 1048: ...9 20 PIN NUMBER CIRCUIT 3406 DG LG 3037 GY WH 3060 GY RD 3405 GY RD 3407 RD WH 3053 BN WH 3054 BK LG 754 LG WH 603 DG 3057 LG OG 21 22 23 24 25 26 27 28 29 30 PIN NUMBER CIRCUIT 3997 DG 6 YE LG 3047 Y...

Page 1049: ...14 15 16 M 16 F 17 18 19 20 PIN NUMBER CIRCUIT 705 LG OG 3396 YE LG 1059 LB OG 3035 LG OG 3603 RD 3601 WH RD 523 RD PK 524 PK BK 21 22 23 M 23 F 24 25 M 25 F 26 27 28 29 30 PIN NUMBER CIRCUIT 619 PK...

Page 1050: ...LG 1048 LB WH 686 TN RD 915 PK LB 12 13 14 15 16 17 18 M 18 F 19 20 21 3036 YE WH 3404 YE 2 WH LB 5 OG LB 914 TN OG 3069 WH 646 YE WH 3 LG WH 9 LG OG 438 RD WH 601 LB PK 22 23 24 25 26 27 28 29 30 322...

Page 1051: ...CTOR FACES 1 2 3 57 BK 512 TN LG 977 VT WH 1 2 3 C137 PIN CIRCUIT CIRCUIT FUNCTION BRAKE FLUID LEVEL SWITCH Ground Brake Indicator Control Brake Indicator Control 1 DB 1 C144 PIN CIRCUIT CIRCUIT FUNCT...

Page 1052: ...IN CIRCUIT CIRCUIT FUNCTION LEFT HEADLAMP EXCEPT POSTAL Power Hot with High Beams On Ground Headlamp Left Fused Feed 12 LG BK 57 BK 1055 WH LG H G L C147 PIN CIRCUIT CIRCUIT FUNCTION LEFT HEADLAMP POS...

Page 1053: ...ER ELECTRIC VEHICLE 150 9 CONNECTOR FACES 57 BK 14 BN 3 LG WH 1 2 3 C148 PIN CIRCUIT CIRCUIT FUNCTION LEFT FRONT PARK TURN LAMP Ground Power Exterior Lamps Left Front Turn Lamps Feed 14290 EXCEPT POST...

Page 1054: ...6 13 RD BK 196 DB OG 298 PK OG 57 BK 12 LG BK 977 PK WH Power Hot in Low and Pass Power Hot at All Times Power Hot in Run Ground High Beam Output Brake Indicator Output 1 2 3 4 5 6 521 TN OG 522 TN B...

Page 1055: ...1 2 3 4 5 6 7 8 9 10 11 12 C154 PIN CIRCUIT CIRCUIT FUNCTION ANTI LOCK BRAKE CONTROL MODULE 603 DG 522 TN BK 521 TN OG 601 LB PK 519 LG BK 518 LG RD 70 LB WH 57 BK 483 RD NOT USED NOT USED NOT USED A...

Page 1056: ...IN CIRCUIT CIRCUIT FUNCTION RIGHT HEADLAMP EXCEPT POSTAL Power Hot with High Beams On Ground Headlamp Left Fused Feed 12 LG BK 57 BK 1055 WH LG H G L PIN CIRCUIT CIRCUIT FUNCTION RIGHT HEADLAMP POSTAL...

Page 1057: ...UIT CIRCUIT FUNCTION RIGHT FRONT PARK TURN LAMP Ground Power Exterior Lamps Right Front Turn Lamps Feed 14290 EXCEPT POSTAL 3 2 1 14 BN 57 BK 2 WH LB P G T C156 PIN CIRCUIT CIRCUIT FUNCTION RIGHT FRON...

Page 1058: ...sor 14290 2 1 181 BN OG 758 VT WH 1 2 C161 PIN CIRCUIT CIRCUIT FUNCTION BLOWER MOTOR Blower Motor to Switch High Blower Motor Relay Switched Output 14290 1 2 941 BK WH 57 BK 1 2 C164 PIN CIRCUIT CIRCU...

Page 1059: ...RCUIT CIRCUIT FUNCTION LEFT FRONT PARK TURN LAMP Ground Power Exterior Lamps Left Front Turn Lamps Feed 14290 EXCEPT POSTAL 3 2 1 14 BN 57 BK 3 LG WH P G T C180 PIN CIRCUIT CIRCUIT FUNCTION LEFT FRONT...

Page 1060: ...1 2 C181 PIN CIRCUIT CIRCUIT FUNCTION LEFT FRONT SIDE LAMP EXCEPT POSTAL Power Exterior Lamps Ground 14290 14 BN 57 BK 3 LG WH P G T C181 PIN CIRCUIT CIRCUIT FUNCTION LEFT FRONT SIDE LAMP Power Exteri...

Page 1061: ...ANGER ELECTRIC VEHICLE 150 17 CONNECTOR FACES 57 BK 14 BN 2 WH LB P T G C182 PIN CIRCUIT CIRCUIT FUNCTION RIGHT FRONT PARK TURN LAMP Ground Power Exterior Lamps Right Front Side Lamp Feed 14290 POSTAL...

Page 1062: ...2 C183 PIN CIRCUIT CIRCUIT FUNCTION RIGHT FRONT SIDE LAMP Power Exterior Lamps Ground 14290 EXCEPT POSTAL 1 2 14 BN 57 BK 2 WH LB P G T C183 PIN CIRCUIT CIRCUIT FUNCTION RIGHT FRONT SIDE LAMP Power Ex...

Page 1063: ...8 9 10 11 12 13 14 15 16 1 2 3 4 6 7 9 11 15 14 16 13 5 12 8 10 765 YE BK 813 LB WH 57 BK 956 OG LG 163 RD OG 313 WH YE 314 TN LB 119 PK YE 544 VT 543 DG 542 YE 120 PK LG 956 OG LG 119 PK YE 544 VT 80...

Page 1064: ...3010 TN 679 GY BK 519 LG BK 118 PK OG 3836 YE LB 802 OG RD 14 15 16 17 18 19 20 21 22 23 24 25 26 PIN NUMBER CIRCUIT 3835 YE RD 3011 BK OG 3014 BK WH 33 WH BK 117 PK BK 3235 YE LG 3837 GY YE 55 BK PK...

Page 1065: ...PIN NUMBER CIRCUIT 543 DG 544 PK 3233 BK LB 3233 BK LB 640 RD YE 813 LB WH 801 TN YE 61 62 63 64 65 66 67 68 PIN NUMBER CIRCUIT 511 LG 914 TN OG 85 BN LB 119 PK YE 3986 DG 603 DG 69 70 71 72 73 74 75...

Page 1066: ...CIRCUIT CIRCUIT FUNCTION PARK BRAKE SWITCH EXCEPT POSTAL Switch Power Feed 13A724 162 LG RD 1 C202 PIN CIRCUIT CIRCUIT FUNCTION PARK BRAKE SWITCH POSTAL Switch Power Feed 14401 C203M 13A724 C203F 146...

Page 1067: ...r Dimmer Module Battery Saver Relay Switched Power 14401 1 2 3 4 15 RD YE 14 BN 584 YE 195 TN WH 196 DB YE 57 BK 484 OG BK 19 LB RD 1 2 3 4 5 6 7 8 9 10 11 C205 PIN CIRCUIT CIRCUIT FUNCTION PARK BRAKE...

Page 1068: ...7 8 9 10 11 12 13 14 15 16 2 WH LB 13 RD BK 15 RD YE 196 DB OG 57 BK 3 LG WH 383 RD WH 8 OG YE 680 LB OG 359 GY RD 632 GY OG 684 PK YE 378 BN YE 374 DB WH 511 LG POSTAL 8 7 5 4 3 2 1 14 13 11 10 9 6...

Page 1069: ...11 12 13 14 15 16 NOT USED J1850 Bus Plus Data Plus NOT USED Ground Communication Network Ground NOT USED ISO 9141 Link NOT USED NOT USED J1850 Bus Minus Data Minus NOT USED NOT USED NOT USED NOT USED...

Page 1070: ...All Times ISO 9141 Link Ground 1 2 3 4 5 PIN CIRCUIT CIRCUIT FUNCTION C210 BRAKE PEDAL POSITION BPP SWITCH 1 2 3 4 5 8 OG YE 383 RD WH 57 BK 44 LB 385 WH RD 30 85 86 87 87A C211 PIN CIRCUIT CIRCUIT F...

Page 1071: ...BK LG 687 GY YE 687 GY YE 37 YE 37 YE 37 YE 37 YE 1050 LG VT 32 RD LB Hot in Acc or Run Output Power Hot in Run NOT USED Power Hot in Run Battery Input Battery Input NOT USED Battery Input Battery In...

Page 1072: ...ON INSTRUMENT CLUSTER 12 3046 YE 3043 WH VT 3400 BN LB 3049 BK LG 3044 LB 19 LB RD 3041 BK 2 WH LB 3407 RD WH 3047 YE WH 3406 DG LG 3049 BK LG 3405 GY RD 679 GY BK 3408 DB OG 57 BK Auxiliary Battery I...

Page 1073: ...Start or Run Left Turn Signal Input ABS Indicator Lamp Brake Warning Indicator Lamp NOT USED Power Hot At All Times Seat Belt Indicator Lamp 1 2 3 4 5 6 7 8 9 10 C216 PIN CIRCUIT CIRCUIT FUNCTION INS...

Page 1074: ...E 150 30 CONNECTOR FACES NOT USED Horn Relay Instrument Panel Power Feed NOT USED Ground Key Warning Switch 6 YE LG 19 LB RD 570 BK WH 158 BK PK 1 2 3 4 5 6 C219 PIN CIRCUIT CIRCUIT FUNCTION PARK BRAK...

Page 1075: ...rnal Delay Wash Input One Touch Down Sense High NOT USED 1 2 3 4 5 6 7 8 9 10 11 C221 PIN CIRCUIT CIRCUIT FUNCTION GENERIC ELECTRONIC MODULE GEM 9 8 7 6 5 4 3 10 12 11 2 1 19 18 17 16 15 14 13 20 PIN...

Page 1076: ...OT USED GEM Battery Saver Output Module One Touch Down Relay Output NOT USED Wiper Pump Relay Control 1 2 3 4 5 6 7 8 9 10 C224 PIN CIRCUIT CIRCUIT FUNCTION GENERIC ELECTRONIC MODULE GEM 9 8 7 6 5 4 3...

Page 1077: ...OG 797 LG PK 137 YE BK 694 BK LG 800 GY LB 801 TN YE 804 OG LG 813 LB WH 694 BK LG Instrument Illumination Ground NOT USED NOT USED Right Rear Speaker Right Rear Speaker Right Front Speaker Right Fro...

Page 1078: ...2 3 C231 PIN CIRCUIT CIRCUIT FUNCTION CLIMATE CONTROL ASSEMBLY 5V Power Return Signal Ground 14401 3 2 1 754 LG WH 57 BK 752 YE RD 751 DB WH A B C D C232 PIN CIRCUIT CIRCUIT FUNCTION CLIMATE CONTROL A...

Page 1079: ...IRCUIT FUNCTION HEATER CONTROL ASSEMBLY OR A C HEATER CONTROL ASSEMBLY Power Feed Ground 14401 2 1 57 BK 3055 BN LG 3056 TN LG 57 BK 1 2 3 4 Ground A C Power Climate Control Power Ground 4 C234 PIN CI...

Page 1080: ...UIT FUNCTION POWER POINT Voltage Supplied At All Times Overload Protected Ground 14401 1 2 30 85 86 87 87A 400 LB BK 57 BK 1002 BK PK 170 RD LB Output Ground Ignition Hot In Acc or Run Power Hot At Al...

Page 1081: ...OT USED Blend Door Actuator Ground Blend Door Actuator 5V Input Blend Door Motor 1 Blend Door Motor 2 1 2 3 4 5 6 7 8 C240 PIN CIRCUIT CIRCUIT FUNCTION BLEND DOOR ACTUATOR 4 8 3 7 2 6 1 5 616 PK BK 60...

Page 1082: ...2001 RANGER ELECTRIC VEHICLE 150 38 CONNECTOR FACES 3069 WH 1048 LB WH 974 OG 1 2 3 C249 PIN CIRCUIT CIRCUIT FUNCTION INERTIA SWITCH Relay Signal Power Hot In Acc or Run Output 14401 1 2 3...

Page 1083: ...nnector Passenger Air Bag Module Passenger Air Bag Passenger Air Bag Deactivation PAD Module Passenger Air Bag Deactivation PAD Module Illumination Ground NOT USED NOT USED 1 2 3 4 5 6 7 8 9 10 11 12...

Page 1084: ...10 11 12 13 14 15 16 1 2 3 4 6 7 9 11 15 14 16 13 5 12 8 10 805 WH LG 761 GY RD 57 BK 811 DG OG 314 TN LB 542 YE 313 WH YE 117 PK BK 118 PK OG 119 PK YE 544 PK 120 PK LG 543 DG 400 LB BK 805 WH LG 761...

Page 1085: ...Feed Left Front Brake Pedal Position Switch to Stoplamps Trailer Tow Connector Output C253 PIN CIRCUIT CIRCUIT FUNCTION MULTIFUNCTION SWITCH 14A320 6 5 1 4 8 9 2 3 7 10 684 PK YE 15 RD YE 13 RD BK 359...

Page 1086: ...nger Air Bag Deactivation Module Illumination C256 PIN CIRCUIT CIRCUIT FUNCTION PASSENGER AIR BAG DEACTIVATION PAD SWITCH 14401 1 2 3 4 5 6 A YE RD 383 RD WH 57 BK 378 BN YE 1 2 3 4 5 6 7 8 Hazard Fla...

Page 1087: ...ass Switch Feed C260 PIN CIRCUIT CIRCUIT FUNCTION MAIN LIGHT SWITCH 14401 8 9 10 11 12 13 14 1011 TN OG 53 BK LG 195 TN WH 14 BN NOT USED NOT USED NOT USED Pulse Width Dimmer Module Fused Feed Courtes...

Page 1088: ...rument Panel Lamps Feed Ground Preheat Inverter Relay Signal NOT USED NOT USED C262 PIN CIRCUIT CIRCUIT FUNCTION PREHEAT SWITCH 14401 6 4 5 3 2 1 POSTAL 1 2 3 4 5 6 S RD 797 LG VT R LG NOT USED NOT US...

Page 1089: ...Switch Feed C271 PIN CIRCUIT CIRCUIT FUNCTION DASH FAN 14401 POSTAL 2 1 30 85 86 87 87A A YE RD 57 BK 378 BN YE NOT USED Hazard Flasher Relay Control Ground NOT USED Fused Power to Turn Park Lamps C2...

Page 1090: ...Ground Driver Safety Belt Return Safety Belt Buckle Switch Input Driver Safety Belt Return C303 PIN CIRCUIT CIRCUIT FUNCTION SAFETY BELT SWITCH 14401 1 2 4 3 1 2 3 57 BK 14 BN 511 LG Ground Power Exte...

Page 1091: ...2 3 57 BK 140 BK PK Ground NOT USED Left Rear Backup Lamp Feed C401 PIN CIRCUIT CIRCUIT FUNCTION LEFT BACKUP LAMP 13A409 3 2 1 1 2 3 57 BK 9 LG OG Ground NOT USED Left Rear Turn Lamp Feed C402 PIN CIR...

Page 1092: ...Exterior Lamps Brake On Off C404 PIN CIRCUIT CIRCUIT FUNCTION RIGHT REAR PARK STOP LAMP 13A409 3 2 1 C403F 13A409 5 1 6 2 7 3 8 4 C403M 14405 1 5 2 6 3 7 4 8 374 DB WH 511 LG 140 BK PK 9 LG OG 378 BN...

Page 1093: ...2 802 OG RD 803 BN BK Speaker Right Rear Speaker Right Rear C408 PIN CIRCUIT CIRCUIT FUNCTION RIGHT REAR SPEAKER 13A724 1 2 3 57 BK 5 OG LB Ground NOT USED Right Rear Turn Lamp Feed C406 PIN CIRCUIT...

Page 1094: ...USED NOT USED C409 PIN CIRCUIT CIRCUIT FUNCTION SIEMANS INTERACTIVE AUTOMOTIVE DIAGNOSTIC INTERFACE SYSTEM SIADIS 14405 1 2 57 BK 14 BN Ground Power C411 PIN CIRCUIT CIRCUIT FUNCTION LEFT LICENSE PLAT...

Page 1095: ...Right Left Mirror Movement Up Down Mirror Movement Mirror Motor Feed C500 PIN CIRCUIT CIRCUIT FUNCTION LEFT EXTERIOR REAR VIEW MIRROR 14631 1 1 2 804 OG LG 813 LB WH Speaker Left Front Speaker Left F...

Page 1096: ...Output Window Switch Feed Right Front Up Master Window Adjust Switch Feed Down Ground Window Switch Feed Right Front Down C502 PIN CIRCUIT CIRCUIT FUNCTION MASTER WINDOW CONTROL SWITCH 14631 1 2 3 4...

Page 1097: ...K 903 RD Master Window Adjust Switch Feed Up Window Motor Feed Down C504 PIN CIRCUIT CIRCUIT FUNCTION LEFT POWER WINDOW MOTOR 14631 1 2 163 RD OG 117 PK BK Door Unlock Output Door Lock Output C505 PIN...

Page 1098: ...543 DG 541 DB 542 YE 542 YE 956 OG LG 57 BK Left Left Right Motor Input Output Right Up Down Motor Input Output Right Left Right Motor Input Output Left Up Down Motor Input Output NOT USED Left Exteri...

Page 1099: ...ight Left Mirror Movement Up Down Mirror Movement Mirror Motor Feed C600 PIN CIRCUIT CIRCUIT FUNCTION RIGHT EXTERIOR REAR VIEW MIRROR 14630 1 1 2 805 WH LG 813 DG OG Speaker Right Front Speaker Right...

Page 1100: ...Switch Down Accessory Relay Switched Power Output Right Window Feed Switch Up Up Window Switch Feed C602 PIN CIRCUIT CIRCUIT FUNCTION RIGHT WINDOW SWITCH 14630 1 2 3 4 5 120 PK LG 57 BK 119 PK YE Door...

Page 1101: ...LB 903 RD Master Window Adjust Switch Feed Up Window Motor Feed Down C604 PIN CIRCUIT CIRCUIT FUNCTION RIGHT POWER WINDOW MOTOR 14630 1 2 1 2 765 YE BK 57 BK Right Door Ajar Switch Ground C606 PIN CI...

Page 1102: ...ound C900 PIN CIRCUIT CIRCUIT FUNCTION OUTSIDE CARGO HIGH MOUNTED STOPLAMP 13A724 EXCEPT POSTAL 1 2 3 1 705 LG OG Battery Saver Relay Switched Power C901 PIN CIRCUIT CIRCUIT FUNCTION INTERIOR MAP LAMP...

Page 1103: ...R ELECTRIC VEHICLE 150 59 CONNECTOR FACES POSTAL D E F G H J K L M N P U T S R 2 WH LB 14 BN 3 LG WH 140 BK PK 57 BK 195 TN WH 378 BN YE 378 BN YE 511 LG 53 BK LB 57 BK T DB U YE C903 GRUMMAN HEADLINE...

Page 1104: ...LE 150 60 CONNECTOR FACES C1748M 10B694 C1748F 14A280 M C1747M 10B694 C1747F 14A280 N 3095 OG YE 3214 LB 3097 RD LG 3096 WH 3096 WH 3095 OG YE 3214 LB 3097 RD LG 3 2 1 6 5 4 1 2 3 4 5 6 1 2 3 4 5 6 3...

Page 1105: ...CONNECTOR FACES C1749M 10B694 C1749F 14A280 L 3091 LB BK 3094 LB RD 3091 LB BK 3094 LB RD 3 2 1 6 5 4 1 2 3 4 5 6 3215 PK BK 3213 BK LB C1750M 10B694 3215 PK BK 3213 BK LB C1750F 14A280 A 3 2 1 6 5 4...

Page 1106: ...VEHICLE 150 62 CONNECTOR FACES 3073 RD WH C1751M 10B694 C1751F 14A280 B 3075 YE 3075 YE 3073 RD WH 3 2 1 6 5 4 1 2 3 4 5 6 C1752M 10B694 C1752F 14A280 C 3072 PK YE 3074 BK OG 3072 PK YE 3074 BK OG 3 2...

Page 1107: ...FACES 3077 OG LB 3079 WH PK 3076 YE WH C1753M 10B694 3079 WH PK 3076 YE WH C1753F 14A280 D 3 2 1 6 5 4 1 2 3 4 5 6 3077 OG LB 3078 LG OG 3080 RD LB C1754M 10B694 C1754F 14A280 E 3078 LG OG 3080 RD LB...

Page 1108: ...ICLE 150 64 CONNECTOR FACES C1755M 10B694 C1755F 14A280 F 3081 WH RD 3083 DG LG 3081 WH RD 3083 DG LG 3 2 1 6 5 4 1 2 3 4 5 6 C1756M 10B694 C1756F 14A280 G 3085 OG LG 3085 OG LG 3 2 1 6 5 4 1 2 3 4 5...

Page 1109: ...ER ELECTRIC VEHICLE 150 65 CONNECTOR FACES C1758M 10B694 C1758F 14A280 J 3087 DG PK 3092 GY OG 3087 DG PK 3092 GY OG 3 2 1 6 5 4 1 2 3 4 5 6 3090 VT 3090 VT C1757F 14A280 H 3086 WH VT 3086 WH VT C1757...

Page 1110: ...2001 RANGER ELECTRIC VEHICLE 150 66 CONNECTOR FACES 3093 WH LB C1759M 10B694 C1759F 14A280 K 3088 DB OG 3093 WH LB 3088 DB OG 3 2 1 6 5 4 1 2 3 4 5 6...

Page 1111: ...RANGER ELECTRIC VEHICLE 150 67 CONNECTOR FACES 1 2 3 4 57 BK 3396 YE LG 3605 DB WH Ground Relay Signal Feed Lube Pressure Switch NOT USED C1801 PIN CIRCUIT CIRCUIT FUNCTION RECIRCULATING FAN 10B691 4...

Page 1112: ...Feed Signal Feedback Return NOT USED C1802 PIN CIRCUIT CIRCUIT FUNCTION FLOW THROUGH FAN 10B691 1 3 2 4 C1803 BATTERY TEMPERATURE SENSOR 1 IOM 10B691 2 1 4001 OG 4000 LB C1804 BATTERY TEMPERATURE SENS...

Page 1113: ...nterrupt Out Battery Temperature Sensor 1 IOM Input Battery Temperature Sensor 2 IOM Input Battery Temperature Sensor 3 IOM Input NOT USED NOT USED NOT USED 21 22 23 24 25 26 27 28 29 30 31 32 33 34 3...

Page 1114: ...ATTERY TEMPERATURE SENSOR 1 10B691 2 1 3216 BN 3703 BN WH C1814 BATTERY TEMPERATURE SENSOR 2 10B691 1 2 3760 DG 3218 GY BK C1815 BATTERY TEMPERATURE SENSOR 3 10B691 1 2 3704 RD WH 3217 LG BK C1816 BAT...

Page 1115: ...EHICLE 150 71 CONNECTOR FACES C1863 LOWER BATTERY HEATER GROUND 10B700 C1859 UPPER BATTERY HEATER POWER 10B700 3709 RD C1862 LOWER BATTERY HEATER POWER 10B700 1201 DB WH C1861 UPPER BATTERY HEATER GRO...

Page 1116: ...TOR FACES 1201 DB WH 57 BK 3709 RD 1161 DG OG 1161 DG OG Lower Battery Heater Feed Ground Upper Battery Heater Feed Batter Heater Present Battery Heater Present NOT USED A B C D E F C1864 PIN CIRCUIT...

Page 1117: ...CUIT FUNCTION BATTERY CONTROL MODULE BCM 3089 LB WH 3075 YE 3080 RD LB 3084 BK PK 3072 PK YE 3073 RD WH 3074 BK OG 3081 WH RD 3082 BK LG 3083 YE WH Battery Control Module BCM Voltage Sense Lead VSL 0...

Page 1118: ...trol Module BCM Voltage Sense Lead VSL 7 1 2 3 4 5 6 7 8 9 10 11 12 C1865 PIN CIRCUIT CIRCUIT FUNCTION BATTERY CONTROL MODULE BCM 3073 RD WH 3077 OG LB 3074 BK OG 3075 YE 3076 YE WH NOT USED NOT USED...

Page 1119: ...VSL 36 NOT USED NOT USED Battery Control Module BCM Voltage Sense Lead VSL 18 NOT USED Battery Control Module BCM Voltage Sense Lead VSL 22 NOT USED Battery Control Module BCM Voltage Sense Lead VSL 2...

Page 1120: ...Control Module BCM Voltage Sense Lead VSL 11 NOT USED Battery Control Module BCM Voltage Sense Lead VSL 15 NOT USED Battery Control Module BCM Voltage Sense Lead VSL 21 Battery Control Module BCM Vol...

Page 1121: ...2001 RANGER ELECTRIC VEHICLE 150 77 CONNECTOR FACES C1867F 14A280 P C1867M 10B694 3095 OG YE 3403 OG 3091 LB BK 3093 WH LB C1868M 10B694 3091 LB BK 3093 WH LB C1868F 14A280 M 3 2 1 6 5 4 1 2 3 4 5 6...

Page 1122: ...ECTOR FACES 3092 GY OG 3090 VT C1869M 10B694 C1869F 14A280 F 3088 DB OG 3090 VT 3088 DB OG 3092 GY OG 3 2 1 6 5 4 1 2 3 4 5 6 C1870M 10B694 C1870F 14A280 N 3096 WH 3097 RD LG 3098 RD YE 3096 WH 3097 R...

Page 1123: ...2001 RANGER ELECTRIC VEHICLE 150 79 CONNECTOR FACES C1871F 14A280 E C1871M 10B694 3094 LB RD 3403 OG C1872F 14A280 K C1872M 10B694 3085 OG LG 3403 OG...

Page 1124: ...80 CONNECTOR FACES 3087 DG VT 3099 BN C1873M 10B694 3087 DG VT 3099 BN C1873F 14A280 L 3 2 1 6 5 4 1 2 3 4 5 6 3083 YE WH 3202 TN YE C1874M 10B694 C1874F 14A280 J 3086 WH VT 3083 YE WH 3202 TN YE 308...

Page 1125: ...81 CONNECTOR FACES C1875M 10B694 C1875F 14A280 S 3200 RD BK 3201 LG BK 3203 LG RD 3200 RD BK 3201 LG BK 3203 LG RD 3 2 1 6 5 4 1 2 3 4 5 6 3075 YE C1876M 10B694 C1876F 14A280 B 3073 RD WH 3075 YE 307...

Page 1126: ...CONNECTOR FACES C1877M 10B694 C1877F 14A280 H 3081 WH RD 3084 BK PK 3081 WH RD 3084 BK PK 3 2 1 6 5 4 1 2 3 4 5 6 3204 LG OG 3205 OG YE C1878M 10B694 C1878F 14A280 T 3206 LG YE 3204 LG OG 3206 LG YE...

Page 1127: ...VEHICLE 150 83 CONNECTOR FACES C1879M 10B694 C1879F 14A280 G 3080 RD LB 3082 BK LG 3079 WH PK 3078 LB OG 3082 BK LG 3080 RD LB 3078 LB OG 3079 WH PK 3 2 1 6 5 4 1 2 3 4 5 6 C1880F 14A280 D C1880M 10B6...

Page 1128: ...R ELECTRIC VEHICLE 150 84 CONNECTOR FACES C1881F 14A280 C C1881M 10B694 3076 YE WH 3403 OG 3213 BK LB C1882M 10B694 C1882F 14A280 R 3089 LB WH 3215 PK BK 3215 PK BK 3089 LB WH 3213 BK LB 3 2 1 6 5 4 1...

Page 1129: ...150 85 CONNECTOR FACES C1884M 10B694 C1884F 14A280 A 3072 PK YE 3074 BK OG 3072 PK YE 3074 BK OG 1 2 3 4 5 6 3 2 1 6 5 4 3214 LB 3212 DB C1885M 10B694 C1885F 14A280 W 3211 WH LB 3214 LB 3211 WH LB 321...

Page 1130: ...R ELECTRIC VEHICLE 150 86 CONNECTOR FACES C1886M 10B694 C1886F 14A280 U 3207 VT LB 3208 GY BK 3209 WH BK 3208 GY BK 3207 VT LB 3209 WH BK 3 2 1 6 5 4 1 2 3 4 5 6 C1887F 14A280 V C1887M 10B694 3210 LG...

Page 1131: ...2001 RANGER ELECTRIC VEHICLE 150 87 CONNECTOR FACES C1902F 19E822 C1902M 14B306 C D F B E A C D F B E A 3230 YE 3153 WH 3411 OG 3154 RD 3152 DG 3229 DB 3411 OG 3153 WH 3230 YE 3230 YE 3152 DG 3154 RD...

Page 1132: ...RE COEFFICIENT PTC SWITCHING MODULE 14B353 3102 DB C1904 POSITIVE TEMPERATURE COEFFICIENT PTC SWITCHING MODULE 14B353 3103 WH C1905 POSITIVE TEMPERATURE COEFFICIENT PTC SWITCHING MODULE 14B353 3101 RD...

Page 1133: ...ONNECTOR FACES 3101 RD C1912F 14B353 3117 DB C1914F 3118 WH DC DC CONVERTER HIGH VOLTAGE POWER DISTRIBUTION BOX HVPDB DRIVER S SIDE VIEW C1914M 14B323 3118 WH 3117 DB 3101 RD 3103 WH 3100 DG 3102 DB C...

Page 1134: ...E COEFFICIENT PTC SWITCHING MODULE TRACTION BATTERY CHARGER 3150 DB 3151 WH 3170 OG 3171 WH 3105 WH 3104 DB HIGH VOLTAGE POWER DISTRIBUTION BOX HVPDB PASSENGER S SIDE VIEW 3141 WH 3140 BK 3009 DG 3008...

Page 1135: ...2001 RANGER ELECTRIC VEHICLE 150 91 CONNECTOR FACES C1931 HVPDB COVER INTERLOCK SWITCH 14B305 3131 RD C1932F 14B305 3131 RD C1932M 14B325 3009 OG C1933F 14B305 3134 OG C1933M WA0496 1 3170 OG...

Page 1136: ...2001 RANGER ELECTRIC VEHICLE 150 92 CONNECTOR FACES C1935F 14B326 3133 WH 3132 YE 3134 OG 3131 RD 3132 YE C1935M 14B305 3133 WH 3134 OG 3131 RD...

Page 1137: ...D 3827 GY WH 915 PK LB 914 TN OG 3008 PK 3002 OG LB 3993 YE RD 3401 DB LG 554 YE BK 57 BK 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76...

Page 1138: ...MASTER CYLINDER PRESSURE SENSOR 14290 3 1 4 2 534 YE LG 57 BK 57 BK 601 LB PK 483 RD 70 LB WH ABS Control Module ABS Control Module ABS Control Module NOT USED ABS Control Module Feed Power Hot at all...

Page 1139: ...ine NOT USED DC DC Signal Return DC DC Enable Auxiliary Battery Termperature Sensor Return Auxiliary Battery Temperature Sensor Signal 1 2 3 4 5 6 7 8 9 10 C1943 PIN CIRCUIT CIRCUIT FUNCTION DC DC CON...

Page 1140: ...3999 DB LG 915 PK LB 914 TN OG 3021 GY BK 3045 TN 3046 YE 3260 OG WH 3261 PK YE 3052 YE LG 3232 YE LG 3035 LG OG Temperature Gauge Traction Battery State of Charge SOC Gauge Economy Gauge NOT USED DC...

Page 1141: ...nsor Signal NOT USED LO Fan Relay Control Coolant Temperature Sensor Reference PIN CIRCUIT CIRCUIT FUNCTION 3059 YE LG 438 RD WH 3994 BK YE 3036 YE WH 931 OG 931 OG 3062 BK WH 3025 YE LG 3060 GY RD 57...

Page 1142: ...D NOT USED 1 2 3 4 5 6 7 8 9 10 11 12 PIN CIRCUIT CIRCUIT FUNCTION C1946 EVAC FILL CONNECTOR 1 1 9 4 12 2 3024 DB LG 3025 YE LG 57 BK 3232 VT 3026 RD PK 3027 RD WH NOT USED NOT USED A C Present NOT US...

Page 1143: ...3 4 619 PK WH Air Bag Crash Sensor Feed NOT USED NOT USED NOT USED C1950 PIN CIRCUIT CIRCUIT FUNCTION LEFT PRIMARY CRASH SENSOR 14290 2 1 3 4 1 2 1 2 519 LG BK 518 LG RD Sensor Low to Module Sensor H...

Page 1144: ...Temperature Ground Reference Ambient Temperature Reference Feed C1952 PIN CIRCUIT CIRCUIT FUNCTION AMBIENT TEMPERATURE SENSOR 14290 1 2 1 2 3224 DG VT 3223 YE RD DC DC Temperature Sensor Signal DC DC...

Page 1145: ...rol Power Hot At All Times Power Hot At All Times NOT USED C1954 FAN LOW SPEED RELAY PIN CIRCUIT CIRCUIT FUNCTION 3829 LB BK 50 RD 50 RD 261 OG BK 1 2 3 5 6 Interface Adapter Assembly IAA Module Relay...

Page 1146: ...ANGER ELECTRIC VEHICLE 150 102 CONNECTOR FACES 1 2 3064 BK OG 3065 LG VT Engine Coolant Temperature Sensor Input Signal Return C1966 PIN CIRCUIT CIRCUIT FUNCTION GLYCOL COOLANT TEMPERATURE SENSOR 1429...

Page 1147: ...USED NOT USED NOT USED C1967 PIN CIRCUIT CIRCUIT FUNCTION RIGHT PRIMARY CRASH SENSOR 14290 2 3 4 C1969F 14B308 1 2 3 261 OG BK 260 RD OG 57 BK Cooling Fan Low Cooling Fan High Ground C1968 PIN CIRCUIT...

Page 1148: ...VBC Control from Interface Adapter Assembly IAA Module VBC Low Side Relay Coil Blower Motor Ground Reference Ground 1 2 3 4 5 C1971 PIN CIRCUIT CIRCUIT FUNCTION VARIABLE BLOWER CONTROLLER VBC 5 4 1 2...

Page 1149: ...Sensor Evaporator Temperature Sensor Reference C1972 PIN CIRCUIT CIRCUIT FUNCTION EVAPORATOR TEMPERATURE SENSOR 14290 1 2 3 4 3232 VT 3222 PK LB A C Low Pressure Switch Sensor Signal NOT USED NOT USED...

Page 1150: ...2001 RANGER ELECTRIC VEHICLE 150 106 CONNECTOR FACES C1980F 10B691 3410 YE C1981 10B691 1197 LG BK 3704 RD WH LOWER FRONT PACK TEMPERATURE SENSOR 3 974 OG C1980M 14B309 3410 YE 974 OG 1 2...

Page 1151: ...8 9 10 11 C1982 PIN CIRCUIT CIRCUIT FUNCTION CONTACTOR BOX 3138 LB BK 295 LB PK 190 WH OG 3706 DB 3997 DG 3007 VT YE 3991 TN 3998 GY 3137 GY YE 3705 LB 3996 RD YE 3602 TN YE Current Sensor Control In...

Page 1152: ...s Power Hot At All Times NOT USED 30 85 86 87 87A C1983 PIN CIRCUIT CIRCUIT FUNCTION TRACTION BATTERY COOLING FAN RELAY 86 85 30 87 87A LEAD ACID 3395 OG LB 3850 LG VT 554 YE BK 554 YE BK Flow Thru Fa...

Page 1153: ...WH RD 57 BK Cooling Fan Control from Battery Control Module BCM NOT USED Cooling Fan Feedback Ground Reference Cooling Fan Feedback Output Signal Traction Battery Cooling Fan Power NOT USED Ground A...

Page 1154: ...2001 RANGER ELECTRIC VEHICLE 150 110 CONNECTOR FACES C1985 10B691 1203 BK LB 3759 DG WH LOWER REAR PACK TEMPERATURE SENSOR 4 1 2...

Page 1155: ...C1986 PIN CIRCUIT CIRCUIT FUNCTION BATTERY CONTROL MODULE BCM 3704 RD WH 1199 GY BK 3218 GY BK 3760 DG 1203 BK LB 3219 BK LB 3759 DG WH 3758 OG RD 3396 YE LG 3605 DB WH 3007 VT YE 3395 OG LB 57 BK 38...

Page 1156: ...ugged In 1 2 3 4 5 6 7 8 9 10 11 12 PIN CIRCUIT CIRCUIT FUNCTION BATTERY CONTROL MODULE BCM 3800 LG BK 3501 DB 3503 YE 914 TN OG 915 PK LB 3138 LB BK 3850 LG VT NOT USED Charger Fault Input NOT USED N...

Page 1157: ...ENSOR 1 C1989 10B691 3760 DG 1199 GY BK UPPER REAR PACK TEMPERATURE SENSOR 2 1 2 1 2 3993 YE RD 3800 LG BK 3985 PK 3827 GY WH 566 DG Charger Ready Charger Fault Output Charger Enable Charger Charging...

Page 1158: ...USED NOT USED Power Hot in Start or Run Ground CIRCUIT CIRCUIT FUNCTION PIN C1992 POWER STEERING ASSEMBLY 1 3022 RD YE 679 GY BK 3023 BK OG 295 LB PK 57 BK 12 13 14 15 16 17 18 19 20 21 22 NOT USED Po...

Page 1159: ...arger Line Capacity Charge Cord Pilot Charge Max Line Charger Pilot Enable Charger Mode NOT USED NOT USED 1 2 3 4 5 6 7 8 9 10 C1993 PIN CIRCUIT CIRCUIT FUNCTION TRACTION BATTERY CHARGER 1 2 3 4 5 6 7...

Page 1160: ...0 LB OG 57 BK A C Over Temperature Sensor Vacuum Pump Power C1996 PIN CIRCUIT CIRCUIT FUNCTION VACUUM PUMP 12B637 A B 1 2 3 3033 BK LB 3034 LG RD 3032 DB LG 5V Power Reference Signal Vacuum Pressure S...

Page 1161: ...emperature Coefficient PTC Switching Module Core B Control Positive Temperature Coeffiecient PTC Switching Module Overtemperature Fault Line Positive Temperature Coefficient PTC Short Fault Line Emerg...

Page 1162: ...826 WH 3827 GY WH Signal Ground J1850 Plus Data Plus J1850 Bus Minus Data Minus Chassis Ground Module Diagnostics Positive Temperature Coefficient PTC Switching Module Switching Power Charger Power Ch...

Page 1163: ...IT CIRCUIT FUNCTION C2991 WA 0397 2 POSITIVE TEMPERATURE COEFFICIENT PTC OVER TEMPERATURE SWITCH 1 3036 YE WH PTC Reference Signal PIN CIRCUIT CIRCUIT FUNCTION C2992 WA 0397 2 POSITIVE TEMPERATURE COE...

Page 1164: ...Cabin Temperature Reference C2997 PIN CIRCUIT CIRCUIT FUNCTION IN CAR TEMPERATURE SENSOR 14401 1 2 2 1 3837 GY YE 3011 BK OG 3012 WH 3010 TN 3013 GY BK 3835 YE WH 3836 YE LB 3014 BK WH 3015 WH RD APS1...

Page 1165: ...TOR FACES 3054 BK LG 19 LB RD 57 BK 3053 BN WH Fresh Recirculation LED Instrument Panel Lamps Feed Ground Fresh Recirculation Switch NOT USED NOT USED 1 2 3 4 5 6 C2998 PIN CIRCUIT CIRCUIT FUNCTION FR...

Page 1166: ...037 GY WH 3066 OG YE 3052 YE LG C2999F 1 4 3 2 1 WA 0397 3066 OG YE 3068 BN PK 3067 LB RD 57 BK 14401 2 3 4 5 6 10 9 8 7 6 4 3 2 1 5 4 3 2 1 7 8 9 10 3052 YE LG 3036 YE WH 3037 GY WH 3036 YE WH 14B326...

Page 1167: ...4 5 6 7 8 9 10 11 12 13 14 15 16 3013 GY BK 3015 WH RD 3600 RD WH 3836 YE LB 3835 YE WH 810 RD LG 3011 BK OG 3012 WH 3010 TN 3014 BK WH 3603 RD 3601 WH RD 491 OG LB 14401 POSTAL ELECTRIC C3997F 14405...

Page 1168: ...G 3235 YE LG 3503 YE 33 WH PK 603 DG 3404 YE 3404 YE C3999F C3999M 14405 57 BK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 6 7 9 11 15 14 16 13 5 12 8 10 3233 BK LB 914 TN OG 511 LG 3233 BK LB 374...

Page 1169: ...le Speed Sensor VSS A Motor Temperature Sensor NOT USED NOT USED Vehicle Speed Sensor VSS 12V Vehicle Speed Sensor VSS Ground Reference NOT USED 1 2 3 4 5 6 7 8 9 10 C4993 PIN CIRCUIT CIRCUIT FUNCTION...

Page 1170: ...994 14405 LEFT REAR ANTI LOCK BRAKE SENSOR 1 2 519 LG BK 518 LG RD Sensor Low to Module Sensor High to Module PIN CIRCUIT 1 2 CIRCUIT FUNCTION C4995 14405 RIGHT REAR ANTI LOCK BRAKE SENSOR 1 2 524 PK...

Page 1171: ...sion Range DTR Sensor TR1 Digital Transmission Range DTR Sensor TR2 Digital Transmission Range DTR Sensor TR4 NOT USED NOT USED Power Hot in Run Jumper to Pin 12 Back up Lamps Jumper to Pin 10 1 2 3 4...

Page 1172: ...Run or Start NOT USED 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 C4998 PIN CIRCUIT CIRCUIT FUNCTION TRACTION INVERTER MODULE TIM 3019 GY BK 3701 DB WH X LB BK 3233 BK LB 3707 OG 57 BK 3997...

Page 1173: ...ge DTR Sensor TR4 Signal 1 2 3 4 5 6 7 8 9 10 11 12 13 PIN CIRCUIT CIRCUIT FUNCTION TRACTION INVERTER MODULE TIM 810 RD LG 3014 BK WH 3015 WH RD 3013 GY BK 3502 DG 3501 DB 3601 WH RD 3600 RD WH 3603 R...

Page 1174: ...FACES 3173 WH 3172 OG 3984 RD 3174 DG NOT USED NOT USED Power from Power Control Station PCS 240 VAC Power from Power Control Station PCS 240 VAC Pilot NOT USED Ground 1 2 3 4 5 6 7 C5000 PIN CIRCUIT...

Page 1175: ...RELAY C1955 FAN HIGH SPEED RELAY C1953 AUXILIARY BATTERY TEMPERATURE SENSOR G1997 C1966 COOLANT TEMPERATURE SENSOR C1952 AMBIENT TEMPERATURE SENSOR C1996 VACUUM PUMP C1997 VACUUM PRESSURE SENSOR G197...

Page 1176: ...FVEHICLE UNDERHOOD VIEW 2 OF 2 1 2 3 4 5 6 7 8 9 10 B C D E F A A B C D E F 1 2 3 4 5 6 7 8 9 10 C1994 A C PRESSURE SENSOR C1967 COOLING FAN C1902 A C INVERTER MOTOR CONTROLLER IMC C1947 A C INVERTER...

Page 1177: ...1 OF 2 C1939 1 2 3 4 5 6 7 8 9 10 B C D E F A A B C D E F 1 2 3 4 5 6 7 8 9 10 C1865 C1866 C1986 C1987 BATTERY CONTROL MODULE BCM C1870 C1869 C1873 C1872 C1877 C1878 C1881 C1879 C1882 C1868 C1886 C499...

Page 1178: ...C1984 TRACTION BATTERY COOLING FAN C1875 C1876 C1864 CONTACTOR BOX C1989 BATTERY TEMPERATURE SENSOR 2 C1861 UPPER BATTERY HEATER C1880 C1874 C1988 BATTERY TEMPERATURE SENSOR 1 C1983 TRACTION BATTERY...

Page 1179: ...ROUP C259 INTERIOR LAMP RELAY C250 AIR BAG DIAGNOSTIC MONITOR C239 ACCESSORY DELAY RELAY C256 PASSENGER AIR BAG DEACTIVATION PAD SWITCH C232 C233 C234 C331 A C HEATER CONTROL ASSEMBLY C210 BRAKE PEDAL...

Page 1180: ...29 DO NOT USE THIS ILLUSTRATION AND GRID FOR REPORTING VEHICLE REPAIR LOCATIONS NiMH BATTERY PACK 1 OF 2 1 2 3 4 5 6 7 8 9 10 B C D E F A A B C D E F 1 2 3 4 5 6 7 8 9 10 C1749 FRONTOFVEHICLE C1759 C...

Page 1181: ...0 FRONTOFVEHICLE C1805 BATTERY TEMPERATURE SENSOR 3 IOM C1982 C1802 FLOW THRU FAN C1939 C1983 FLOW THRU FAN RELAY C1813 BATTERY TEMPERATURE SENSOR 1 C1804 BATTERY TEMPERATURE SENSOR 2 IOM C1814 BATTER...

Page 1182: ...ILLUSTRATION AND GRID FOR REPORTING VEHICLE REPAIR LOCATIONS UNDERHOOD POSTAL 1 OF 4 1 2 3 4 5 6 7 8 9 10 B C D E F A A B C D E F 1 2 3 4 5 6 7 8 9 10 FRONTOFVEHICLE C134 C137 BRAKE FLUID LEVEL SWITCH...

Page 1183: ...OF 29 DO NOT USE THIS ILLUSTRATION AND GRID FOR REPORTING VEHICLE REPAIR LOCATIONS UNDERHOOD POSTAL 2 OF 4 1 2 3 4 5 6 7 8 9 10 B C D E F A A B C D E F 1 2 3 4 5 6 7 8 9 10 FRONTOFVEHICLE G104 C1954 C...

Page 1184: ...TING VEHICLE REPAIR LOCATIONS UNDERHOOD POSTAL 3 OF 4 1 2 3 4 5 6 7 8 9 10 B C D E F A A B C D E F 1 2 3 4 5 6 7 8 9 10 FRONTOFVEHICLE C144 HORN C182 RIGHT FRONT PARK TURN LAMP C180 LEFT FRONT PARK TU...

Page 1185: ...R FCS 12887 01 23 OF 29 DO NOT USE THIS ILLUSTRATION AND GRID FOR REPORTING VEHICLE REPAIR LOCATIONS UNDERHOOD POSTAL 4 OF 4 1 2 3 4 5 6 7 8 9 10 B C D E F A A B C D E F 1 2 3 4 5 6 7 8 9 10 FRONTOFVE...

Page 1186: ...ID FOR REPORTING VEHICLE REPAIR LOCATIONS INSTRUMENT PANEL POSTAL 1 OF 3 1 2 3 4 5 6 7 8 9 10 B C D E F A A B C D E F 1 2 3 4 5 6 7 8 9 10 FRONTOFVEHICLE C202 PARKING BRAKE SWITCH C219 STEERING COLUMN...

Page 1187: ...F A A B C D E F 1 2 3 4 5 6 7 8 9 10 FRONTOFVEHICLE C262 PREHEAT SWITCH C234 A C HEATER CONTROL ASSEMBLY SWITCH C270 DASH FAN SWITCH C904 CARGO SWITCH GUIDE LAMP C214 C215 C216 INSTRUMENT CLUSTER C905...

Page 1188: ...N AND GRID FOR REPORTING VEHICLE REPAIR LOCATIONS INSTRUMENT PANEL POSTAL 3 OF 3 1 2 3 4 5 6 7 8 9 10 B C D E F A A B C D E F 1 2 3 4 5 6 7 8 9 10 FRONTOFVEHICLE C131 WIPER MOTOR C221 C224 GENERIC ELE...

Page 1189: ...NG VEHICLE REPAIR LOCATIONS LEFT SIDE OF UNDERHOOD POSTAL 1 2 3 4 5 6 7 8 9 10 B C D E F A A B C D E F 1 2 3 4 5 6 7 8 9 10 FRONTOFVEHICLE C181 LEFT FRONT SIDE MARKER LAMP C1944 ANTI LOCK BRAKE SYSTEM...

Page 1190: ...AND GRID FOR REPORTING VEHICLE REPAIR LOCATIONS POWERTRAIN POSTAL 1 2 3 4 5 6 7 8 9 10 B C D E F A A B C D E F 1 2 3 4 5 6 7 8 9 10 FRONTOFVEHICLE C1992 POWER STEERING INVERTER ELECTRIC VEHICLE POWER...

Page 1191: ...29 OF 29 DO NOT USE THIS ILLUSTRATION AND GRID FOR REPORTING VEHICLE REPAIR LOCATIONS AIR DISTRIBUTION POSTAL 1 2 3 4 5 6 7 8 9 10 B C D E F A A B C D E F 1 2 3 4 5 6 7 8 9 10 FRONTOFVEHICLE C271 DAS...

Page 1192: ...2001 RANGER ELECTRIC VEHICLE 151 30 COMPONENT LOCATION VIEWS...

Page 1193: ...ture Sensor Postal LH side of underhood compartment C1952 151 22 F6 150 100 Anti Lock Brake System ABS Control Module LH front of underhood compartment C154 151 1 B10 150 11 Anti Lock Brake System ABS...

Page 1194: ...c vehicle power distribution box EVPDB 151 28 A4 K Battery Temperature Sensor 3 Lead Acid Inside front of traction battery pack C1981 151 16 A3 150 106 Battery Temperature Sensor 4 Lead Acid Inside mi...

Page 1195: ...column C209 151 9 F6 150 25 Data Link Connector Postal LH side of I P C2099 151 26 F7 150 118 Daytime Running Lamps DRL Module LH side of radiator support C150 151 4 F10 150 10 DC DC Converter In und...

Page 1196: ...e of underhood compartment C1966 151 23 D2 150 102 Grumman Headliner Harness Postal Near RH cowl C903 151 24 B10 150 59 Hazard Flasher Postal Behind center of I P C272 151 26 A9 150 45 Hazard Switch P...

Page 1197: ...Front Side Marker Lamp Postal LH front of engine compartment C181 151 27 E9 150 16 Left High Beam Relay Postal In auxillary relay box 2 151 26 E8 K Left Rear Anti Lock Brake Sensor At left rear wheel...

Page 1198: ...1 15 F5 K Preheat Inverter Relay Postal In relay module 151 26 A2 K Preheat Switch Postal Behind center of I P C262 151 25 E1 150 44 Radiator Cooling Fan Postal Center of underhood compartment C1967 1...

Page 1199: ...1984 151 16 A5 150 109 Traction Battery Cooling Fan Relay Lead Acid Inside traction battery pack near traction battery cooling fan C1983 151 16 E1 150 108 Traction Inverter Module TIM Under rear of ve...

Page 1200: ...me running lamp DRL module 151 4 F10 150 10 8 C151 LH inner fender well on left front caliper bracket K 150 10 2 C154 LH side of underhood compartment on anti lock brake system ABS control module 151...

Page 1201: ...A8 150 28 12 C215 Postal Behind top RH side of I P on rear of instrument cluster 151 25 A5 150 28 BK 12 C216 Behind top LH side of I P on rear of instrument cluster 151 8 A8 150 29 10 C216 Postal Behi...

Page 1202: ...262 Postal Behind center of I P on preheat switch 151 25 E1 150 44 6 C270 Postal Center of I P on dash fan switch 151 25 A9 150 44 6 C271 Postal LH side of I P on dash fan 151 29 A7 150 45 2 C272 Bott...

Page 1203: ...headliner on map lamp K 150 58 1 C903 Postal Near RH cowl on grumman headliner harness 151 24 B10 150 59 15 C904 Postal Center of I P on cargo lamp switch 151 25 A7 K 3 C905 Postal Center of I P on ca...

Page 1204: ...sensor 3 151 19 A10 150 70 2 C1816 NiMH Inside middle of traction battery on battery temperature sensor 4 151 19 F6 150 70 2 C1859 Lead Acid Inside front of traction battery on upper battery heater 15...

Page 1205: ...3 1 C1881 Lead Acid Inside traction battery near label C 151 15 A7 150 84 1 C1882 Lead Acid Inside traction battery near label R 151 15 A8 150 84 6 C1884 Lead Acid Inside traction battery near label A...

Page 1206: ...ion battery charger 151 13 F2 K BK 4 C1939 On LH side of traction battery case 151 15 C1 150 93 BK 76 C1939 Postal On RH side of traction battery case 151 28 B5 150 93 76 C1940 LH side of underhood co...

Page 1207: ...ray on fan low speed relay 151 13 C10 150 101 5 C1954 Postal RH side of underhood compartment near auxiliary battery tray on fan low speed relay 151 21 F3 150 101 5 C1955 LH side of underhood compartm...

Page 1208: ...D1 150 113 2 C1989 Inside rear of traction battery on battery temperature sensor 2 151 16 B10 150 113 2 C1991 Top of card table on RH side of battery charger 151 13 E2 150 113 GY 6 C1991 Postal Center...

Page 1209: ...select switch 151 17 A4 150 121 6 C2998 Postal Behind left of I P on fresh recirculation select switch 151 25 D1 150 121 6 C2999 Behind center of I P 151 17 A1 150 122 10 C3985 Inside traction battery...

Page 1210: ...cowl near I P fuse box 151 24 C10 G1997 LH front of underhood compartment below auxiliary battery 151 13 F10 G1998 RH side of safety wall 151 13 A5 G1998 Postal RH side of underhood compartment on ra...

Page 1211: ...S170 Postal Main harness in T O to I P fuse panel S171 Postal Main harness in T O to I P fuse panel S172 Postal Main harness near T O to C2995 S173 Postal Main harness in T O to I P fuse panel S174 Po...

Page 1212: ...C1882 S1956 Battery harness near T O to C1885 S1957 Dash panel to headlamp junction harness near T O to C136 S1958 Dash panel to headlamp junction harness near T O to C136 S1959 Dash panel to headlamp...

Page 1213: ...T O to C216 S2987 Main harness near T O to C216 S2988 Courtesy lamp switch extension harness in T O to C201 S2989 Main harness on T O to C202 S2990 Main harness near T O to C216 S2991 Main harness ne...

Page 1214: ...2001 RANGER ELECTRIC VEHICLE 152 22 NOTES...

Page 1215: ...14401 C240 14401 C242 Postal 14401 C249 Postal 14401 C250 Postal 14401 C252F 19A041 C252M 14401 C253 Postal 14A320 C254 Postal 14A320 C256 14401 C257 Postal 14401 C260 Postal 19A044 14631 C261 Postal...

Page 1216: ...C1917 14B312 C1920 14B311 C1923 14B307 C1931 14B305 C1932F 14B305 C1932M 14B325 C1933F 14B305 C1933M WA 0496 C1935F 14B326 C1935M 14B305 C1938 10B705 C1939F 10B691 C1939M 14290 C1940 14290 C1941 1429...

Page 1217: ...Wire Connector Wire Connector Wire Connector Wire Number Assembly Number Assembly Number Assembly Number Assembly C3999F 14405 C3999M 13A724 C4992 14405 C4992 Postal 13A724 C4993 14405 C4994 14405 C4...

Page 1218: ...2001 RANGER ELECTRIC VEHICLE 153 7 NOTES...

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Chevrolet 2002 Prizm Owner'S Manual preview
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