Ford Escape: Voltage Converter/Inverter / Removal and Installation - Direct Current/Direct Current (DC/DC) Converter Control Module

Special Tool(s) / General Equipment

Removal

  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. NOTE: If installing a new module, it is necessary to upload the module configuration information to the scan tool prior to removing the module. This information must be downloaded into the new module after installation.

   Upload the DCDC configuration to the scan tool by following the scan tool on-screen instructions.
   

1. De-energize the high voltage system.
   Refer to: High Voltage System De-energizing (414-03A High Voltage Battery, Mounting and Cables, General Procedures).
   

1. Disconnect the battery.
   Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
   

1. NOTICE: Before disconnecting the high voltage battery electrical connector, the electrical connector must be cleaned with a nylon brush and free of debris. Blow any dirt or debris from the electrical connector with compressed air before disconnecting or component damage may occur.

   NOTICE: High voltage electrical connectors may require unique methods to be disconnected. If not properly disconnected, component damage may occur.

   1. Clean the high voltage battery electrical connector with a nylon brush. Blow any dirt or debris from the electrical connector with compressed air.
      
   2. Disconnect the high voltage battery electrical connector from the DCDC .
      Refer to: High Voltage Connector Disconnect and Connect (414-03A High Voltage Battery, Mounting and Cables, General Procedures).
      
   3. Detach the retainers and position the wire harness aside.
      

1. 1. Remove the terminal cover.
      
   2. Remove the nut and position aside the wire.
      Torque: 106 lb.in (12 Nm)

1. 1. Clamp the coolant hoses.
      Use the General Equipment: Hose Clamp(s)
   2. Disconnect the coolant hoses.
      

1. Disconnect the electrical connector, detach the wire harness retainers from the studs and position aside the harness.
   

1. Remove the stud bolts and the DCDC .
   Torque: 159 lb.in (18 Nm)

Installation

1. Make sure the brackets slide retainers are properly positioned.
   

1. To install, reverse the removal procedure.
   

1. If replacing the module, download the DCDC configuration information from the scan tool to the new DCDC following the scan tool on-screen instructions.
   

1. Bleed the cooling system.
   Refer to: Cooling System Filling and Bleeding (303-03D Electric Powertrain Cooling - Hybrid Electric Vehicle (HEV), General Procedures).