Visual Checks

WARNING: This page is about a different car, the 2011 Mercury Milan, 2011 Lincoln MKZ, 2011 Ford Fusion, 2010 Mercury Milan, and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

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 HYBRID SYSTEM UTILIZES APPROXIMATELY 300 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.

Inspect the air cleaner and inlet duct.
Check all engine vacuum hoses for damage, leaks, cracks, kinks and correct routing.
Check the powertrain control module (PCM) or transaxle control module (TCM) wiring harness for correct connections, bent or broken pins, corrosion, loose wires and correct routing.
Examine all high voltage cables and connectors for secure connection, damaged, burned or overheated insulation and loose or broken condition.
Verify the high voltage traction battery service plug is correctly connected.
Check the PCM, sensors, and actuators for physical damage.
Check the engine coolant for correct level and mixture.
Check the motor electronics coolant for correct level and mixture.
Check the transaxle fluid level and quality. Refer to the ELECTRONICALLY CONTROLLED CONTINUOUSLY VARIABLE TRANSMISSION (ECVT)
Make all necessary repairs before continuing with the quick test. For additional information refer to QUICK TEST DESCRIPTION .