Lincoln Aviator 2020-2025 Service Manual / Electrical / Battery and Charging System / High Voltage Battery, Mounting and Cables / Description and Operation - High Voltage Battery, Mounting and Cables - Plug-In Hybrid Electric Vehicle (PHEV) - Overview

Lincoln Aviator: High Voltage Battery, Mounting and Cables / Description and Operation - High Voltage Battery, Mounting and Cables - Plug-In Hybrid Electric Vehicle (PHEV) - Overview

OVERVIEW

WARNING: To prevent the risk of high-voltage shock, always follow precisely all warnings and service instructions, including instructions to depower the system. The high-voltage system utilizes approximately 450 volts DC, provided through high-voltage cables to its components and modules. The high-voltage cables and wiring are identified by orange harness tape or orange wire covering. All high-voltage components are marked with high-voltage warning labels with a high-voltage symbol. Failure to follow these instructions may result in serious personal injury or death.

NOTICE: The high voltage battery in a PHEV can be affected and damaged by excessively high temperatures. The temperature in some body shop paint booths can exceed 60°C (140°F). Therefore, during refinishing operations, the paint booth temperature must be set at or below 60°C (140°F) with a bake time of 45 minutes or less. Temperatures exceeding 60°C (140°F) or bake durations longer than 45 minutes require the high voltage battery be removed from the vehicle prior to placing in the paint booth.

The plug in hybrid can be used as an electric vehicle, conventional hybrid vehicle, or both. The high voltage battery on the plug in hybrid application has more capacity than a full hybrid application and can be fully charged using EVSE (Electric Vehicle Supply Equipment) connected to the vehicle charge port. A drive mode dial located on the center console is used to change the vehicle operating strategy.

The vehicle can be placed in electric mode only (Pure EV Mode) allowing only the electric motor to propel the vehicle. In this mode the high voltage battery depletes and the gas engine does not operate unless a calibratable condition exists such as a malfunction, heavy acceleration, high electric motor temperature, elevated high voltage battery temperature, low high voltage battery state of charge, or certain climate control functions are selected (e.g. defrost).

The vehicle also operates as a conventional hybrid (Preserve EV Mode) and utilize both the electric motor and the gasoline engine to propel the vehicle. In this mode the high voltage battery state of charge is sustained (not depleted or charged). When the vehicle is operating in charge (Preserve EV Mode) the electric motor supports the gas engine during moderate to heavy acceleration and uphill driving. In low-speed driving situations the vehicle moves under only battery power and without the internal combustion engine running. The internal combustion engine automatically shuts off when the vehicle is stopped/idling or when coasting. If certain conditions are met the engine restarts when the accelerator is pressed to provide assistance to the electric motor or when the high voltage battery state of charge is low. This avoids using excess fuel when the vehicle is not in motion.

When the vehicle is placed in (Normal Mode) the vehicle automatically controls usage of the high voltage battery and switches between maintaining, depleting, and charging of the High Voltage Battery to maximize vehicle performance and fuel economy based on vehicle operating conditions.

Regenerative braking is utilized in all modes of operation which transforms the energy that is normally wasted during stop and go operation (when coasting and braking) into electricity. The generated electricity is stored in the high voltage battery until it is needed by the electric motor or the 12-volt system.

The vehicle does not require to be plugged into an external source of electricity. The energy provided by the engine and the regenerative braking, via the electric motor used as a generator motor, sustains the high voltage battery state of charge.

The high voltage battery pack consists of the following serviceable components:

BECM
High voltage battery upper cover seal
High voltage battery lower seal
High voltage battery junction box
High voltage high current fuse (mounted in the high voltage battery junction box)
High voltage low current fuse (mounted in the high voltage battery junction box and supplies voltage to the DCDC and SOBDM also known as the BCCM (Battery Charger Control Module
High voltage low current fuse (mounted in the high voltage battery junction box and supplies voltage to the Cabin Coolant Heater and ACCM
Wiring harness (BECM to vehicle low voltage connector)
Low voltage connector header
High Voltage connector header
Coolant port assembly
Vent patch

All of the high voltage battery components listed above can be serviced separately. All other components are serviced as part of the high voltage battery pack and should not be removed. If the high voltage battery pack is replaced it includes all of the components in the list.

The high-voltage system consists of the following components:

High-voltage battery cable
High-voltage ACCM cable
Electric motor 3 phase AC cable
Inverter System Controller (ISC) also known as the SOBDMC
Electric motor assembly (mounted to the front of the transmission)
DCDC
Battery Charger Control Module (BCCM) also known as the SOBDM
Cabin Coolant Heater
ACCM and A/C compressor assembly located on the lower LH side of the engine block
High-voltage battery pack

High Voltage Battery, Mounting and Cables

Description and Operation - High Voltage Battery, Mounting and Cables - Plug-In Hybrid Electric Vehicle (PHEV) - System Operation and Component Description

System Diagram Item Description 1 Current Sensor 2 Contactor Sense Leads 3 BECM 4 Precharge Contactor Coil 5 Positive Contactor Coil 6 Negative Contactor Coil 7 High Voltage Battery Junction Box 8 Temperature Sensors 9 Cell Voltage Sense Leads 10 PCM 11 Battery Cell Arrays 12 GWM 13 RCM 14 DCDC 15 12 Volt Battery Monitoring Sensor 16 TCU (if equipped) 17 Ignition Switch 18 Main 12 Volt Battery 19 HVAC 20 Service Disconnect 21 High Voltage Battery Coolant Diverter Valve 22 Motor Electronics Coolant Pump 23 Isolation Switch (BIB) 24 Auxiliary 12 Volt Battery 25 Coolant Temperature Sensor 26 High Voltage Battery 27 BCM 28 High Voltage Battery Coolant Pump 29 BCMC 30 SOBDMC 31 High Voltage Interlock Loop (HVIL) 32 Auxillary Contactor Coil 33 SOBDM also known as the Battery Charger Control Module (BCCM) System Operation Network Message Chart - Battery Energy Control Module (BECM) Broadcast Message Originating Module Message Purpose 12 volt battery voltage BCM Battery voltage measured with battery sensor...

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Lincoln Aviator 2020-2025 Service Manual: Diagnosis and Testing - Evaporative Emissions

Diagnostic Trouble Code (DTC) Chart Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.REFER to: Diagnostic Methods (100-00 General Information, Description and Operation). Diagnostic Trouble Code Chart Module DTC Description Action PCM P00FE:00 EVAP System Tank Vapor Line Restricted/Blocked: No Sub Type Information GO to Pinpoint Test HX PCM P043E:00 EVAP System Leak Detection Reference Orifice Low Flow: No Sub Type Information GO to Pinpoint Test HX PCM P043F:00 EVAP System Leak Detection Reference Orifice High Flow: No Sub Type Information GO to Pinpoint Test HX PCM P0442:00 EVAP System Leak Detected (Small Leak): No Sub Type Information GO to Pinpoint Test HX PCM P0443:00 EVAP System Purge Control Valve A Circuit: No Sub Type Information GO to Pinpoint Test HX PCM P0446:00 EVAP System Vent Control Circuit: No Sub Type Information GO to Pinpoint Test HX PCM P0451:00 EVAP System Pressure Sensor / Switch A Circuit Range / Performance: No Sub Type Information GO to Pinpoint Test HX PCM P0452:00 EVAP System Pressure Sensor / Switch A Circuit Low: No Sub Type Information GO to Pinpoint Test HX PCM P0453:00 EVAP System Pressure Sensor / Switch A Circuit High: No Sub Type Information GO to Pinpoint Test HX PCM P0454:00 EVAP System Pressure Sensor / Switch A Circuit Intermittent: No Sub Type Information GO to Pinpoint Test HX PCM P0455:00 EVAP System Leak Detected (Large Leak): No Sub Type Information GO to Pinpoint Test HX PCM P0456:00 EVAP System Leak Detected (Very Small Leak): No Sub Type Information GO to Pinpoint Test HX PCM P0457:00 EVAP System Leak Detected (Fuel Cap Loose / Off): No Sub Type Information GO to Pinpoint Test HX PCM P0460:00 Fuel Level Sensor A Circuit: No Sub Type Information GO to Pinpoint Test HX PCM P0461:00 Fuel Level Sensor A Circuit Range/Performance: No Sub Type Information GO to Pinpoint Test HX PCM P0462:00 Fuel Level Sensor A Circuit Low: No Sub Type Information GO to Pinpoint Test HX PCM P0463:00 Fuel Level Sensor A Circuit High: No Sub Type Information GO to Pinpoint Test HX PCM P0496:00 EVAP System High Purge Flow: No Sub Type Information GO to Pinpoint Test HX PCM P04EA:00 EVAP System Small Leak Detected - Fuel Tank Side: No Sub Type Information GO to Pinpoint Test HX PCM P04EB:00 EVAP System Small Leak Detected - Fresh Air Side: No Sub Type Information GO to Pinpoint Test HX PCM P04ED:00 EVAP System Large Leak Detected - Fresh Air Side: No Sub Type Information GO to Pinpoint Test HX PCM P04EE:00 EVAP System Very Small Leak Detected - Fuel Tank Side: No Sub Type Information GO to Pinpoint Test HX PCM P04EF:00 EVAP System Very Small Leak Detected - Fresh Air Side: No Sub Type Information GO to Pinpoint Test HX PCM P04F0:00 EVAP System High Load Purge Line A Performance: No Sub Type Information GO to Pinpoint Test HX PCM P144A:00 EVAP System Purge Vapor Line Restricted/Blocked: No Sub Type Information GO to Pinpoint Test HX PCM P144B:00 EVAP System Secondary Purge Vapor Line Restricted/Blocked: No Sub Type Information GO to Pinpoint Test HX PCM P144C:00 EVAP System Purge Flow Performance During Boost: No Sub Type Information GO to Pinpoint Test HX PCM P1450:00 Unable To Bleed Up Fuel Tank Vacuum: No Sub Type Information GO to Pinpoint Test HX PCM P2401:00 EVAP System Leak Detection Pump Control Circuit Low: No Sub Type Information GO to Pinpoint Test HX PCM P2402:00 EVAP System Leak Detection Pump Control Circuit High: No Sub Type Information GO to Pinpoint Test HX PCM P2418:00 EVAP System Switching Valve Control Circuit/Open: No Sub Type Information GO to Pinpoint Test HX PCM P2450:00 EVAP System Switching Valve Performance/Stuck Open: No Sub Type Information GO to Pinpoint Test HX PCM P2451:00 EVAP System Switching Valve Stuck Closed: No Sub Type Information GO to Pinpoint Test HX PCM P24B9:00 EVAP System Leak Detection Pump Pressure Sensor Circuit Range/Performance: No Sub Type Information GO to Pinpoint Test HX PCM P24BA:00 EVAP System Leak Detection Pump Pressure Sensor Circuit Low: No Sub Type Information GO to Pinpoint Test HX PCM P24BB:00 EVAP System Leak Detection Pump Pressure Sensor Circuit High: No Sub Type Information GO to Pinpoint Test HX PCM P24BC:00 EVAP System Leak Detection Pump Pressure Sensor Circuit Intermittent: No Sub Type Information GO to Pinpoint Test HX PCM P24BE:00 EVAP System Leak Detection Pump Vacuum Switching Valve Control Circuit Low: No Sub Type Information GO to Pinpoint Test HX PCM P24BF:00 EVAP System Leak Detection Pump Vacuum Switching Valve Control Circuit High: No Sub Type Information GO to Pinpoint Test HX PCM P24C0:00 EVAP System Leak Detection Pump Vacuum Switching Valve Stuck On: No Sub Type Information GO to Pinpoint Test HX PCM P24C1:00 EVAP System Leak Detection Pump Vacuum Switching Valve Performance/Stuck Off: No Sub Type Information GO to Pinpoint Test HX PCM P260F:00 EVAP System Monitoring Processor Performance: No Sub Type Information GO to Pinpoint Test HX PCM P2DDA:00 EVAP System Leak Detection Pump Performance/Stuck Off: No Sub Type Information GO to Pinpoint Test HX PCM P2DDB:00 EVAP System Leak Detection Pump Stuck On: No Sub Type Information GO to Pinpoint Test HX Global Customer Symptom Code (GCSC) Chart Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices...

Emergency Locking

Each door has a backup power system which allows the door to function if your vehicle has no power. The system has a limited number of operations before the power is depleted and turns off. When the system turns off, the door remains open and unlatched and does not close.

If your vehicle has no power and the backup power system is turned off, you can close and secure your vehicle by manually resetting each door latch using a key in the position shown.