ATTACHMENT III
PAGE 1 OF 14
CUSTOMER SATISFACTION PROGRAM 07B48
CERTAIN 2005 THROUGH 2007 MODEL YEAR ESCAPE HYBRID AND
2006 THROUGH 2007 MODEL YEAR MARINER HYBRID VEHICLES —
SERVICE HARNESS INSTALLATION
OVERVIEW
This program involves installing a service harness in the High-Voltage Traction Battery (HVTB) and
reprogramming the Battery Control Module (BCM).
Verify that the caution light is not ON before performing this repair. If caution light is ON, correct the
condition before performing this program. Correcting a caution light resulting from any DTC other than
P0A27 is NOT covered under this program.
NOTE: While it is not required, we recommend that this service procedure be performed by a technician
that has completed the Hybrid Escape / Mariner New Model Classroom Training (course code 30N10T0).
SERVICE PROCEDURE
WARNING:
WHEN SERVICING THE HIGH-VOLTAGE SYSTEM, ESTABLISH A BUFFER ZONE
PER THE SPECIFIED PROCEDURE IN THE WORKSHOP MANUAL. FAILURE TO
FOLLOW THIS INSTRUCTION MAY RESULT IN SERIOUS PERSONAL INJURY
OR DEATH.
WARNING:
DEPOWER THE HIGH-VOLTAGE TRACTION BATTERY (HVTB) BEFORE CARRYING
OUT ANY REMOVAL OR INSTALLATION PROCEDURES AFFECTING THE
HIGH-VOLTAGE BATTERY SYSTEM. FAILURE TO FOLLOW THIS INSTRUCTION
MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH.
WARNING:
WEAR HIGH-VOLTAGE INSULATED SAFETY GLOVES AND A FACE SHIELD WHEN
WORKING WITH HIGH-VOLTAGE BATTERIES OR CABLES. THE HIGH-VOLTAGE
INSULATED SAFETY GLOVES SHOULD BE OF APPROPRIATE SAFETY AND
PROTECTION RATING. INSPECT THE GLOVES BEFORE USE AND ALWAYS WEAR
THEM WITH THE LEATHER OUTER GLOVE. ANY HOLE IN THE RUBBER INSULATING
GLOVE IS A POTENTIAL ENTRY POINT FOR HIGH-VOLTAGE. FAILURE TO FOLLOW
THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH.
WARNING:
DO NOT PUT WATER ON THE BATTERY BOX AND AVOID CONTACT OF THE
BATTERY BOX WITH WATER WHILE WORKING ON THE HIGH VOLTAGE TRACTION
BATTERY (HVTB). REMOVE ALL JEWELRY FROM FINGERS AND WRISTS PRIOR TO
STARTING WORK ON THE HVTB. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN SERIOUS PERSONAL INJURY OR DEATH.
CPR © 2007 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
09/07
RTS-32405
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CUSTOMER SATISFACTION PROGRAM 07B48
WARNING:
TURN OFF THE IGNITION SWITCH FOR A MINIMUM OF 5 MINUTES BEFORE
REMOVING HIGH-VOLTAGE CABLES. HIGH-VOLTAGE CABLES, CONNECTORS
AND WIRING ARE ORANGE IN COLOR. DO NOT TOUCH ORANGE-COLORED CABLES,
CONNECTORS OR WIRING ONCE THE BATTERY BOX IS REMOVED. THE NOMINAL
HIGH-VOLTAGE TRACTION BATTERY (HVTB) VOLTAGE IS 330 VOLTS DC.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL
INJURY OR DEATH. SEE FIGURE 1 FOR LOCATIONS OF ORANGE HIGH-VOLTAGE
CONNECTORS AND WIRES THAT SHOULD NOT BE TOUCHED.
HV
OUTLET
HV
CONNECTOR
FRONT OF BATTERY
TBCM
CONNECTOR
JSCM
HARNESS
SERVICE DISCONNECT
SOCKET SIDE AND HV OUTLET
07X28A
FIGURE 1
CPR © 2007 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
09/07
RTS-32405
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CUSTOMER SATISFACTION PROGRAM 07B48
1.
NOTE: There is a possibility of the isolator frames coming off from the battery box, do not
swing or displace the battery box in any direction.
Remove the High-Voltage Traction Battery (HVTB) and place on a suitable work table that can
support at least 100 kg (220 lb). Refer to the applicable model year Workshop Manual Section
414-03 for the removal procedure and warnings.
CAUTION:
2.
Do not use power tools to remove the screws from the battery box. The screws thread
into plastic bosses in the battery box. The use of power tools may damage the battery
box bosses. Damage to the battery box bosses requires replacement of the battery,
which is not covered by this program.
Remove the Allen-head bolt and Torx-head bolt from both sides of the front battery cover.
See Figure 2.
RH SIDE
FRONT OF
BATTERY
ALLEN-HEAD BOLTS
LH SIDE
FRONT OF
BATTERY
TORX-HEAD BOLTS
07X28B
FIGURE 2
CPR © 2007 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
09/07
RTS-32405
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CUSTOMER SATISFACTION PROGRAM 07B48
3.
Remove the 2 Hex-head bolts securing the front side of the front battery cover. See Figure 3.
HEX-HEAD BOLTS
FRONT OF BATTERY
07X28C
FIGURE 3
4.
Remove the 18 Torx screws from the front battery cover. See Figure 4.
FRONT OF
BATTERY
FRONT
BATTERY
COVER
REAR
BATTERY
COVER
07X28D
FIGURE 4
CPR © 2007 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
09/07
RTS-32405
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CUSTOMER SATISFACTION PROGRAM 07B48
5.
Remove the 15 Torx screws from the rear battery cover. See Figure 5.
SERVICE
DISCONNECT
PLUG
SERVICE/
SHIPPING
POSITION
FRONT OF
BATTERY
REAR BATTERY
COVER
07X28E
FIGURE 5
6.
Remove the service disconnect plug and remove the front battery cover.
7.
Reinstall the service disconnect plug in the SERVICE/SHIPPING position. See Figure 5.
8.
Open the rear battery cover. The rear battery cover is connected to the battery box with 2
metal tethers, do not disconnect the tethers.
CPR © 2007 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
09/07
RTS-32405
ATTACHMENT III
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CUSTOMER SATISFACTION PROGRAM 07B48
9.
Cover the battery box using fender covers to make sure no debris falls into the battery box,
leaving the lower RH area exposed. See Figure 6.
FRONT OF
BATTERY
FENDER
COVERS
LOWER
RH AREA
07X28F
FIGURE 6
CPR © 2007 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
09/07
RTS-32405
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CUSTOMER SATISFACTION PROGRAM 07B48
10. Pull the connector, which is located near the service disconnect plug, out of the battery box and
remove the insulation from the connector. Do not use any solvent to remove the insulation.
See Figure 7.
HARNESS CONNECTOR
LOCATION IN BATTERY BOX
INSULATION
HARNESS CONNECTOR
POSITIONED OUT OF BATTERY BOX
07X28G
FIGURE 7
11. Slide out the lock cover (dark red part) and depress the release mechanism to unlock and
disconnect the connector. Attach the service harness between the male and female parts of
the original connectors. See Figure 8.
ORIGINAL MALE
CONNECTOR
SERVICE
HARNESS
LOCK
COVER
ORIGINAL FEMALE
CONNECTOR
07X28H
CPR © 2007 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
09/07
RTS-32405
FIGURE 8
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CUSTOMER SATISFACTION PROGRAM 07B48
12. Wrap the thin insulation provided around the original male side of the connector. See Figure 9.
THIN
INSULATION
MALE SIDE OF
CONNECTOR
SERVICE
HARNESS
07X28I
FIGURE 9
13. Run the service harness between the 2 bosses and guide the original female connector to the cavity
next to the fan motor assembly. Attach the service harness to the boss using the provided tie strap
and cut and remove the unused part of the strap. See Figure 10.
BOSS
FAN MOTOR
ASSEMBLY
FRONT OF
BATTERY
MALE
CONNECTOR
SERVICE
HARNESS
TIE STRAP
FEMALE CONNECTOR
FIGURE 10
CPR © 2007 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
09/07
RTS-32405
07X28J
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CUSTOMER SATISFACTION PROGRAM 07B48
14. Wrap the female side of the original connector and service harness together with the provided
thicker insulation. Attach the tie strap provided around the insulation. Make sure that the connector
is completely covered. See Figure 11.
TIE STRAP
FRONT OF
BATTERY
SERVICE
HARNESS
FEMALE SIDE
OF CONNECTOR
WRAPPED IN
INSULATION
BATTERY
BOX SEAL
07X28K
FIGURE 11
15. Remove the fender covers.
16. Before installing the front and rear battery covers:
• check for and remove any unused material in the battery box.
• check that the harness does not protrude out of the battery box.
• check that the seal is in the groove of the battery box.
17. Install the rear battery cover assembly but do not install the screws at this time.
18. Remove the service disconnect plug and install the front cover assembly, but do not install the
screws at this time.
CPR © 2007 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
09/07
RTS-32405
ATTACHMENT III
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CUSTOMER SATISFACTION PROGRAM 07B48
19. Reinstall the service disconnect plug in the SERVICE/SHIPPING position. See Figure 12.
SERVICE
DISCONNECT
PLUG
SERVICE/SHIPPING
POSITION
FRONT OF
BATTERY
07X28L
FIGURE 12
20. Before installing the screws, make sure that the battery seal is in the correct location and there is
nothing protruding from the battery box.
CAUTION:
Do not use power tools to tighten the battery box screws. The screws thread into
plastic bosses. The use of power tools may over-tighten the screws and damage
the battery box bosses. Damage to the battery box bosses requires replacement
of the battery, which is not covered by this program.
CAUTION:
For the finger tightening, manually align screw and tighten 2 threads or more to
prevent crossthreading and then run them down until they just touch the battery cover.
21. Install the 15 Torx screws finger-tight in the rear battery cover, then tighten to 3 Nm (26 lb-in) in the
sequence shown in Figure 13.
REAR BATTERY
COVER
FRONT OF
BATTERY
13
11
1
12
14
15
10
2
9
3
4
5
6
7
8
07X28M
FIGURE 13
CPR © 2007 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
09/07
RTS-32405
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CUSTOMER SATISFACTION PROGRAM 07B48
22. Install and finger-tighten the 2 Torx-head bolts and 2 Allen-head bolts (2 each side) in the side
of the battery box. Make sure that the tether bracket is correctly installed. Do not tighten the
bolts at this time. See Figure 14.
ALLENHEAD BOLT
FRONT OF
BATTERY
TORXHEAD
BOLT
TETHER BRACKET
07X28N
FIGURE 14
23. Install and finger-tighten the 2 Hex-head bolts securing the front side of the front battery cover.
Do not tighten the bolts at this time. See Figure 15.
HEX-HEAD BOLTS
FRONT OF BATTERY
07X28C
FIGURE 15
CPR © 2007 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
09/07
RTS-32405
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CUSTOMER SATISFACTION PROGRAM 07B48
24. Install the 18 Torx screws finger-tight in the front battery cover. Do not tighten the screws at
this time. See Figure 16.
FRONT OF
BATTERY
FRONT
BATTERY
COVER
REAR
BATTERY
COVER
07X28D
FIGURE 16
25. Tighten 11 of the 18 Torx screws in the front battery cover to 5.2 Nm (46 lb-in) in the sequence
shown in Figure 17.
FRONT OF
BATTERY
8
9
FRONT
BATTERY
COVER
11
10
7
5
6
1
2
3
4
REAR
BATTERY
COVER
07X28O
FIGURE 17
CPR © 2007 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
09/07
RTS-32405
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CUSTOMER SATISFACTION PROGRAM 07B48
26. Tighten the remaining 7 Torx screws in the front battery cover to 3 Nm (26 lb-in) in the sequence
shown in Figure 18.
FRONT OF
BATTERY
4
3
5
FRONT
BATTERY
COVER
6
2
7
1
REAR
BATTERY
COVER
07X28P
FIGURE 18
27. Tighten the Allen-head bolt on each side of the front battery cover to 20 Nm (15 lb-ft).
See Figure 19.
28. Tighten the Torx screw on each side of the front battery cover to 14 Nm (10 lb-ft). See Figure 19.
ALLENHEAD BOLT
FRONT OF
BATTERY
TORXHEAD
BOLT
TETHER BRACKET
07X28N
FIGURE 19
CPR © 2007 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
09/07
RTS-32405
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CUSTOMER SATISFACTION PROGRAM 07B48
29. Tighten the 2 Hex-head bolts securing the front side of the front battery cover to 12 Nm (9 lb-ft).
See Figure 20.
HEX-HEAD BOLTS
FRONT OF BATTERY
07X28C
FIGURE 20
30. Install the HVTB. Refer to the applicable model year workshop manual Section 414-03 for the
installation procedure.
31. Reprogram the BCM using version B50 or higher on Integrated Diagnostic System (IDS).
CPR © 2007 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
09/07
RTS-32405