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Ford FCS-15101-10 Automobile User Manual

1. NO109096 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 4 10 Reference Section 4 Reference N0109097 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 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 cy DO NOT BLOCK VENT 2 N0109087 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009
2. 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 Reference 4 3 Section 4 Reference Note Do not mount equipment on the instrument panel between the driver and passenger airbags due to deployment variability N0053065 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 3 610 mm 24 in 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 4 4 Reference Section 4 Reference N0069471 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 Reference 4 5 Section 4 Reference N0053067 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 4 6 Reference Section 4 Reference Note Vehicles equipped with safety canopy module and side air bag module only _ i SERRA poes RSS BS SOL RRR KYL ROKK RRR ae so X A N x 3 7 LE N0069459 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 the
3. Exterior and IP Lamps non dimmable Headlamps Low Beam Fog Lamps Brake Lights with CHMSL Heated Features Heated Rear Window includes heated mirrors Heated Front Seat LH Heated Front Seat RH Radio DC AC Inverter Speed Control Typical Vehicle Load 95 110 Amps Typical Police Taxi Equipment Loads for equipment commonly found on police vehicles are shown in the table below Not all equipment will be operating at the same time so actual loads on the power supply system will vary Component Communications Radio Light Bar LED Light Bar Siren Headlamp Flasher LED Deck Bars Led Visor Lights Radar Taximeter Receipt Printer Spot Lights each Alley Lights each Camcorder 5 0 20 0 28 0 43 0 15 0 30 0 1 0 1 5 2 0 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 Electrical 2 11 Section 2 Electrical General Guidelines Provide circuit protection fuses for all wiring The fuse rating should not exceed either the rated wiring current capacity or the total current requirements for all the add on components on the circuit Install fuses as close to the point of tapped power as possible Document all revisions to the electrical system and place with the vehicle Owner s Literature Color code and or label all revisions or additions to wiring Provide protective covering in all areas that could be damaged during normal equipment installations Disconnect the negativ
4. SECTION 4 Reference Contents Section 4 Reference Engineering Drawings Air Bag Deployment Interference Evaporative Emissions and Fuel Systems High Voltage System High Voltage Traction Battery HVTB Vent 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 Reference 4 1 Section 4 Reference Engineering Drawings Air Bag Deployment Interference A WARNING Do not place objects or mount equipment in front of the air bag module cover or in front seat areas that may come in contact with a deploying air bag Dash tunnel or console mounted equipment should be placed within the specified zone Failure to follow these instructions may result in personal injury A WARNING Do not put anything on or over the air bag module Placing objects on or over the air bag inflation area may cause those objects to be propelled by the air bag into your face and torso causing serious injury A WARNING Dash tunnel or console mounted equipment should not be placed outside of the specified zone Failure to follow these instructions may result in personal injury A WARNING Do not mount equipment between the side of the front seat and the door trim that would block deployment of the side air bag if equipped Failure to follow these instructions may result in personal injury A WARNING Do not attempt to service repair or modify the airbag supplemental restraint systems or its fuses See your Ford or Lincoln Mercury dealer PA
5. periods exceed 60 days The manufacturer s instructions packaged with the product should be followed The vehicle should then be operated at an idle speed to circulate the additive throughout the fuel system Vehicle Storage Tires Most high performance tires are made with nylon overlay As such the following steps should be taken to avoid flat spotting when the vehicles are not used for a period of time e Store the vehicles with 303 kPa 44 psi in the tires If the cars are to be driven the air pressure should be reduced to recommended operating pressure and then increased back up to 303 kPa 44 psi when returned to storage e If the vehicle is stored for periods longer than 30 days it should be moved several feet at least once during each 30 day period so that a different portion of the tread contacts the ground 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 SECTION 2 Electrical Contents Section 2 Electrical Electrical Basics Electrical Terms Control Modules Red Area Controller Area Network CAN Bus General Electrical Considerations Communication Equipment Vehicle Speed Signal Disabling Brake Lights High and Low Voltage Systems 12 Volt Battery High Voltage Traction Battery HVTB DC DC Converter DC AC Inverter and AC Power Point Auxiliary Power Point 12V Buffer Zone Rubber Insulating Gloves Testing 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 SECTION 2 El
6. 151 9 151 10 AC OUTLET HYA01 OG GN CONNECTOR HYA02_OG WH 15159 LYA03 YE VT C2292 5 19 EE I Is RYAO3_ BU BN 8 LED_GND N0109783 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 Electrical 2 29 Section 2 Electrical Connector End Views C339 Inline O 0000000 000000 N0068537 C340 Inline 14A699 O 000000 000000 o N0068536 2000000 o 0000005 FEMALE FEMALE 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 2 30 Electrical Section 2 Electrical C2293A GY 14405 DC AC INVERTER MODULE 19G317 N0053100 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 2 31 Electrical l 1ca fm rd Q Y Section 2 Connector and Ground Locator LES AH y he ZA f V e ZA f D j LT N0069473 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 2 32 Electrical Section 2 Electrical N0069476 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 Electrical 2 33 Section 2 Electrical N0069472 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 Electrical 2 34 l 1ca fm rd Q Y Section 2 N0070301 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 Electr
7. agency against the risk of injury to the officer associated with prisoner transportation Failure to follow these instructions may result in personal injury 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 All fasteners in this predominantly sheet metal environment should be made of steel or a non conductive plastic to guarantee retention and longevity If any part of a steel fastener is exposed to a wet area it should be plated to resist corrosion Safety Belt Retractor The safety belt retractors are located in the base of the B pillars The pretensioner located in the retractor is referred to as the safety belt retractor pretensioner In the event the restraints control module RCM senses an impact pretensioners provide improved occupant protection by rapidly removing slack from the safety belt Removing slack from the safety belt helps to properly position the occupant and allows for maximum effectiveness of the safety belts and the air bags e Do not use the safety belt retractor bolts for mounting the partition Do not mount any partition hardware on the inboard side of the B pillar within the bottom 305 mm 12 in Do not mount any partition hardware that will interfere with the proper sealing of the
8. before use and must always be worn in conjunction with the leather outer gloves Any hole in the rubber insulating glove is a potential entry point for high voltage Failure to follow these instructions may result in severe personal injury or death A WARNING A buffer zone is required when modifying the vehicle in close proximity to the high voltage system Failure to follow this instruction may result in severe personal injury or death 1 Set up the buffer zone around the vehicle For additional information refer to Buffer Zone in this section 2 Turn the ignition to the OFF position 3 Disconnect the 12 volt battery 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 2 8 Electrical Section 2 Electrical 4 Remove the service disconnect plug N0053779 Rotate the service disconnect plug from the LOCK 1 position to the UNLOCK 2 position 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 If the service disconnect plug is left out and placed on the bench or toolbox dirt or other contaminants may enter the high voltage traction battery HVTB which can cause damage Insert the service disconnect plug into the SERVICE SHIPPING position This disconnects the HVTB 6 To connect reverse the disconne
9. depowered Failure to follow these instructions may result in severe personal injury or death The nominal HVTB voltage is 330 volts 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 The HVTB and charging system contain high voltage components and wiring High voltage cables and wiring are orange in color 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 personal injury or death The high voltage insulated safety rubber insulating gloves that are to be worn when modifying the vehicle in close proximity to the high voltage system should be of the appropriate safety and protection rating for use on the high voltage system They must be inspected before use and must always be worn in conjunction with the leather outer gloves Any hole in the rubber insulating glove is a potential entry point for high voltage Failure to follow these instructions may result in severe personal injury or death Exposure to high voltage may result in severe personal injury or death High voltage components must be serviced by a trained service technician Always wear safety glasses for eye protection Use safety stands w
10. door 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 3 4 Mounting Section 3 Mounting Refer to the following illustration for locations that must not be used for partition mounting N0069470 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 Mounting 3 5 Section 3 Mounting Side Impact Sensor if equipped N0069470 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 Do not use the attachment bolts of the impact sensors to mount any equipment Console Design and Installation Restraints Control Module RCM The restraints control module RCM is mounted on the center tunnel under the instrument panel The RCM orientation is critical for proper operation of the restraint systems Do not use the RCM mounting bolts for attachment purposes of any equipment 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 3 6 Mounting Section 3 Mounting Air Bag Deployment Interference A WARNING Do not place objects or mount equipment in front of the air bag module cover or in front seat areas that may come in contact with a deploying air bag Dash tunnel or console mounted equipment should be placed within the specified zon
11. is the unit of electrical potential equal to the difference of electrical potential between 2 points on a circuit AMPERE is the unit used to measure the amount of current that is the number of electrically charged particles called electrons that flows past a given point on a circuit each second It is similar to measuring the amount of water flowing through a pipe at any given point The larger the pipe is the more water that can flow past the point per second Similarly the bigger the wire is the more current that can flow through it at any given point Current that has lost its voltage still has amperage as it completes the circuit and returns to the battery WATT is the unit of power lt indicates that rate at which a device converts electric current to another form of energy either heat or motion or to put it another way the rate at which a device consumes energy The relationship of volts amperes and watts to one another is expressed in a simple equation that enables you to make any calculations you may need for proper and safe electrical modifications to the vehicle Volts x amperes watts If the current is at 12 volts and a device requires 4 amperes of current the equation will read 12 volts x 4 amperes 48 watts To figure the current needed for a device rated in watts turn the equation around Watts volts amperes For example if you have a piece of equipment such as a communications radio that uses 120 watts 120 watts
12. not recommended Splice balancing is critical with heat shrink insulation If the splice is extremely unbalanced more circuits on one side than the other heat shrink insulation will not provide a proper seal Evaluate the use of double terminals instead of splices where practical in these situations Recommended Splicing Method Crimp For 10 22 AWG Diameter Wire to Like Wire Diameter 1 Disconnect the battery ground cable 2 Strip wires to appropriate length 3 Install heat shrink tubing 1 in 25 4 mm QS 1 4 in 6 35 mm lI PROPER WIRE STRIP IMPROPER WIRE STRIP N0053047 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 2 24 Electrical Section 2 Electrical 4 Select the appropriate wire splice for the wires to be spliced from Rotunda Wire Splice Kit 164 R5903 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 1 Cavity 2 Indenter N0053048 6 Crimp the connector 1 Center one end of the wire splice in the appropriate crimping chamber 2 Insert stripped wire into the barrel 3 Holding the wire in place squeeze the tool handles until ratchet releases bo Dre 11 N0053049 7 Repeating Step 6 crimp the other half of th
13. or translation in whole or part is not permitted without written authorization from Ford Motor Company 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 This book is divided into topics pertinent to modifiers of vehicles Reference is made to the current Escape Mariner Hybrid Workshop Manual for appropriate service procedures torque specifications component separation clearances and other standard information which is common with the unmodified vehicle Specifications which are unique to the guide are designated This modifier guide is not a how to book it should be used as a checklist to help make sure that certain important steps in the modification process are considered While Ford is providing this information to assist modifiers it does not warrant the products methods materials or the workmanship of the modifier Nor does it warrant against failures that result from the modification of a vehicle Following the guidelines contained in this guide does not assure individual modifiers that the products they modify comply with U S Federal or Canadian Motor Vehicle Safety Standards in effect at the time of the modification The guidelines set forth are based
14. reduce the possibility of a short circuit when disconnected Air bag restraint systems must remain intact as received from Ford Motor Company Before modifications are done to the vehicle the system must be disarmed by following the instructions provided in the current 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 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 2 12 Electrical Section 2 Electrical Keep Alive Memory Power The electronic engine and transmission control modules require battery power to be supplied at all times to maintain the keep alive memory Keep this in mind when installing load disconnect switches or solenoids Equipment Grounding Guidelines e Do not ground the body to the transmission or transmission crossmember Ground accessories to the chassis or the vehicle battery e Splicing into circuitry relating to the electronic engine and or transmission control systems is not acceptable because of the adverse effect on the electronic system operation Adequately protect electrical connections exposed to the elements Wire Insulation Polyvinyl Chloride PVC rated at 90 C 194 F is the standard wire insulation that is acceptable for inside body use but is not acceptable for underhood underbody wiring Hypalon insulation shou
15. 12 volts 10 amperes 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 2 2 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 Controller Area Network CAN Bus NOTICE Wiring faults in the controller area network CAN bus may shut down the vehicle and prevent further operation Do not splice or connect any equipment to the controller area network CAN bus wiring General Electrical Considerations Communication Equipment Mobile communication systems may harm the operation of the vehicle particularly if they are not properly designed for automotive use or are not properly installed For example when operated such systems may cause the engine to stumble or stall Citizen band CB transceivers garage door openers and other transmitters whose power output is 5 watts or less will not ordinarily affect the operation of the vehicle Vehicle Speed Signal The vehicle speed signal is sent from the PCM to other vehicle modules through the CAN bus There is no specific wire or circuit that carries the vehicle speed signal pulses D
16. 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 2 20 Electrical Section 2 Electrical Splices and Repairs For quality splicing and to reduce potential problems the following guidelines are recommended e 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 When soldering make sure an adequate mechanical joint exists before applying solder Use only resin core solder Acid core solder should not be used since it may result in corrosion For crimp joints use butt type metal barrel fasteners and the proper tool at the appropriate setting for the wire size such as Motorcraft Crimp Tool S 9796 specifically designed for this type of work Make sure splice joints are adequately sealed and insulated In an outside environment use Duraseal butt connectors or equivalent A durable substitute splice joint can be achieved by using a bare metal barrel crimping flow soldering and covering with shrink tubing Quality electrical tape can be used inside the vehicle but is not recommended for an outside environment Be sure that the new wire is not a lesser gauge than its original mating wire CONNECTOR SHRINK TUBING e 2L A0074039 oe Splicing Method Solder For 16 AWG and Smaller Diameter Wire nly 1 Disconnect the battery ground cable 2010 Esca
17. ESCAPE HYBRID MARINER HYBRID MODIFIERS GUIDE TABLE OF CONTENTS INTRODUCTION ie sle EE 1 General Information 2 Electrical 3 Mounting 4 Reference NOTE The descriptions and specifications contained in this manual 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 any obligation All rights reserved Reproduction by any means electronic or mechanical including photocopying recording or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from Ford Motor Company Copyright 2009 Ford Motor Company SECTION 0 Introduction Contents Introduction Genuine Ford Accessories For Your Vehicle Considerations When Using or Installing Accessories 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 Introduction 0 1 Introduction The descriptions and specifications contained in this manual 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 any obligation All rights reserved Reproduction by any means electronic or mechanical including photocopying recording or by any information storage and retrieval system
18. Guide 07 2009 2 6 Electrical Section 2 Electrical 2 Position 4 orange cones around the corners of the vehicle to mark off a 1 m 3 ft perimeter around the vehicle A0090643 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 Rubber Insulating Gloves Testing A WARNING The high voltage insulated safety rubber insulating gloves that are to be worn when modifying the vehicle in close proximity to the high voltage system should be of the appropriate safety and protection rating for use on the high voltage system They must be inspected before use and must always be worn in conjunction with the leather outer gloves Any hole in the rubber insulating glove is a potential entry point for high voltage Failure to follow these instructions may result in severe personal injury or death Note The high voltage insulated safety gloves must be re certified every 6 months to remain within OSHA guidelines Roll the glove up from the open end until the lower portion of the glove begins to balloon from the resulting air pressure If the glove leaks any air it must not be used The gloves should not be used if they show any signs of wear and tear The leather gloves must always be worn over the rubber insulating gloves in order to protect them The rubber insulating gloves must be
19. IN 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 Do not modify the front end of the vehicle AN WARNING Do not place objects or mount equipment on or near the headliner at the siderail that may come into contact with a deploying safety canopy if equipped Failure to follow these instructions may increase the risk of personal injury in the event of a collision 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 4 2 Reference Section 4 Reference A 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 AS WARNING To reduce risk of injury do not obstruct or place objects in the deployment path of the inflatable safety canopy 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 All fasteners in this predominantly sheet metal environment should be made of steel or a non conductive plas
20. b The resulting figure equals the available amount of cargo and luggage load capacity For example if the XXX amount equals 1 400 Ib and there will be five 150 Ib passengers in your vehicle the amount of available cargo and luggage load capacity is 650 Ib 1400 750 5 x 150 650 Ib In metric units 635 340 5 x 68 295 kg Determine the combined weight of luggage and cargo being loaded on the vehicle That weight may not safely exceed the available cargo and luggage load capacity calculated in the step above Vehicle Storage Vehicle Storage General e Vehicles should be stored in a dry ventilated place and protected from sunlight if possible e If vehicles are stored outside maintenance against rust and damage as described below is recommended NOTICE Keep all rubber parts free from oil and solvents Vehicle Storage Electrical Note Extended storage times which result in the discharge of the low or high voltage batteries may result in the setting of DTCs and or a no start condition Your vehicle must be started and run for a minimum of 10 minutes once a month in order to maintain the high voltage battery charge This will maintain the high voltage battery but it is not enough to maintain the low voltage underhood battery and additional low voltage underhood battery charging may be required after 60 days 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 General Information 1 7 Se
21. cipate problems and design accordingly Try to anticipate what could go wrong and modify your designs to address any adverse impact Review all connector applications and electrical systems to determine the need for solder grease weather resistant or sealed connectors Make sure components and wire insulation are compatible with greased connectors important for long term durability Make sure that drip loops or other means are provided to prevent water leakage into the vehicle through wiring assemblies that pass through the dash panel Use greased or sealed connectors in floor pan troughs which are subject to moisture coming through the carpeting Use XLPE insulation for uncovered runs that exceed 305 mm 12 in 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 Electrical 2 15 Section 2 Electrical Electrical Protection Properly route wires away from noise generating wires or components However if routing near noisy wires or plugging into noisy components is unavoidable additional protection must be designed into the harness Shielding Electro Magnetic Interference EMI Consider shielding if you must route close to high current or noisy circuits Use shielded wire and ground one side Seal all splices in wire assemblies that use bare coaxial shielding braid or tape for EMI suppression and insulate or tape over all shielding ends that terminate near any open connectors This prevents splice and terminal
22. class 00 and meet all of the American Society for Testing and Materials ASTM standards 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 Electrical 2 7 Section 2 Electrical High Voltage Traction Battery HVTB Systems Depowering A 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 A WARNING The high voltage traction battery HVTB and charging system contains high voltage components and wiring High voltage cables and wiring are orange in color 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 personal injury or death A WARNING Before carrying out any vehicle modifications the high voltage traction battery HVTB must be depowered Failure to follow these instructions may result in severe personal injury or death A WARNING The high voltage insulated safety rubber insulating gloves that are to be worn when modifying the vehicle in close proximity to the high voltage system should be of the appropriate safety and protection rating for use on the high voltage system They must be inspected
23. cle in a paint booth make sure that the high voltage traction battery HVTB is not installed in the vehicle High paint booth temperatures may damage the HVTB Place the service disconnect plug into the SERVICING SHIPPING position while carrying out any vehicle modifications If the service disconnect plug is left out and placed on the bench or toolbox dirt or other contaminants may enter the HVTB which can cause damage Making Safety Devices and Elements Inoperative The vehicle contains many safety features required by Federal or Canadian Motor Vehicle Safety Standards These features which include the key in ignition chime and brake lights should never be disabled or modified CFR 49 Section 30122 states that A manufacturer distributor dealer or motor vehicle repair business may not knowingly make inoperative any part of a device or element of design installed on or in a motor vehicle or motor vehicle equipment in compliance with an applicable motor vehicle safety standard prescribed under this chapter unless the manufacturer distributor dealer or repair business reasonably believes the vehicle or equipment will not be used except for testing or a similar purpose during maintenance or repair when the device or element is inoperative Good Practices Process and Quality Assurance Systems A formalized Process and Quality Assurance Systems check may be helpful in consistently producing high quality products An overview of some
24. ct procedure 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 Electrical 2 9 Section 2 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 Add up the current requirements If the current requirements exceed what the vehicle can reasonably be expected to be able to provide the battery will begin discharging to provide the power to the equipment that the generator is unable to provide After some period of time the vehicle will shut off as the battery voltage decreases to a level that cannot sustain vehicle operation There are alternatives that can be considered to minimize system electrical overload Consider the current requirements of equipment before it is purchased and installed Modern light bars and radios use a fraction of the current than units made as recently as 1996 As the light bar is the most power intensive unit installed on most vehicles considerable attention should be given to its current requirements Changes in driver habits can make a difference as well When a vehicle is sitting and no one is in the car the air conditioner can be turned off until the driver is ready to get back into the vehicle The air conditio
25. ction 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 e Wash vehicle thoroughly to remove dirt grease oil tar or mud from exterior surfaces and underside of front fender Periodically wash vehicles stored in exposed locations Touch up exposed raw or primed metal to provide rust protection Cover chrome and stainless steel parts with a thick coat of auto wax to prevent discoloration Rewax as necessary when the vehicle is washed Lubricate all hood door hinges and latches with a light grade oil e Cover the interior soft trim to prevent fading Vehicle Storage Engine e Start the engine every month Run it at fast idle until it reaches normal operating temperature e With foot on brake pedal and brake applied shift the transmission into all gears while the engine is running Vehicle Storage Fuel System e Regularly move vehicles short distances to mix fuel anti oxidation agents Note During extended periods of vehicle storage 60 days or more gasoline may deteriorate due to oxidation This can damage rubber and other polymers in the fuel system and may clog small orifices A commercially available gasoline fuel stabilizer Sta Bil or equivalent should be added to gasoline powered vehicles whenever actual or expected storage
26. d result in an increased risk of loss of vehicle control vehicle rollover personal injury and death Additionally the use of non recommended tires and wheels could cause steering suspension axle or transfer case power transfer unit failure If you have questions regarding tire replacement see an authorized Ford or Lincoln Mercury dealer A WARNING Do not install an offroad aggressive tread or incorrectly sized tire Any of these may cause elevated stress to the steering system This can cause the power steering system to overheat and shut off the power assist which can affect the safety and performance of your vehicle Note The Escape Mariner Hybrid vehicle is equipped with a reduced rolling resistance tire design The use of a different tire can effect the fuel economy of your vehicle Make sure all tires and wheels on the vehicle are of the same size type tread design brand load carrying capacity and speed rating because it 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 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 General Information 1 5 Section 1 General Information Using Snow Tires and Traction Devices Note Snow tires must be the same size and grade as originally equipped on your vehicle The tires on your vehicle have all weather treads to provide traction in rain and snow However i
27. e Failure to follow these instructions may result in personal injury A WARNING Do not put anything on or over the air bag module Placing objects on or over the air bag inflation area may cause those objects to be propelled by the air bag into your face and torso causing serious injury A WARNING Dash tunnel or console mounted equipment should not be placed outside of the specified zone Failure to follow these instructions may result in personal injury A WARNING Do not mount equipment between the side of the front seat and the door trim that would block deployment of the side air bag if equipped Failure to follow these instructions may result in personal injury A 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 AS 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 Do not modify the front end of the vehicle A WARNING Do not place objects or mount equipment on or near the headliner at the siderail that may come into contact with a deploying safety canopy if equipped Failure to follow these instructions may increase the risk of personal injury in the event of a collision 2010 Esca
28. e battery cable of vehicles stored on site to reduce the possibility of draining the battery by lights or other equipment Do not allow control panels attached to the instrument panel to protrude into the driver and passenger air bag deployment zones For additional information refer to Section 4 Reference in this guide Do not install switches and gauges in the driver or passenger knee impact areas Inspect all Ford gauges lights and switches for correct operation after instrument panel work is performed Properly secure all wiring relocated or removed while working behind the instrument panel to prevent chafing squeaks and rattles Provide adequate retention for wiring harnesses so that they are clear of bolts corners or edges which could abrade the wires during normal vehicle operation Anticipate misrouted wiring situations and protect all wiring from penetration by screws and raw edges Weather seal all electrical connectors exposed to the elements Do not use quick splice connectors or wire nuts Install the fuse panel so fuses are readily accessible Make sure that connections are easily accessible for assembly and service Make sure submersible connectors do not lose their seals under extreme assembly conditions such as bending wires 90 degrees immediately after the connector Whenever using connectors use a socket female connector on the electrical source side and a plug male connector on the electrical load side to
29. e low voltage battery systems The PCM controls the operation of the DC DC converter through an enable input from the PCM to the DC DC converter DC AC Inverter and AC Power Point Note Do not keep electrical devices plugged in the power point whenever the device is not in use lt is not recommended to use any extension cord with the 110 VAC power point since it will defeat the safety protection design provided by the cap and twist tab It will also cause the power point to overload due to powering multiple devices that can reach beyond the 150 watt load limit The DC AC inverter converts 12 volt DC to 110 volt AC to power a device that uses AC current with a rating of less than 150 watts The power point will automatically shut off if the load exceeds 150 watts This prevents damage to the inverter or load The inverter supplies 110 volt AC power only when the key is in the ON START position This reduces the draw on the 12 volt system when the vehicle is not running The DC AC inverter outlet AC power point is equipped with a green LED that indicates the system integrity The green LED illuminates continuously when the key is in the ON START position and the system is operating normally The green LED flashes constantly if the key is in the ON START position and a fault is detected Short circuits overloads or overheating of the inverter will cause the green LED to flash and the power to be cut off to the outlet If the LED is flashing the proble
30. e splice 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 Electrical 2 25 Section 2 Electrical 8 Check for acceptable crimp 1 Crimp should be centered on each end of the butt splice 2 Wire insulation does not enter butt splice 3 Wire is visible through inspection hole of splices N0053050 9 Evenly position supplied heat shrink tubing over wire repair 10 Use shielded heat gun to heat the repaired area until adhesive flows out of both ends for the heat shrink tubing 2 E O N0070450 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 Other methods tape PVC mold do not provide a hermetic seal and are not recommended Splice balancing is critical with heat shrink insulation If the splice is extremely unbalanced more circuits on one side than the other heat shrink insulation will not provide a proper seal Evaluate the use of double terminals instead of splices where practical in these situations 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 2 26 Electrical Section 2 Electrical Wiring Reference Information 2009 Escape Mariner Hybrid Wiring Diagram Excerpts The following pages are from sections of the 2009 Escape Mariner Hybrid Wiring Diagrams Orde
31. ections and minimize assembly time Avoid using similar types and colors of connectors close together Be sure that connectors have positive locking devices that allow easy installation with a low insertion force and easy removal The connector snap should be easily felt and heard Eliminate the use of edgeboard tang type and molded over connectors The use of blade type weather resistant connectors is restricted to high current applications which cannot be handled by submersible connectors Circuit Protection and Electrical Load e Modification to existing vehicle wiring should be done only with caution and careful consideration of effects on the completed vehicle s electrical system Anticipated circuitry should be studied to determine the required circuit protection and to avoid feedback loops Added circuitry must be protected either by a base vehicle fuse or circuit breaker or by a similar device supplied by the modifier 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 2 14 Electrical Section 2 Electrical e 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 e Use 135 of the fuse rating when sizing wiring to protect the circuit in the event of an overload Fuses will last for o
32. ectrical Contents Continued High Voltage Traction Battery HVTB Systems Depowering Electrical Systems Management Generator Output Vehicle Component Electrical Loads Typical Police Taxi Equipment General Guidelines Keep Alive Memory Power Equipment Grounding Guidelines Wire Insulation Terminals and Connectors Circuit Protection and Electrical Load Wire Protection Requirements Grommets and Sealing Requirements Wire Routing Wire Retention and Routing Splices and Repairs 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 SECTION 2 Electrical Contents Continued Recommended Splicing Method Solder For 16 AWG and Smaller Diameter Wire Only Heat Shrinkable Tubing Heat Shrink Ford Specification ESB M99D56 A2 Recommended Splicing Method Crimp For 10 22 AWG Diameter Wire to Like Wire Diameter Wiring Reference Information Wiring Diagrams Connector End Views Connector and Ground Locator 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 Electrical 2 1 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 glo
33. ectricity for later use e Voltage stabilizer for the electrical system e Temporary power source when electrical loads exceed the DC DC converter output current High Voltage Traction Battery HVTB NOTICE Do not splice the high voltage wiring Voltage in the system is in the range of 216 to 397 volts Damage may occur to equipment added to the system The high voltage traction battery HVTB is a 216 397 volt DC source connected in a floating ground system The battery receives stores and delivers high voltage electrical power when required It contains the traction battery control module TBCM which controls the higher functions of the battery The TBCM also estimates the state of charge estimates the power available estimates the power it can absorb and controls the battery temperature The TBCM controls the battery temperature by activating or deactivating the fans contained within the HVTB N0052770 Figure 1 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 2 4 Electrical Section 2 Electrical 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 The converter steps down the high voltage to 12 volts providing power to the vehicl
34. ed 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 Considerations When Using or Installing Accessories For maximum vehicle performance keep the following information in mind when adding accessories or equipment to your vehicle When adding accessories equipment passengers and luggage to your vehicle do not exceed the total weight capacity of the vehicle or of the front or rear axle GVWR or GAWR as indicated on the Safety Compliance Certification label Consult your dealer for specific weight information The Federal Communications Commission FCC and Canadian Radio Telecommunications Commission CRTC regulate the use of mobile communications systems such as 2 way radios telephones and theft alarms that are equipped with radio transmitters Any such equipment installed in your vehicle should comply with FCC or CRTC regulations and should be installed only by a qualified service technician Mobile communications systems may harm the operation of your vehicle particularly if they are not properly designed for automotive use To avoid interference with other vehicle functions such as anti lock braking systems amateur radio users who install radios and antennas onto their vehicle should not locate the Amateur Radio Antennas in the area of the driver s side hood Electrica
35. ed with safety canopy module and side air bag module only e Do not mount equipment to the A B and C pillars Do not mount equipment on the headliner within 200 mm 8 in of the side edges Do not mount equipment above the beltline within 200 mm 8 in of the side glass from the A pillar leading edge to the rear edge of the C pillar Do not mount equipment on the headliner along the siderails Do not install a partition divider or equipment that spans the vehicle above the beltline Partition Installation Guidelines Vehicles Not Equipped With Safety Canopy Module and Side Air Bag Module Only Zs WARNING If the vehicle is equipped with a safety canopy module and side air bag module do not install a partition divider or equipment that spans the vehicle above the beltline Failure to follow these instructions may result in personal injury 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 Mounting 3 3 Section 3 Mounting A 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 A WARNING Installation of prisoner partitions may increase the risk of injury to front seat occupants if the vehicle is impacted from a high speed rear end collision This risk should be balanced by the law enforcement
36. ehicles as well as the personal safety of the individual doing the work This manual provides general directions and guidelines for performing modifications to the Escape Mariner Hybrid Following them will help assure reliability There are numerous variations in procedures techniques tools and parts for modifying vehicles as well as in the skill of the individual doing the work This manual cannot possibly anticipate all such variations and provide advice or cautions as to each Accordingly anyone who departs from the instructions provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods tools or parts 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 1 2 General Information 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 NOTICES are given to prevent you from making an error that could damage the vehicle WARNINGS remind you to be especially careful in those areas where carelessness can cause you personal injury The following list contains some general warnings that you should follow when you work on a vehicle Z WARNING Before carrying out any vehicle modifications the high voltage traction battery HVTB must be
37. g 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 CONVOLUTE OR CLIP PROTECTION ne EDGE DIRECT CONTACT N HARNESS SATISFACTORY UNSATISFACTORY A0073514 Route wires to provide at least 76 mm 3 in of clearance to moving parts in their extreme movement location unless positively fastened and protected by a conduit Avoid wire routing without conduit in areas where temperatures exceed 82 C 180 F Minimum clearance of 152 mm 6 in should be maintained from exhaust system components Heat insulation and heat shields must be used on the wires routed in high temperature areas Make certain that all underhood or underbody wiring is cross linked polyethylene high temperature insulation wire 135 C 275 F minimum rating consistent with SAE specification J1128 Type SXL wire Normal PVC wire must not be used in underhood or underbody applications Make sure all ground locations are readily accessible for installation service and verification Do not place ground attachments in high splash areas Do not route underbody wiring over the exhaust system Underhood underbody wiring must be routed in conduit for protection Minimum conduit rating is 177 C 350 F 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 2 18 Electrical Section 2 Electrical Wire Rete
38. heet metal panels new holes with proper wire protection and sealing must be used 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 Electrical 2 19 Section 2 Electrical RUBBER ee e ELECTRIC WIRE of T STEEL PLATE SATISFACTORY UNSATISFACTORY e Cables should not be in contact with sharp edges or pierced holes WHEN PARALLEL 0 4 IN OR MORE FINE TAPING WHEN ACROSS 0 8 IN OR MORE y A I LS _ AA SATISFACTORY a y UNSATISFACTORY HARNESS Harnesses should not be taped to fuel lines or other lines A sufficient clearance should be maintained between harness and lines N0070449 For retainer screws the following guidelines apply e 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 Do not use pointed screws for attachments Also check that screws used in the vicinity of the wiring are blunt ended To minimize the potential for wiring shorts do not use drill point screws Trim components including wiring shields should use pin type attachments instead of screws Always check areas that screws protrude into for verification that an interference condition to other components does not exist Make sure that retainers used are capable of withstanding the environment over the vehicle s life expectancy
39. henever a procedure requires you to be under the vehicle Make sure that the ignition switch is always in the OFF position unless otherwise required by the procedure Set the parking brake when working on the vehicle The gear selector should be set in PARK unless instructed otherwise for a specific operation Place wood blocks 4 inch x 4 inch or larger against the front and rear surfaces of the tires to help prevent the vehicle from moving Operate the engine only in a well ventilated area to avoid the danger of carbon monoxide poisoning 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 General Information 1 3 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 Do not smoke while working on a vehicle To reduce the risk of injury always remove rings watches loose hanging jewelry and loose clothing before beginning to work on a vehicle When it is necessary to work under the hood keep hands and other objects clear of the radiator fan blades Failure to follow these instructions may result in personal injury NOTICE Do not disable the A C system The high voltage traction battery HVTB cooling system uses the cabin air to cool the HVTB Before placing the vehi
40. ical 2 35 Section 2 Electrical TZ a f f 1 ao Es ER ig j PA p E 3 oh i SSS _ ds a ER Stee 9 A N0069474 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 2 36 Electrical Section 2 Electrical N0069593 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 Electrical 2 37 Section 2 Electrical N0069592 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 SECTION 3 Mounting Contents Section 3 Mounting Push Bumpers Using the Vehicle for Snowplowing Using the Vehicle as an Ambulance Siren and Grille Lights Mounting Equipment to the Vehicle Partition Installation Guidelines Vehicles Not Equipped With Safety Canopy Module and Side Air Bag Module Only Safety Belt Retractor Side Impact Sensor if equipped Console Design and Installation Restraints Control Module RCM Air Bag Deployment Interference Seat Bolts Driveshaft Clearance 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 Mounting 3 1 Section 3 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 The Escape Mariner Hybrid is not equipped with the Ford ambu
41. in sheet metal holes Ramp grommets at the insertion end to facilitate installation and sealing Be sure that the direction of the hole punch is in the direction of grommet seating and the hole is burr free Make sure the grommet molding compound will adhere to the harness to prevent slippage Make sure the grommet will withstand the environment temperature splash Be sure that holes are large enough to allow the installation of the harness without causing circuit damage Use adhesive tape on main trunks or branches with at least a 50 overlap to prevent wicking through grommets Be certain to diaper wrap the takeouts Wire Routing A WARNING Do not place electrical component attachments or ground screws adjacent to vehicle fuel tanks fuel filler pipes fuel lines fuel vapor lines or carbon canisters Failure to follow these instructions may result in personal injury in the event of a collision Wire harness routing should conform to the following e Protect wires routed through holes in sheet metal or castings with a grommet whether or not conduit is used see figure below 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 Electrical 2 17 Section 2 Electrical RUBBER nt al TAN T STEEL P SATISFACTORY UNSATISFACTORY e Cables should not be in contact with sharp edges or pierced holes A0073515 e Route wires to avoid metal edges screws trim fasteners and abrasive surfaces When such routin
42. isabling Brake Lights Do not disable the brake light circuits for any reason Disabling the A C System Do not disable the A C system The cabin air is used to cool the high voltage traction battery HVTB High and Low Voltage Systems NOTICE Do not splice the high voltage system Voltage in the system is in the range of 216 to 397 volts Damage may occur to equipment added to the system 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 Electrical 2 3 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 Excess high voltage current is converted from high voltage AC to high voltage DC electrical power inside the motor generator unit and transmitted through the high voltage cables The high voltage DC electrical power is converted to low voltage DC electrical power through the DC DC converter This low voltage DC electrical power is then supplied to the 12 volt battery through the low voltage battery cables 12 Volt Battery The 12 volt battery is a standard automotive battery It is a DC source connected in a negative ground system The battery case is sealed with 2 vent holes to release gases The battery has 3 major functions e Storage of el
43. l or electronic accessories or components that are added to the vehicle by the dealer or the owner may adversely affect battery performance and durability 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 SECTION 1 General Information Contents Section 1 General Information Important Safety Notice Notes Notices and Warnings Making Safety Devices and Elements Inoperative Good Practices Process and Quality Assurance Systems Quality Assurance Minimum and Maximum Screw Sizes Tires and Loading Tire Replacement Requirements Using Snow Tires and Traction Devices Vehicle Loading Vehicle Storage Vehicle Storage General Vehicle Storage Electrical Vehicle Storage Body Vehicle Storage Engine 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 SECTION 1 General Information Contents Continued Vehicle Storage Fuel System Vehicle Storage Tires 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 General Information 1 1 Section 1 General Information Important Safety Notice 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 Appropriate repair methods and procedures are essential for the safe reliable operation of all motor v
44. lance preparation package Siren and Grille Lights The engine cooling system relies on proper airflow through the radiator to keep the engine at its proper operating temperature When adding sirens and grille lights to a vehicle make sure this airflow is not obstructed Reduced airflow could put additional strain on the cooling system and shorten the operational life of related components The cooling system also cools the electric motors and electronics If the coolant exceeds certain temperatures the components will attempt to protect themselves by limiting the power and torque available During the installation process keep the placement of components away from the grille area of the vehicle Mounting Equipment to the Vehicle NOTICE Do not disable the electrical air conditioning system The high voltage traction battery HVTB system uses the cabin air to cool the HVTB Do not mount equipment to the cargo load floor high voltage traction battery HVTB Do not mount equipment on the instrument panel between the driver and passenger airbags due to deployment variability Do not mount equipment obstructing the HVTB service disconnect Do not mount equipment to the LH rear quarter trim panel Do not cover or block the LH interior trim panel air intake or exhaust vents to the high voltage battery Do not cover any vehicle or warning labels 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 3 2 Mounting Section 3 M
45. ld be used on links only Ford Specification ESB M1L54 A 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 Terminals and Connectors Connector Types e Submersible sealed A connector that is capable of being immersed in water e Weather resistant A connector that will retain its sealing and connection qualities while being exposed to adverse weather conditions e Duraseal crimp A supplier trade name for a sealed wiring repair or splice 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 Electrical 2 13 Section 2 Electrical When a connection is not defined typical situation harness to harness connectors the following suggestions should be implemented e 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 underhood exterior panels and footwells Use in line co
46. m must be corrected that is short circuit or excessive load If the inverter is overheated it must be allowed time to cool off without the load connected The power outlet is not designed for the following electric appliances they may not work properly e Cathode ray tube type televisions e Motor loads such as vacuum cleaners electric saws and other electric power tools compressor driven refrigerators e Measuring devices which process precise data such as medical equipment measuring equipment e Other appliances requiring an extremely stable power supply microcomputer controlled electric blankets touch sensor lamps 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 Electrical 2 5 Section 2 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 Note Do not use the power point for operating the cigarette lighter element if equipped To prevent the fuse from being blown do not use the power point s over the vehicle capacity of 12 VDC 180W To prevent the battery from being discharged do not use the power point longer than necessary when the engine is not running Buffer Zone A WARNING The nominal high
47. mperature ranges and harness sizes Use polyethylene convolute when abrasion is the only consideration this convolute is adequate up to 96 C 205 F maximum Use nylon convolute when underhood underbody or abrasion and temperature are considerations nylon convolute is adequate up to 177 C 350 F maximum On all engine mounted wiring or bend points Use vinyl tape on the outside of the convolute to prevent wiring from looping out This tape must be able to withstand temperatures 135 C 275 F or higher Tape convolute junctions with abrasion resistant tape Polyken 267 fiberglass e Scroll Similar to convolute but without the ridges Scroll is used where harness rigidity is required especially for maintaining critical locator dimensions Use scroll for short lengths only as it is quite inflexible 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 2 16 Electrical Section 2 Electrical 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 Two piece grommets rubber with plastic inserts are recommended to facilitate installation and retention Locate grommets so they are accessible for proper seating achieved by pulling
48. n some climates using snow tires or traction devices may be necessary Follow these guidelines when using snow tires and traction devices SAE Class S cables should ONLY be used on the front axle tires Install cables or chains securely verifying that the cables or chains do not touch any wiring brake lines or fuel lines Drive cautiously If you hear the cables or chains rub or bang against the vehicle stop and retighten them If this does not work remove the cables or chains to prevent vehicle damage Avoid overloading your vehicle Remove the cables or chains when they are no longer needed 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 A WARNING The appropriate loading capacity of your vehicle can be limited either by volume capacity how much space is available or by payload capacity how much weight the vehicle should carry Once you have reached the maximum payload of your vehicle do not add more cargo even if there is space available Overloading or improperly loading your vehicle can contribute to loss of vehicle control and vehicle rollover AS WARNING Exceeding the Safety Compliance Certification Label axle and or vehicle weight rating limits could result in substandard vehicle handling or performance engine transmission and or structu
49. ne hour at 135 of their rating Total current draw is the sum of the base vehicle s circuit current requirement measured with an ammeter and the anticipated add on component current requirements Never increase the rating of a factory installed fuse or circuit breaker If the total electrical load including additional electrical components on any circuit is less than the fuse protection rating or the capacity of some limiting component switch relay the items to be added can be connected directly to that circuit The headlamp switch circuits should never have additional lighting or electrical components directly connected Added devices that exceed the current capabilities of the factory installed system are best controlled through the use of a relay or separate switch The coil of the relay can be fed from the circuit in the factory harness now acting as a signal circuit with added wiring providing feeds to the added electrical device The relay selection is important and depends on current requirements number of cycles expected in the relay lifetime whether the relay is to be operated intermittently or for long periods of time and whether the relay is exposed to weather conditions or is installed in a protected area When the current requirements of a circuit exceed the capacity of an available relay the load should be reduced or divided through the use of additional relays Wire Protection Requirements General Notes Anti
50. ner is among the largest current user of OEM equipment As such it can impact available power for other uses as well Generator Output The Escape Mariner Hybrid generator is different from that used on the standard Escape Mariner The Escape Mariner Hybrid has a 110 amp generator Vehicle Component Electrical Loads Vehicle component electrical loads are shown in the table below Not all features are powered all the time so actual vehicle loads on the power supply system will vary Note Smart junction box SJB fuse 1 30A circuit SBP04 GN 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 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 Do not splice into this fused circuit when the heated seats option is installed and used If the heated seat connectors are disconnected DTCs will set in the electronic automatic temperature control EATC module Component amps Continued 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 2 10 Electrical Section 2 Electrical Component 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
51. nnectors with secondary locks to prevent the terminal from being pushed out Do not use single wires smaller than 14 gauge in a 2 way or larger weather resistant connector the very large style since the wire may break during disengagement Use Hypalon XLPE or Elexar insulation in submersible connectors to maintain sealing integrity PVC is not acceptable because it cold flows and allows setting in a deformed pattern therefore compromising the integrity of the seal Determine the terminal type Base your decision on wire gauge current carrying capacity connector type and insulation type Use non detent low insertion force terminals whenever possible Do not use low insertion force female terminals in weather resistant connectors Analyze circuit requirements signal levels current voltage to determine the proper plating material such as gold Use of non plated terminals is not recommended Do not use plugs to seal holes in micropin connector grommets lt is very easy to forget to insert them during manufacturing and ruin the seal Use a grommet with only the necessary number of holes or use dummy wires at least 600 mm 24 in long Fully align connectors prior to terminal connection terminal cavities should have minimum tolerance to prevent terminals from floating bending or pin push out during mating engagement Make sure connectors of similar type and color are identifiable to the operator to eliminate crossed conn
52. ntion and Routing Use the following criteria to determine the location of retainers e Size and weight of wire bundle Holes with poor accessibility that prevent installation of locators Movement of wires that can result in abrasion squeaks and rattles When wiring is routed between 2 members where relative motion can occur the wiring should be secured to each member with enough wire slack to allow flexing without damaging the wire Wiring exposed to weather must provide a drip loop to prevent moisture from being conducted into the device through the wire connection see figure below A Tr Drip loops should be provided at connectors and grommets to direct water away from terminals or inside the vehicle A0073517 e Avoid routing wires into areas exposed to wheel splash When such routing cannot be avoided adequate clipping and or protective shields are required to protect the wires from stone and ice damage Allow adequate slack in wiring between the engine and stationary components to compensate for engine roll Avoid routing wires under the frame side members or at points lower than the bottom frame flange Use plastic zip straps for bundling only securing to other wires 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 s
53. of air bags is not compatible with any configuration of equipment mounting that places objects in the air bag deployment path Equipment mounted or placed in the deployment area of an air bag will reduce the effectiveness of the air bag damage the air bag and potentially damage or dislodge the equipment Air bag deployment drawings are provided in Section 4 Consult the drawings before equipment is installed inside the passenger compartment to make sure that the mounted equipment does not interfere with air bag deployment Seat Bolts The vehicle safety belts and seat assemblies are factory installed in their correct location Seat attaching bolts are not to be used as attachment points for any equipment Any added material between the seat bolt and the seat frame could have unpredictable effects on the seat bolt torque If the safety belts are removed for any reason all of the appropriate attaching hardware must be hand started and then tightened to the correct torque specifications as per the workshop manual Proper operation must be verified before returning the vehicle to service Driveshaft Clearance When installing equipment such as a console or other equipment in the console area it is important to consider the available clearance between the underbody and the driveshaft Never use self tapping screws and never use screws that are longer than necessary in the console area 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009
54. of the key items for such a system are outlined in this section 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 1 4 General Information Section 1 General Information Quality Assurance Completed unit sign off All control items should be inspected with a written sign off All labels should be inspected and signed off including verification that the information on the labels is correct All appropriate systems should be checked for leaks A road test should be performed to verify that all systems are operating correctly All systems and functions that were provided by Ford should be checked to make sure that they function correctly after the build process The modifier s Process and Quality Assurance Systems should also make sure that appropriate training is provided to the employees Minimum and Maximum Screw Sizes When installing aftermarket equipment 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 Tires and Loading Tire Replacement Requirements A WARNING Only use replacement tires and wheels that are the same size and type 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 coul
55. on engineering analysis of typical vehicles If followed the modifier s efforts in certifying vehicles to applicable standards should be aided Compliance testing that may be required for certification of specific vehicle configurations or construction is however the sole responsibility of the individual modifier Genuine Ford Accessories For Your Vehicle A wide selection of Genuine Ford Accessories are available for your vehicle through your local authorized Ford or Ford of Canada dealer These quality accessories have been specifically engineered to fulfill your automotive needs they are custom designed to complement the style and aerodynamic appearance of your vehicle In addition each accessory is made from high quality materials and meets or exceeds Ford s rigorous engineering and safety specifications Ford Motor Company will repair or replace any properly dealer installed Genuine Ford Accessory found to be defective in factory supplied materials or workmanship during the warranty period as well as any component damaged by the defective accessory The accessory will be warranted for whichever provides you the greatest benefit e 12 months or 12 000 miles 20 000 km whichever occurs first or e the remainder of your new vehicle limited warranty 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 0 2 Introduction Introduction This means that Genuine Ford Accessories purchased along with your new vehicle and install
56. ostatic limit 151 13 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 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 Hot at all time Hot in Start and Run SMART i JUNCTION F An BOX SJB Do not splice attach to or modify the high voltage system orange wiring and or 11 3 cables in any way Failure to follow this instruction may result in severe personal injury or death e When servicing the high voltage system establish a buffer zone per the specified procedure Failure to follow this instruction may result in severe personal injury or death e The High Voltage Traction Battery HVTB and charging systems contain high voltage components and wiring High voltage cables and wiring are orange in color 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 personal injury or death N wo e Exposure to high voltage may result in severe personal injury or death High voltage components must be serviced by a trained service technician 1 CBP35 CBP35 YE GY 13 15 POWER DISTRIBUTION SJB DC AC INVERTER MODULE
57. ounting 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 All fasteners in this predominantly sheet metal environment should be made of steel or a non conductive plastic to guarantee retention and longevity If any part of a steel fastener is exposed to a wet area it should be plated to resist corrosion Note Vehicles not equipped with safety canopy module and side air bag module only e Do not mount equipment to the C pillars within 15 25 cm 6 in of the retractors and side impact sensors e Do not mount equipment to the B pillars within 30 5 cm 12 in of the floor 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 All fasteners in this predominantly sheet metal environment should be made of steel or a non conductive plastic to guarantee retention and longevity If any part of a steel fastener is exposed to a wet area it should be plated to resist corrosion Note Vehicles equipp
58. pe Hybrid Mariner Hybrid Modifiers Guide 07 2009 Electrical 2 21 Section 2 Electrical 2 Strip wires to appropriate length A0075761 Install heat shrink tubing Twist the wires together Note Use resin core mildly activated RMA solder Do not use acid core solder Solder wires together A0075762 6 Note Wait for solder to cool before moving wires Bend wire No 1 back in a straight line 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 2 22 Electrical Section 2 Electrical A0075763 7 Note Overlap tubing on both wires Evenly position heat shrink tubing over wire repair 25 4 mm 49 9 mm 1 in 2 in A0075764 8 Use a shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing A0075765 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 Electrical 2 23 Section 2 Electrical 9 Reconnect the battery ground cable Sealed Connectors Ford Part Number E6FZ 14488 A Butt Connector C Gauge 18 22 Color Red E6FZ 14488 B Butt Connector C Gauge 14 16 Color Blue E6FZ 14488 C Butt Connector C Gauge 10 12 Color Yellow 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
59. pe Hybrid Mariner Hybrid Modifiers Guide 07 2009 Mounting 3 7 Section 3 Mounting A 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 A WARNING To reduce risk of injury do not obstruct or place objects in the deployment path of the inflatable safety canopy if equipped 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 All fasteners in this predominantly sheet metal environment should be made of steel or a non conductive plastic to guarantee retention and longevity If any part of a steel fastener is exposed to a wet area it should be plated to resist corrosion Driver passenger air bags affect the way equipment can be mounted in vehicles Any surfaces that could come into contact with an air bag during deployment must not damage the air bag or alter its deployment path Sharp edges corners or protrusions could damage the nylon air bag material and reduce the effectiveness of the air bag Do not mount or place any objects in the deployment path of an air bag Air bags must be allowed to fully deploy without restriction The deployment
60. ral damage serious damage to the vehicle loss of control and personal injury Gross Vehicle Weight Rating GVWR is the maximum allowable weight of the fully loaded vehicle including all options equipment passengers and cargo The GVWR is shown on the Safety Compliance Certification Label located on the B pillar or the edge of the driver s door 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 1 6 General Information 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 drivers door The total load on each axle must never exceed its GAWR AS WARNING Do not use replacement tires with lower load carrying capacities than the original tires because they may lower the vehicle s Gross Vehicle Weight Rating GVWR and Gross Axle Weight Rating GAWR limitations Replacement tires with a higher limit than the originals do not increase the GVWR and GAWR limitations Steps for determining the correct load limit Locate the statement The combined weight of occupants and cargo should never exceed XXX kg or XXX Ib on your vehicle s placard Determine the combined weight of the driver and passengers that will be riding in your vehicle Subtract the combined weight of the driver and passengers from XXX kg or XXX I
61. ring Information To obtain information about ordering complete copies of Ford or Lincoln Mercury publications call 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 Do not splice into this fused circuit when the heated seats option is installed and used 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 Electrical 2 27 Section 2 Electrical Hot at all times Hot in Run and Acc SMART JUNCTION BOX SJB 11 3 C2280A CBP43 GY CBP43 GY 13 16 POWER DISTRIBUTION SJB HEATED WINDOW 56 1 DRIVER HEATED SEAT REQUEST PASS HEATED SEAT REQUEST i N0109782 187 HVAC MODULE DATC 55 4 C2356A C215 chHs29 C339 8 WH BU CHS30 C340 8 HEATED SEAT RELAY DRIVER 151 12 Y C3250 CHS11_VT GN 2 Y C3283 HEATED SEAT RELAY PASSENGER 151 13 C3251 CHS12 YE GN Backrest i C3283 BACKREST AND CUSHION HEATER MATS DRIVER SIDE FRONT 1 Normal position 2 Thermostatic limit 151 12 Backrest BACKREST AND CUSHION HEATER MATS DRIVER SIDE FRONT 1 Normal position 2 Therm
62. se components must be avoided Additions such as padding wire connectors retainers tape or fasteners of any kind should not be used All fasteners in this predominantly sheet metal environment should be made of steel or a non conductive plastic to guarantee retention and longevity If any part of a steel fastener is exposed to a wet area it should be plated to resist corrosion NOTICE Any surfaces that could come into contact with side air curtain Safety Canopy during deployment must not damage the curtain Sharp edges corners or protrusions could damage the curtain and reduce the overall effectiveness of the side air curtain Do not mount equipment to the A B and C pillars Do not mount equipment on the headliner within 200 mm 8 in of the side edges Do not mount equipment above the beltline within 200 mm 8 in of the side glass from the A pillar leading edge to the rear edge of the C pillar Do not mount equipment on the headliner along the siderails 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 Reference 4 7 Section 4 Reference Evaporative Emissions and Fuel Systems N0109140 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 4 8 Reference Section 4 Reference N0109141 2010 Escape Hybrid Mariner Hybrid Modifiers Guide 07 2009 Reference 4 9 Section 4 Reference High Voltage System
63. shorts to the shielding Minimize the length of conductors which extend beyond the shield Failure to do this reduces the effectiveness of the shield Spike suppression in general is accomplished by connecting a diode or resistor diode combination across the terminals of the noisy component The diode should be sufficiently close to the component both electrically and physically so that inductive spikes are clamped off Make sure the diode is connected with the proper polarity Proper routing and retention will reduce the likelihood of chafing or pinching When this ideal routing is unattainable the following additional protection is needed Mechanical Environmental Protection 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 Polyken 267 is a substitute tape that may be used in lower temperature areas of the engine compartment apron area e Convolute Use convolute for all underhood underbody applications or when increased temperature abrasion or pinch resistance is required Convoluted tubing comes in different diameters and materials to accommodate different te
64. tic to guarantee retention and longevity If any part of a steel fastener is exposed to a wet area it should be plated to resist corrosion Driver passenger air bags affect the way equipment can be mounted in vehicles Any surfaces that could come into contact with an air bag during deployment must not damage the air bag or alter its deployment path Sharp edges corners or protrusions could damage the nylon air bag material and reduce the effectiveness of the air bag Do not mount or place any objects in the deployment path of an air bag Air bags must be allowed to fully deploy without restriction The deployment of air bags is not compatible with any configuration of equipment mounting that places objects in the air bag deployment path Equipment mounted or placed in the deployment area of an air bag will reduce the effectiveness of the air bag damage the air bag and potentially damage or dislodge the equipment Some approximate dimensions for air bags at full inflation are provided below These dimensions are somewhat flexible and represent free form deployments without the loading of occupants The zone dimensions provided below are approximate and will vary with the loading of occupants in the seats All air bag and equipment mounting zone dimensions are approximate due to different air bag deployment characteristics Do not mount equipment between the side of the front seat and the door trim that would block deployment of the side air bag
65. 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 A WARNING The high voltage traction battery HVTB and charging system contains high voltage components and wiring High voltage cables and wiring are orange in color High voltage insulated safety gloves and a face shield must be worn when carrying out any modifications on this vehicle Failure to follow these instructions may result in severe personal injury or death A WARNING Before carrying out any vehicle modifications the high voltage traction battery HVTB must be depowered Failure to follow these instructions may result in severe personal injury or death A WARNING The high voltage insulated safety rubber insulating gloves that are to be worn while working on the high voltage system should be of the appropriate safety and protection rating for use on the high voltage system They must be inspected before use and must always be worn in conjunction with the leather outer gloves Any hole in the rubber insulating glove is a potential entry point for high voltage Failure to follow these instructions may result in severe personal injury or death 1 Position the vehicle in the repair bay 2010 Escape Hybrid Mariner Hybrid Modifiers
66. w Once the electricity has done its work its potential drops to zero just as water loses pressure after flowing through a sink or laundry tub The electrical system has drains which are the ground wires that return the current to its source just as a plumbing system has drain pipes through which water runs into the sewer mains or the ground The light or equipment powered by the current technically called the load can be compared to a water wheel that remains motionless until a stream of water causes it to turn A load may be one of 2 kinds The first consists of a resistance a material that permits the passage of electric current but only with difficulty and thereby creates heat The tungsten filament of an incandescent bulb is resistance so is the heating element of an electric heater of a coffee pot A load may also be an inductance typically a motor with windings of copper wire in which the magnetic fields generated by the current create motion At any moment the demand on an electrical system depends on the number of loads in operation and their consumption of energy just as demand on a water system depends on how many faucets are opened and how wide they are opened The mechanics and physical fittings of the system are simple Current moves throughout the vehicle in wires of different sizes according to the current a circuit may have to carry Power is supplied directly to equipment through connectors Electrical Terms VOLT

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