Ford Explorer: High Voltage Battery, Mounting and Cables / General Procedures - High Voltage System De-energizing

Ford Explorer 2020-2021 Service Manual / Electrical / Battery and Charging System / High Voltage Battery, Mounting and Cables / General Procedures - High Voltage System De-energizing

Depower

  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.

  1.   WARNING: Before beginning any service procedure in this manual, refer to health and safety warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

    Refer to: High Voltage System Health and Safety Precautions - Overview (100-00 General Information, Description and Operation).
  1. Using the FDRS CARRY OUT the Zero Voltage Confirmation routine and follow the on-screen instructions.
    • Detach the pin-type retainer and position the electrical connector and wiring harness aside.
    • Release the Connector Position Assurance (CPA) clip.
    • Depress the tab while pulling the connector until the hole is completely visible on the top of the connector.
    • Insert a suitable tool inside the connector hole to prevent the connector from closing.
  1. Using the FDRS COMPLETE the Zero Voltage Confirmation routine and verify the High Voltage System has been de-energized.

Manual Depower

  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: Manual De-energization should only be performed when a Ford – specific diagnostic tool is not available.

NOTICE: Excessive use of this method may cause damage to electrical connectors.

NOTICE: To prevent the risk of high voltage shock, the high voltage battery cover must not be removed if any of the following conditions exist:

  • BECM DTC P0AA6:00 that has been diagnosed to be an internal fault with the high voltage Battery.
  • BECM Diagnostic Trouble Codes (DTCs) P0AA1:00 AND P0AA4:00 are present.
  • BECM Diagnostic Trouble Codes (DTCs) P0D0F:00 AND P0AA4:00 are present (PHEV only).
  1.   WARNING: Before beginning any service procedure in this manual, refer to health and safety warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

    Refer to: High Voltage System Health and Safety Precautions - Overview (100-00 General Information, Description and Operation).
  1. Disconnect the Electric Vehicle Supply Equipment (EVSE) from the vehicle charge port. (PHEV only).
  1. Turn the ignition ON without depressing the brake pedal (Accessory mode).
  1. NOTE: A scan tool that is capable of performing a self-test on the BECM is required.

    • Using a scan tool perform BECM self test and record the Diagnostic Trouble Codes (DTCs).
    • If BECM Diagnostic Trouble Codes (DTCs) P0AA1:00 AND P0AA4:00 are present.
      Refer to: High Voltage Battery, Mounting and Cables (414-03 High Voltage Battery, Mounting and Cables, Diagnosis and Testing).
    • If BECM Diagnostic Trouble Codes (DTCs) P0D0F:00 AND P0AA4:00 are present (PHEV only).
  1. Turn the ignition OFF.
    • Detach the pin-type retainer and position the electrical connector and wiring harness aside.
    • Release the Connector Position Assurance (CPA) clip.
    • Depress the tab while pulling the connector until the hole is completely visible on the top of the connector.
    • Insert a suitable tool inside the connector hole to prevent the connector from closing.
  1. Disconnect the low voltage electrical connector at the High Voltage Battery.
  1. Disconnect the high voltage electrical connector at the High Voltage Battery.
  1. Wait a minimum of 5 minutes.

Repower

  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.

    • Remove the suitable tool from the connector hole.
  1. NOTE: The tab must be depressed prior to pushing the connector back in or damage to the connector may result.

    • Depress the tab while pushing the connector until the hole is not visible on the top of the connector.
    • Push the Connector Position Assurance (CPA) clip until it touches the connector body.
    • Attach the pin-type retainer.

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