Related more details with pictures (not in this post, follow link to see in-line pictures):
http://www.escape-city.com/viewtopic...&t=1229#p26893
Re: 2005-2008 EH/MH/TH - Wrench lamp on, DTC B1239
(click on thumbnails to enlarge)
Bulletin No.: 07-001/08
Last Issued: 1/14/2008
Subject:
HYBRID - WRENCH LIGHT ON - B1239 SET
APPLICABLE MODEL(S)/VINs
2008 Tribute Hybrid
DESCRIPTION
Some 2008 Tribute Hybrid vehicles may exhibit a wrench light on with DTC B1239 set. This may or may not be accompanied by driveability symptoms.
Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE
1. Verify customer concern.
2. Remove the 2 pin-type retainers and the rear door scuff plate trim panel.
3. Position the liftgate weather-strip aside.
4. If equipped, remove the cargo net hold-down.
5. Insert a tape-wrapped screwdriver between the D-pillar trim panel and rear quarter trim panel to release the retainers and remove the rear quarter trim panel.
6. Remove the D-pillar trim panel.
7. Remove the four (4) battery airflow duct screws, the one (1) pin-type retainer and remove the battery airflow duct assembly.
8. Remove the two (2) auxiliary climate control fresh air inlet duct nuts and remove the duct.
NOTE:
The "D" pillar bracket will remain in place.
9. Remove two (2) upper climate control housing bolts and two (2) lower climate control housing nuts.
10. Position the climate control housing to allow access to the auxiliary mode door actuator. DO NOT REMOVE.
11. Remove the auxiliary airflow mode door actuator screws and remove and replace the auxiliary airflow mode door actuator.
12. Inspect auxiliary airflow mode door actuator and mode door linkage for free movement from any obstructions including the wiring harness.
13. Install the modified auxiliary airflow mode door actuator. Tighten screws to 18 lb-in (2 N.m).
NOTE:
^ The auxiliary climate control housing must be installed behind the lower portion of the D-pillar bracket. When installed correctly, the auxiliary climate control housing bolt will go through the d-pillar bracket first, then through the housing mounting location.
14. Position the climate control housing to installed position and install screws/nuts.
15. Install the battery airflow duct assembly, one (1) pin-type retainer and the four (4) screws. Tighten to 18 lb-in (2N.m).
16. Install the left rear D-pillar trim panel and rear quarter trim panel.
17. Using IDS 52.4 or later software, reprogram the Traction Battery Control Module (TBCM) to the latest calibration by following the "Module Reprogramming" procedure for the BCM.
WARNING:
^ During BCM module programming, you will be instructed to remove and install the High Voltage Service Disconnect from the battery pack located in the trunk. To prevent injury or death, review the HIGH-VOLTAGE TRACTION BATTERY SYSTEMS DEPOWERING - HYBRID procedure PRIOR to performing BCM module programming.
NOTE:
^ Always update the IDS tool first, then follow on-screen instructions to download the needed calibration file for TBCM reprogramming.
^ It is not necessary to remove any fuses or relays during BCM reprogramming when the IDS screen prompts you to do so. You may accidentally stop power to one of the BCM terminals and cause the BCM to be blanked, or you may receive error messages during the IDS reprogramming procedure.
^ IDS shows the calibration part numbers after programming the BCM.
^ Please be aware that BCM calibration part numbers and file names listed in any Service Bulletin may change due to future releases of IDS software, and additional revisions made to those calibrations for service related concerns.
^ When reprogramming a BCM, IDS will always display the "latest" calibration P/N available for that vehicle. If any calibration has been revised/updated to contain new information for a new service concern/issue, it will also contain all previously released calibrations.
^ When performing this procedure, we recommend that a battery charger be installed on the vehicle battery located in the engine compartment and turned ON to a maximum charge of no more than 20 AMPS to keep the vehicle battery up to capacity. If you exceed 20 AMPS, it could damage the VCM.
18. After performing the BCM reprogramming procedure, verify the repair by starting the engine and making sure there are no MIL illumination or abnormal warning lights present.
NOTE:
^ If any DTCs should remain after performing DTC erase, diagnose the DTCs according to the appropriate Troubleshooting section of the Workshop Manual.
^ After BCM reprogramming, it is no longer necessary to road test the vehicle to relearn" KAM (Keep Alive Memory).
19. Verify repair.
HIGH-VOLTAGE TRACTION BATTERY SYSTEMS DEPOWERING - HYBRID
WARNING:
^ The nominal high-voltage traction battery (HVTB) voltage is 330 volts DC. The buffer zone must be set up and high-voltage insulated safety gloves and a face shield must be worn. Failure to follow these instructions may result in severe personal 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 worn when carrying out any diagnostics on this vehicle. Failure to follow these instructions may result in severe personal injury or death.
^ Before carrying out any removal and installation procedures of the high-voltage traction battery system, the high-voltage traction battery must be depowered. Failure to follow these instructions may result in severe personal injury or death.
^ The high-voltage insulated safety 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 glove. 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.
^ High-voltage insulated safety gloves and a face shield must be worn when working with high-voltage cables. The ignition switch must be OFF for a minimum of 5 minutes before removing high-voltage cables. Failure to follow these instructions may result in severe personal injury or death.
The buffer zone is required only when working with the high-voltage system. Failure to follow these instructions may result in severe personal injury or death.
1. Set up buffer zone around the vehicle.
a. Position the vehicle in the repair bay.
b. Position 4 orange cones around the corners of the vehicle to mark off a 1 m (3 ft) perimeter around the vehicle.
c. 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.
2. Remove the service disconnect plug.
a. Rotate the service disconnect plug from the lock (1) position to the unlock (2) position.
b. Remove the service disconnect plug and place in the servicing shipping (3) position.
3. Insert the service disconnect plug into the servicing shipping position. This disconnects the HVTB.
CAUTION:
Place the service disconnect plug into the servicing shipping position while the high-voltage traction battery (HVTB) is being removed and/or while the high-voltage system is having repairs carried out. If the service disconnect plug is left out and placed on the bench or tool - box, dirt or other contaminants may enter the HVTB, which can cause damage.
4. To connect, reverse the disconnect procedure.
CALIBRATION INFORMATION
New TBCM Calibration Part Number: 8M64-10B687-AG
NOTE:
^ The TBCM Calibration Part Numbers listed above are provided for TBCM reprogramming purposes only. These are not necessarily the same Mazda part numbers used to order an actual TBCM through the Mazda Parts System. It is not necessary to order a TBCM as part of this repair procedure.
PART(S) INFORMATION
ZZCB-61-B8Z - Auxiliary Door Mode Actuator - Qty. 1
NOTE:
^ The TBCM Calibration Part Numbers listed above are provided for TBCM reprogramming purposes only. These are not necessarily the same Mazda part numbers used to order an actual TBCM through the Mazda Parts System. It is not necessary to order a TBCM as part of this repair procedure.
WARRANTY INFORMATION
Warranty Type: A
Symptom Code: 6X
Damage Code: 97
Part Number Main Cause: ZZCB-61-B8Z
Quantity: 1
Operation Number / Labor Hours: YY492XRX / 1.1 Hrs.
NOTE:
^ This warranty information applies only to verified customer complaints on vehicles eligible for warranty repair. Refer to the Warranty Wizard for warranty term information.
^ Additional diagnostic time cannot be claimed for this repair.
Re: Throttle Control/Powertrain Warning Light
Linear Mode
