Pinpoint Test G: DTC C1862 - Contactor Circuit Failure
High-Voltage Traction Battery
Pinpoint Tests
Pinpoint Test G: DTC C1862 - Contactor Circuit Failure
Refer to Wiring Diagram Set 12 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Charging System for schematic and connector information. Diagrams By Number
Normal Operation
With the engine running, the battery power off (BPO) function may be triggered by the front and/or rear Inertia Fuel Shutoff (IFS) switches opening, a high-voltage interlock circuit opening, the electrical interlock (EL I) circuit opening (fuse protected by the Battery Junction Box (BJB) fuse 26 [5A]) or if the contactor box within the Battery Control Module (BCM) requests a BPO mode. If the IFS switch opens and causes the BPO mode to occur, no DTCs are set. Also, if the IFS switch is open, a power reset indicator in the Instrument Cluster (IC) illuminates.
- DTC C1862 Contactor Circuit Failure - The PCM monitors the frequency signal the BCM sends out on the BPO circuit CDC05 (GY/VT). With the ignition switch in the ON position and the engine ON or OFF (the engine must have run at least once after the key was cycled to ON), the BCM monitors the contactors continuously. During a power down (key OFF) sequence, one or both of the contactors may cause the BCM to set this DTC if they fail.
This pinpoint test is intended to diagnose the following:
- High Voltage Traction Battery (HVTB)
- Service disconnect plug
PINPOINT TEST G: DTC C1862 - CONTACTOR CIRCUIT FAILURE
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G1 INSPECT THE SERVICE DISCONNECT PLUG FOR AN OPEN
WARNING: Wear high-voltage insulated safety gloves and a face shield when working with high-voltage batteries or cables. The high-voltage insulated safety gloves should be of the appropriate safety and protection rating. Inspect the gloves before use and always wear them with the leather outer glove. Any hole in the rubber insulating glove is a potential entry point for high-voltage. Failure to follow these instructions may result in serious personal injury or death.
WARNING: Turn OFF the ignition switch for a minimum of 5 minutes before removing high-voltage cables. High-voltage cables and wiring are orange in color. The nominal high-voltage traction battery voltage (HVTB) is 330 V DC. Failure to follow these instructions may result in serious personal injury or death.
WARNING: Depower the high-voltage traction battery (HVTB) before carrying out any removal or installation procedures affecting the high-voltage battery system. Failure to follow this instruction may result in serious personal injury or death.
WARNING: When servicing the high-voltage system, establish a buffer zone per the specified procedure. Failure to follow this instruction may result in serious personal injury or death.
- Ignition OFF.
- Remove the service disconnect plug and inspect for an open. Make sure that the high-voltage fuse resistance is less than one ohm. If the high-voltage fuse is open, refer to DTC P0A95 for instructions. Refer to High-Voltage Traction Battery Systems Depowering High-Voltage Traction Battery Systems Depowering. Diagnostic Trouble Code Tests and Associated Procedures
- Is the service disconnect plug open?
Yes
NOTE: Do not install service disconnect plug until it is confirmed that the HVTB system is OK.
INSTALL a new service disconnect plug. REFER to High-Voltage Traction Battery Systems Depowering High-Voltage Traction Battery Systems Depowering. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
No
GO to G2.
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G2 CHECK FOR A HARD FAULT
- Connect the scan tool.
- Ignition ON.
- Clear the DTCs. Cycle the key twice, starting the engine each time. Repeat the self-test.
- Is DTC C1862 still present?
Yes
GO to G3.
No
RETURN the vehicle to the customer until the concern can be verified.
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G3 CHECK FOR CORRECT BCM OPERATION
NOTE: This pinpoint test step only addresses the 6-pin and 40-pin connectors for the BCM. It is not necessary to disconnect the high-voltage connectors when following this pinpoint test step procedure.
- Disconnect BCM electrical connector C4227a.
- Check for:
- corrosion.
- pushed-out pins.
- Connect BCM connector C4227a and make sure it seats correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
Yes
INSTALL a new HVTB. REFER to High-Voltage Traction Battery High-Voltage Traction Battery. TEST the system for normal operation.
No
The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test.
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