Ford ESCAPE HYBRID FCS-15101-10 Modifiers Manual
  1. Manuals
  2. Brands
  3. Ford Manuals
  4. Automobile
  5. ESCAPE HYBRID FCS-15101-10
  6. Modifiers manual

Ford ESCAPE HYBRID FCS-15101-10 Modifiers Manual

Ford motor company automobile user manual
Hide thumbs
Table of Contents

Advertisement

Quick Links

ESCAPE HYBRID
MARINER HYBRID
MODIFIERS GUIDE
FCS-15101-10
2010
2010

Advertisement

Table of Contents
loading

Related Manuals for Ford ESCAPE HYBRID FCS-15101-10

Summary of Contents for Ford ESCAPE HYBRID FCS-15101-10

  • Page 1 ESCAPE HYBRID MARINER HYBRID MODIFIERS GUIDE FCS-15101-10 2010 2010...

  • Page 2: General Information

    Ford Mo tor Company.
  • Page 3 SECTION 0 Introduction Contents Introduction...0-1 Genuine Ford Accessories For Your Vehicle ...0-1 Considerations When Using or Installing Accessories ...0-2 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009...

  • Page 4: Genuine Ford Accessories For Your Vehicle

    Ford Motor Company has assembled this Escape/Mariner Hybrid Modifier Guide to assist vehicle modifiers in producing safe and quality products. Ford believes that safety and quality come first. To achieve customer satisfaction, we want to assist modifiers in achieving the highest standards of safety and quality in their products.
  • Page 5 This means that Genuine Ford Accessories purchased along with your new vehicle and installed by the dealer are covered for the full length of your New Vehicle’s Limited Warranty — 3 years or 36,000 miles (60,000 km) (whichever occurs first). Contact your dealer for details and a copy of the warranty.

  • Page 6: Table Of Contents

    SECTION 1 Section 1: General Information ...1-1 Important Safety Notice...1-1 Notes, Notices and Warnings ...1-2 Making Safety Devices and Elements Inoperative...1-3 Good Practices ...1-3 Process and Quality Assurance Systems ...1-3 Quality Assurance ...1-4 Minimum and Maximum Screw Sizes ...1-4 Tires and Loading...1-4 Tire Replacement Requirements ...1-4 Using Snow Tires and Traction Devices ...1-5 Vehicle Loading ...1-5...
  • Page 7 SECTION 1 General Information Contents (Continued) Vehicle Storage — Fuel System ...1-7 Vehicle Storage — Tires...1-7 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009...

  • Page 8: Escape Hybrid, Mariner Hybrid Modifiers Guide,

    Note: The descriptions and specifications contained in this guide were in effect at the time this manual was approved for printing. Ford Motor Company reserves the right to discontinue models at any time, or change specifications or design without notice and without incurring obligation.

  • Page 9: Notes, Notices And Warnings

    Section 1: General Information Notes, Notices and Warnings As you read through this guide, you will come across NOTES, NOTICES and WARNINGS. Each one is there for a specific purpose. NOTES give you added information that will help you to complete a particular procedure.

  • Page 10: Making Safety Devices And Elements Inoperative

    General Information Section 1: General Information • Keep yourself and your clothing away from moving parts when the engine is running, especially the drive belts. • To reduce the risk of serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler.

  • Page 11: Quality Assurance

    (such as P-metric versus LT-metric or all-season versus all-terrain) as those originally provided by Ford. Use of any tire or wheel not recommended by Ford can affect the safety and performance of your vehicle, which could result in an increased risk of loss of vehicle control, vehicle rollover, personal injury and death.

  • Page 12: Using Snow Tires And Traction Devices

    • Do not use cables or chains on dry roads. • Do not exceed 48 km/h (30 mph) with tire cables or chains on your vehicle. Consult your dealer for information on other Ford approved methods of traction control. Vehicle Loading...

  • Page 13: Vehicle Storage

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

  • Page 14: Vehicle Storage — Fuel System

    General Information Section 1: General Information If your vehicle is to be stored for 30 days or longer, the low-voltage (underhood) battery negative terminal must be disconnected. Failure to do this could damage your vehicle’s battery systems. Vehicle Storage — Body •...
  • Page 15 SECTION 2 Section 2: Electrical ...2-1 Electrical Basics ...2-1 Electrical Terms ...2-1 Control Modules — Red Area ...2-2 Controller Area Network (CAN) Bus ...2-2 General Electrical Considerations ...2-2 Communication Equipment ...2-2 Vehicle Speed Signal...2-2 Disabling Brake Lights ...2-2 High- and Low-Voltage Systems...2-2 12-Volt Battery ...2-3 High-Voltage Traction Battery (HVTB) ...2-3 DC/DC Converter ...2-4...
  • Page 16 SECTION 2 Contents (Continued) High-Voltage Traction Battery (HVTB) Systems Depowering ...2-7 Electrical Systems Management ...2-9 Generator Output...2-9 Vehicle Component Electrical Loads ...2-9 Typical Police/Taxi Equipment...2-10 General Guidelines ...2-11 Keep-Alive Memory Power ...2-12 Equipment Grounding Guidelines...2-12 Wire Insulation ...2-12 Terminals and Connectors...2-12 Circuit Protection and Electrical Load ...2-13 Wire Protection Requirements...2-14 Grommets and Sealing Requirements ...2-16...
  • Page 17 Contents (Continued) Recommended Splicing Method — Solder (For 16 AWG and Smaller Diameter Wire Only) ...2-20 Heat Shrinkable Tubing (Heat Shrink) (Ford Specification ESB-M99D56-A2) ...2-23 Recommended Splicing Method — Crimp (For 10 - 22 AWG Diameter Wire to Like Wire Diameter) ...2-23 Wiring Reference Information...2-26...

  • Page 18: Section 2: Electrical

    Electrical Section 2: Electrical Electrical Basics Inside a vehicle, electricity is supplied through ‘‘hot’’ wires, comparable to the pressurized supply pipes of a plumbing system. At various points along the wires are outlets in the form of lights, switches and receptacles. Turning on a light switch is somewhat like opening a faucet to let water run, an electric current flows through the hot wire to make the light glow.

  • Page 19: Control Modules - Red Area

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

  • Page 20: 12-Volt Battery

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

  • Page 21: Dc/Dc Converter

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

  • Page 22: Auxiliary Power Point - 12V

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

  • Page 23: Rubber Insulating Gloves Testing

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

  • Page 24: High-Voltage Traction Battery (Hvtb) Systems Depowering

    Electrical High-Voltage Traction Battery (HVTB) Systems Depowering WARNING: The nominal high-voltage traction battery (HVTB) voltage is 330 volt DC. A buffer zone must be set up and high-voltage insulated safety gloves and a face shield must be worn when modifying the vehicle in close proximity to the high-voltage system. Failure to follow these instructions may result in severe injury or death.
  • Page 25 4. Remove the service disconnect plug. a. Rotate the service disconnect plug from the LOCK (1) position to the UNLOCK (2) position. b. Remove the service disconnect plug and place in the SERVICE SHIPPING (3) position. 5. NOTICE: Place the service disconnect plug into the SERVICE SHIPPING position while carrying out any vehicle modifications.

  • Page 26: Electrical Systems Management

    Electrical Electrical Systems Management Care must be given in deciding what equipment should be installed into a vehicle given the power demands of the equipment and the power available from the vehicle. A power load strategy should be developed to minimize the risk of running out of power. Examine the proposed equipment for vehicle installation.

  • Page 27: Typical Police/Taxi Equipment

    2-10 A/C Clutch A/C Fan to Face — High Speed (recirculating air) A/C Fan to Face — M/H Speed (recirculating air) Heater Fan to Foot — M/H Speed (fresh air) Lighting Exterior and IP Lamps (non-dimmable) Headlamps — Low Beam Fog Lamps Brake Lights (with CHMSL) Heated Features...

  • Page 28: General Guidelines

    Escape/Mariner Hybrid Workshop Manual. • Adherence to the above guidelines is not to be construed as approval by Ford Motor Company of any specific revisions or additions to the vehicle’s original electrical system.

  • Page 29: Keep-Alive Memory Power

    • Cross-linked Polyethylene (XPLPE or SXL) rated at 125 C (257 F) is the required insulation for underhood/underbody applications (Ford Specification ESB-M1L123-A). • GXL can be used as an alternate wire (Ford Specification ESB-M7L85B) as long as the concentricity specifications are met. To provide a water-resistant seal in conjunction with crimp connectors, a Duraseal crimp connector is recommended since it is designed to account for outside wire diameter that is smaller than the present SXL wire.

  • Page 30: Circuit Protection And Electrical Load

    Electrical When a connection is not defined (typical situation — harness-to-harness connectors), the following suggestions should be implemented: • Determine the connector type. If it will be located in a hostile environment, use a sealed connector; if not, use an open connector. A hostile environment is defined as being exposed to water and/or salt accumulation and/or high temperatures (that is;...

  • Page 31: Wire Protection Requirements

    2-14 • When adding loads to a base vehicle-protected circuit, make sure that the total electrical load through the base vehicle fuse or circuit breaker is less than the device’s load rating. • Use 80% of the fuse rating to determine maximum steady state load to reduce nuisance fuse failures.
  • Page 32 • Tape — Tape is the most basic means of protection. It contains the wires in a loose bundle and provides limited environmental protection. It does not protect against chafing and pinching. — Kendall Polyken Fiberglass Base Tape (Ford Specification ESB-M3G38-A) is used for engine compartment applications. This durable tape provides protection against cut-through and abrasion commonly found in underhood applications.

  • Page 33: Grommets And Sealing Requirements

    2-16 Note: This is not meant to be an all-inclusive list of methods for physically protecting the wires. There are other means of protection available that are not listed. Grommets and Sealing Requirements Any additional wiring routed through sheet metal must pass through a grommet that both seals the opening and locates the wire(s).
  • Page 34 Electrical • Route wires to avoid metal edges, screws, trim fasteners and abrasive surfaces. When such routing is not possible, use protective devices (shields, caps) to protect the wires. Cover metal edges with a protective shield and fasten the wiring within 76 mm (3 in) on each side of the edge (see figure below).

  • Page 35: Wire Retention And Routing

    • The wire retainers and grommets installed by the assembly plant are usually designed to accommodate only the Ford-installed wires. Additional wiring or tubing should be retained by additional clips. When added wires or tubes are routed through sheet metal panels, new holes with proper wire protection and sealing must be used.
  • Page 36 Electrical For retainer screws, the following guidelines apply: • Avoid using fasteners that are too long for the application or are in an area which might damage vehicle components, including wiring, brake lines, fuel tank and lines, powertrain components, exhaust system and suspension. •...

  • Page 37: Splices And Repairs

    2-20 Splices and Repairs For quality splicing and to reduce potential problems, the following guidelines are recommended: • Stagger the splices within a harness to reduce increased harness diameter. Splice only on straight areas as installed, not on bends. • Strip wire ends making sure that individual conductor strands are not damaged. •...
  • Page 38 Electrical 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist the wires together. 5. Note: Use resin-core mildly-activated (RMA) solder. Do not use acid-core solder. Solder wires together. 6. Note: Wait for solder to cool before moving wires. Bend wire No.
  • Page 39 2-22 7. Note: Overlap tubing on both wires. Evenly position heat shrink tubing over wire repair. 8. Use a shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. Section 2: Electrical 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009 Electrical...

  • Page 40: Heat Shrinkable Tubing (Heat Shrink) (Ford Specification Esb-M99D56-A2)

    E6FZ-14488-A E6FZ-14488-B E6FZ-14488-C Heat Shrinkable Tubing (Heat Shrink) (Ford Specification ESB-M99D56-A2) Heat shrinkable tubing is available in various diameters for different splice sizes and configurations. When shrunk, it forms a small, flexible hermetic seal. Other methods (tape, PVC mold) do not provide a hermetic seal and are not recommended. Splice balancing is critical with heat shrink insulation.
  • Page 41 2-24 4. Select the appropriate wire splice for the wires to be spliced from Rotunda Wire Splice Kit 164-R5903. 5. Note: Rotunda 164-R5901 Pro-Crimper supplied with the wire splice kit is the only tool that can be used with these splices. Identify the appropriate chamber on the Rotunda Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice.
  • Page 42 11. Reconnect the battery ground cable. Heat Shrinkable Tubing (Heat Shrink) (Ford Specification ESB-M99D56-A2) Heat shrinkable tubing is available in various diameters for different splice sizes and configurations. When shrunk, it forms a small, flexible hermetic seal.

  • Page 43: Wiring Reference Information

    1-800-782-4356. Available publications include Workshop Manuals, Wiring Diagrams, PC/ED Manuals and Owner’s Literature. In addition, a publications order form can be obtained by writing to: Ford Publications, C/O Helm Inc., PO Box 07150, Detroit, MI 48207 Wiring Diagrams Note: Smart junction box (SJB) fuse 18 (20A), circuit SBP18 (YE/RD) for the heated seats is at maximum available current limit when the heated seats option is installed and used.
  • Page 44 Electrical 2-27 Section 2: Electrical 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009...
  • Page 45 2-28 Electrical Section 2: Electrical Note: Smart junction box (SJB) fuse 1 (30A), circuit SBP01 (RD) for the DC/AC power inverter is at maximum available current limit when the power inverter is installed and used. Do not splice into this fused circuit when the DC/AC power inverter is installed and used. 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009...

  • Page 46: Connector End Views

    Electrical 2-29 Section 2: Electrical Connector End Views 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009...
  • Page 47 2-30 Electrical Section 2: Electrical 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009...

  • Page 48: Connector And Ground Locator

    Electrical 2-31 Section 2: Electrical Connector and Ground Locator 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009...
  • Page 49 2-32 Electrical Section 2: Electrical 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009...
  • Page 50 Electrical 2-33 Section 2: Electrical 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009...
  • Page 51 2-34 Electrical Section 2: Electrical 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009...
  • Page 52 Electrical 2-35 Section 2: Electrical 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009...
  • Page 53 2-36 Electrical Section 2: Electrical 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009...
  • Page 54 Electrical 2-37 Section 2: Electrical 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009...
  • Page 55 SECTION 3 Section 3: Mounting ...3-1 Push Bumpers ...3-1 Using the Vehicle for Snowplowing...3-1 Using the Vehicle as an Ambulance...3-1 Siren and Grille Lights...3-1 Mounting Equipment to the Vehicle ...3-1 Partition Installation Guidelines — Vehicles Not Equipped With Safety Canopy Module and Side Air Bag Module Only ...3-2 Safety Belt Retractor...3-3 Side Impact Sensor (if equipped) ...3-5...

  • Page 56: Section 3: Mounting

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

  • Page 57: Partition Installation Guidelines - Vehicles Not Equipped With Safety Canopy Module And Side Air Bag Module Only

    • Do not mount equipment to the high-voltage connector shield located under the RH rear seat back and bottom. NOTICE: The side impact sensor is tuned to excite based on its mass (including wiring), as well as the host sheet metal. Any alteration to these components must be avoided. Additions, such as padding, wire connectors, retainers, tape or fasteners of any kind should not be used.

  • Page 58: Safety Belt Retractor

    Mounting WARNING: The partition and the installation hardware of the partition must not interfere with the proper operation of the safety belt, safety belt retractor, side impact sensor and the safety belt height adjusters. Failure to follow these instructions may result in personal injury.
  • Page 59 Mounting Section 3: Mounting Refer to the following illustration for locations that must not be used for partition mounting: 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009...

  • Page 60: Side Impact Sensor (If Equipped)

    Mounting Section 3: Mounting Side Impact Sensor (if equipped) The side impact sensors are located in the base of the B-pillars. They are positioned below the safety belt retractors. The location and orientation are critical for the correct operation of all the impact sensors.

  • Page 61: Air Bag Deployment Interference

    WARNING: Do not attempt to service, repair or modify the airbag supplemental restraint systems or its fuses. See your Ford or Lincoln Mercury dealer. Failure to follow these instructions may result in personal injury.

  • Page 62: Seat Bolts

    A-, B-, or C-pillar trim, or the headliner on a vehicle containing a safety canopy. See your Ford or Lincoln Mercury dealer. WARNING: To reduce risk of injury, do not obstruct or place objects in the deployment path of the inflatable safety canopy (if equipped).
  • Page 63 SECTION 4 Reference Contents Section 4: Reference ...4-1 Engineering Drawings ...4-1 Air Bag Deployment Interference ...4-1 Evaporative Emissions and Fuel Systems ...4-7 High-Voltage System ...4-9 High Voltage Traction Battery (HVTB) Vent...4-11 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009...

  • Page 64: Section 4: Reference

    WARNING: Do not attempt to service, repair or modify the airbag supplemental restraint systems or its fuses. See your Ford or Lincoln Mercury dealer. WARNING: Modifications to the front end of the vehicle, including frame, bumper, front end body structure, tow hooks and B-pillar surrounding parts may affect the performance of the airbag sensors, increasing the risk of injury.
  • Page 65 WARNING: Do not attempt to service, repair or modify the safety canopy system (if equipped), its fuses, the A-, B-, or C-pillar trim, or the headliner on a vehicle containing a safety canopy. See your Ford or Lincoln Mercury dealer. Failure to follow these instructions may result in personal injury.
  • Page 66 Reference Section 4: Reference Note: Do not mount equipment on the instrument panel between the driver and passenger airbags due to deployment variability. Figure 1. 1. 324 mm (12.75 in) from center of air bag door 2. 450 mm (17.7 in) from center of air bag door 3.
  • Page 67 Reference Section 4: Reference Figure 2. 1. 648 mm (25.5 in) from center of air bag door 2. 229 mm (9.0 in) from center of air bag door 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009...
  • Page 68 Reference Section 4: Reference Figure 3. 1. 730 mm (28.7 in) from center of air bag door 2. 650 mm (25.6 in) from center of air bag door 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009...
  • Page 69 Reference Section 4: Reference Note: Vehicles equipped with safety canopy module and side air bag module only. Figure 4. NOTICE: The side impact sensor is tuned to excite based on its mass (including wiring), as well as the host sheet metal. Any alteration to these components must be avoided. Additions, such as padding, wire connectors, retainers, tape or fasteners of any kind should not be used.

  • Page 70: Evaporative Emissions And Fuel Systems

    Reference Section 4: Reference Evaporative Emissions and Fuel Systems 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009...
  • Page 71 Reference Section 4: Reference 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009...

  • Page 72: High-Voltage System

    Reference Section 4: Reference High-Voltage System 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009...
  • Page 73 4-10 Reference Section 4: Reference 2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009...

  • Page 74: High Voltage Traction Battery (Hvtb) Vent

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

This manual is also suitable for:

Escape hybrid 2008Escape hybrid 2006Escape hybrid 2007Mariner hybrid 2006Mariner hybrid 20072010 escape hybrid ... Show all

Table of Contents