2006
2007
ESCAPE HYBRID
MARINER HYBRID
MODIFIERS GUIDE

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TABLE
OF
CONTENTS
INTRODUCTION
SECTIONS 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.
Al rights reserved. Reproduction by any means, elec tron ic or me chan ical, in clud ing pho to copy ing,
recording, or by any in for ma tion storage and re triev al system or trans la tion in whole or part is not
per mit ted without writ ten au tho ri za tion from Ford Mo tor Company.
Copyright © 2006, Ford Motor Company

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Introduction
0-1
Introduction
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 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:
• 12 months or 12,000 miles (20,000 km) (whichever occurs first), or
• the remainder of your new vehicle limited warranty.
This means that Genuine Ford Accessories purchased along with your new vehicle and installed
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.
2006/2007 Escape Hybrid, Mariner Hybrid Modifiers Guide, 8/2006

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0-2
Introduction
Introduction
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.
• Electrical or electronic accessories or components that are added to the vehicle by the dealer or
the owner may adversely affect battery performance and durability.
2006/2007 Escape Hybrid, Mariner Hybrid Modifiers Guide, 8/2006

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SECTION 1
General Information
Contents
Section 1: General Information ........................................................1-1
Important Safety Notice................................................................1-1
Notes, Cautions and Warnings.................................................1-2
Making Safety Devices and Elements Inoperative...................1-3
Good Practices .............................................................................1-3
Process and Quality Assurance Systems ................................1-3
Quality Assurance.....................................................................1-4
Minimum and Maximum Screw Sizes ......................................1-4
Tires and Loading.........................................................................1-4
Tire Replacement Requirements ..............................................1-4
Using Snow Tires and Traction Devices ..................................1-5
Vehicle Loading ........................................................................1-5
Vehicle Storage ............................................................................1-6
Vehicle Storage — General......................................................1-6
Vehicle Storage — Electrical ....................................................1-6
Vehicle Storage — Body ..........................................................1-7
Vehicle Storage — Engine .......................................................1-7
2006/2007 Escape Hybrid, Mariner Hybrid Modifiers Guide, 8/2006

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SECTION 1
General Information
Contents (Continued)
Vehicle Storage — Fuel System ..............................................1-7
Vehicle Storage — Tires...........................................................1-7
2006/2007 Escape Hybrid, Mariner Hybrid Modifiers Guide, 8/2006

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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 vehicles 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.
2006/2007 Escape Hybrid, Mariner Hybrid Modifiers Guide, 8/2006

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1-2
General Information
Section 1: General Information
Notes, Cautions and Warnings
As you read through this guide, you will come across NOTES, CAUTIONS and WARNINGS. Each
one is there for a specific purpose. NOTES give you added information that will help you to
complete a particular procedure. CAUTIONS 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.
WARNING:
• Before carrying out any vehicle modifications, the high voltage traction battery must be
depowered. Failure to follow these instructions may result in severe personal injury or
death.
• The nominal high voltage traction battery (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 high voltage traction battery 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 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 whenever 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.
2006/2007 Escape Hybrid, Mariner Hybrid Modifiers Guide, 8/2006

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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.
CAUTION:
• Before placing the vehicle in a paint booth, insure 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 system may be helpful in consistently producing high
quality products. An overview of some of the key items for such a system are outlined in this
section.
2006/2007 Escape Hybrid, Mariner Hybrid Modifiers Guide, 8/2006

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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 assure 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
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 could 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.
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.
2006/2007 Escape Hybrid, Mariner Hybrid Modifiers Guide, 8/2006

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Document Outline

• Introduction
  • Genuine Ford Accesories For Your Vehicle
  • Considerations When Using or Installing Accessories
• Section 1: General Information
  • Table of Contents
  • Important Safety Notice
    • Notes, Cautions 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
    • Vehicle Storage „ Fuel System
    • Vehicle Storage „ Tires
• Section 2: Electrical
  • Table of Contents
  • 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
  • High-Voltage Traction Battery 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
      • Electrical Protection
      • Mechanical/Environmental Protection
    • Grommets and Sealing Requirements
    • Wire Routing
    • Wire Retention and Routing
  • Splices and Repairs
    • Recommended Splicing Method „ Solder (For 16 AWG and Smaller Diameter WireOnly
    • Heat Shrinkable Tubing (Heat Shrink) (Ford Specification ESB-M99D56-A2)
    • Recommended Splicing Method „ Crimp (For 10„22 AWG Diameter Wire to Like WireDiameter)
  • Wiring Reference Information
  • Wiring Diagrams
  • Connector End Views
  • Connector and Ground Locator
• Section 3: Mounting
  • Table of Contents
  • 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 Moduleand Side Air Bag Module Only.
    • Safety Belt Retractor
    • Side Impact Sensor (if equipped)
  • Console Design and Installation
    • Restraint Control Module (RCM)
    • Air Bag Deployment Interference
    • Seat Bolts
    • Driveshaft Clearance
• Section 4: Reference
  • Table of Contents
  • Engineering Drawings
    • Air Bag Deployment Interference
    • Evaporative Emissions and Fuel Systems
    • High Voltage System
    • Auxiliary Air Conditioning (A/C) System

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