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
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...
Other information:
Overview
The
AGS (Active Grille Shutter) system is primarily used to improve fuel
economy by reducing aerodynamic drag while the vehicle in moving. It is
also used to shorten engine warm-up time, which increases engine
efficiency and provides faster heat delivery to the vehicle cabin...
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...