service FORD C MAX ENERGI 2017 Service Manual

UNDER HOOD OVERVIEW -
PLUG-IN HYBRID ELECTRIC
VEHICLE (PHEV)
WARNING
The inverter system controllercontains high-voltage componentsand is not serviceable. Do not touch,probe, or tamper with it. Failure to followthis instruction could result in personalinjury or death.
Note:Do not attempt to service any of thehigh-voltage components or wiring. Foreasier identification, the high-voltage wiringinsulation is color coded orange.
Engine coolant reservoir cap. See Engine Coolant Check (page 228).A
Engine oil filler cap. See Engine Oil Check (page 226).B
Engine oil dipstick. See Engine Oil Dipstick (page 226).C
Engine air filter cover. See Changing the Engine Air Filter (page 244).D
Inverter system controller.E
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Note:If prediluted coolant is not available,use the approved concentrated coolantdiluting it to 50/50 with distilled water. SeeCapacities and Specifications (page 282).Using water that has not been deionisedmay contribute to deposit formation,corrosion and plugging of the small coolingsystem passageways.
Note:Coolants marketed for all makes andmodels may not be approved to Fordspecifications and may cause damage tothe cooling system. Resulting componentdamage may not be covered by the vehicleWarranty.
If the coolant level is at or below theminimum mark, add prediluted coolantimmediately.
To top up the coolant level do thefollowing:
1. Unscrew the cap slowly. Any pressureescapes as you unscrew the cap.
2. Add prediluted coolant approved tothe correct specification. SeeCapacities and Specifications (page282).
3. Add enough prediluted coolant toreach the correct level.
4.Replace the coolant reservoir cap, turnit clockwise until you feel a strongresistance.
5. Check the coolant level in the coolantreservoir the next few times you driveyour vehicle. If necessary, add enoughprediluted engine coolant to bring thecoolant level to the correct level.
If you have to add more than 1.1 qt (1 L) ofengine coolant per month, have yourvehicle checked as soon as possible.Operating an engine with a low level ofcoolant can result in engine overheatingand possible engine damage.
Note:During normal vehicle operation, thecoolant may change color from orange topink or light red. As long as the coolant isclear and uncontaminated, this color changedoes not indicate the coolant has degradednor does it require the coolant to be drained,the system to be flushed, or the coolant tobe replaced.
Note:In case of emergency, you can add alarge amount of water without coolant inorder to reach a vehicle service location.Water alone, without coolant, can causeengine damage from corrosion, overheatingor freezing. When you reach a servicelocation, you must have the cooling systemdrained and refilled with prediluted coolantapproved to the correct specification. SeeCapacities and Specifications (page 282).
Do not use the following as a coolantsubstitute:
•Alcohol.
•Methanol.
•Brine.
•Any coolant mixed with alcohol ormethanol antifreeze.
Alcohol and other liquids can cause enginedamage from overheating or freezing.
Do not add extra inhibitors or additives tothe coolant. These can be harmful andcompromise the corrosion protection ofthe coolant.
Recycled Coolant
We do not recommend the use of recycledcoolant as an approved recycling processis not yet available.
Dispose of used engine coolant in anappropriate manner. Follow yourcommunity’s regulations and standardsfor recycling and disposing of automotivefluids.
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Maintenance

Your vehicle has limited engine powerwhen in the fail-safe mode, drive yourvehicle with caution. Your vehicle does notmaintain high-speed operation and theengine may operate poorly.
Remember that the engine is capable ofautomatically shutting down to preventengine damage. In this situation:
1. Pull off the road as soon as safelypossible and switch the engine off.
2. If you are a member of a roadsideassistance program, we recommendthat you contact your roadsideassistance service provider.
3. If this is not possible, wait a shortperiod for the engine to cool.
4. Check the coolant level. If the coolantlevel is at or below the minimum mark,add prediluted coolant immediately.
5. When the engine temperature cools,you can re-start the engine. Have yourvehicle checked as soon as possible tominimize engine damage.
Note:Driving your vehicle without repairincreases the chance of engine damage.
Engine Coolant TemperatureManagement (If Equipped)
WARNING
To reduce the risk of crash and injury,be prepared that the vehicle speedmay reduce and the vehicle may notbe able to accelerate with full power untilthe coolant temperature reduces.
If you tow a trailer with your vehicle, theengine may temporarily reach a highertemperature during severe operatingconditions, for example ascending a longor steep grade in high ambienttemperatures.
At this time, you may notice the coolanttemperature gauge moves toward the redzone and a message may appear in theinformation display.
You may notice a reduction in vehiclespeed caused by reduced engine power.In order to manage the engine coolanttemperature. Your vehicle may enter thismode if certain high-temperature andhigh-load conditions take place. Theamount of speed reduction depends onvehicle loading, grade and ambienttemperature. If this occurs, there is no needto pull off the road. You can continue todrive your vehicle.
The air conditioning may automaticallyturn on and off during severe operatingconditions to protect the engine fromoverheating. When the coolanttemperature decreases to the normaloperating temperature, the air conditioningturns on.
If the coolant temperature gauge movesfully into the red zone, or if the coolanttemperature warning or service enginesoon messages appear in your informationdisplay, do the following:
1. Pull off the road as soon as safelypossible and shift the transmission intopark (P).
2. Leave the engine running until thecoolant temperature gauge needlereturns to the normal position. Afterseveral minutes, if the temperaturedoes not drop, follow the remainingsteps.
3.Switch the engine off and wait for it tocool. Check the coolant level.
4. If the coolant level is at or below theminimum mark, add prediluted coolantimmediately.
5. If the coolant level is normal, restartthe engine and continue.
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Maintenance

AUTOMATIC TRANSMISSION
FLUID CHECK
If required, have an authorized dealer checkand change the transmission fluid at thecorrect service interval. See ScheduledMaintenance (page 441).
The automatic transmission does not havea transmission fluid dipstick. Yourtransmission does not consume fluid.
An authorized dealer should check thefluid:
•If the transmission is not workingproperly.
•If you notice signs of fluid leakage.
Do not use supplemental transmissionfluid additives, treatments or cleaningagents. The use of these materials mayaffect transmission operation and resultin damage to internal transmissioncomponents.
BRAKE FLUID CHECK
WARNINGS
Do not use any fluid other than therecommended brake fluid as this willreduce brake efficiency. Use ofincorrect fluid could result in the loss ofvehicle control, serious personal injury ordeath.
Only use brake fluid from a sealedcontainer. Contamination with dirt,water, petroleum products or othermaterials may result in brake systemdamage or failure. Failure to adhere to thiswarning could result in the loss of vehiclecontrol, serious personal injury or death.
Do not allow the fluid to touch yourskin or eyes. If this happens, rinse theaffected areas immediately withplenty of water and contact your physician.
WARNINGS
A fluid level between the MAX andMIN lines is within the normaloperating range and there is no needto add fluid. A fluid level not in the normaloperating range could compromise theperformance of the system. Have yourvehicle checked immediately.
To avoid fluid contamination, the reservoircap must remain in place and fully tight,unless you are adding fluid.
Only use fluid that meets Fordspecifications. See Capacities andSpecifications (page 282).
POWER STEERING FLUID
CHECK
Your vehicle is equipped with an electricpower steering (EPS) system. There is nofluid reservoir to check or fill.
WASHER FLUID CHECK
WARNING
If you operate your vehicle intemperatures below 40°F (5°C), usewasher fluid with antifreezeprotection. Failure to use washer fluid withantifreeze protection in cold weather couldresult in impaired windshield vision andincrease the risk of injury or accident.
Note:The front and rear washer systemsare supplied from the same reservoir.
Add fluid to fill the reservoir if the level islow. Only use a washer fluid that meetsFord specifications. See Capacities andSpecifications (page 282).
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Maintenance

State or local regulations on volatileorganic compounds may restrict the useof methanol, a common windshield washerantifreeze additive. Washer fluidscontaining non-methanol antifreezeagents should be used only if they providecold weather protection without damagingthe vehicle’s paint finish, wiper blades orwasher system.
FUEL FILTER
Your vehicle is equipped with a lifetimefuel filter that is integrated with the fueltank. Regular maintenance or replacementis not needed.
CHANGING THE 12V BATTERY
WARNINGS
Batteries normally produce explosivegases which can cause personalinjury. Therefore, do not allowflames, sparks or lighted substances tocome near the battery. When working nearthe battery, always shield your face andprotect your eyes. Always provide correctventilation.
When lifting a plastic-cased battery,excessive pressure on the end wallscould cause acid to flow through thevent caps, resulting in personal injury anddamage to the vehicle or battery. Lift thebattery with a battery carrier or with yourhands on opposite corners.
WARNINGS
Keep batteries out of reach ofchildren. Batteries contain sulfuricacid. Avoid contact with skin, eyes orclothing. Shield your eyes when workingnear the battery to protect against possiblesplashing of acid solution. In case of acidcontact with skin or eyes, flushimmediately with water for a minimum of15 minutes and get prompt medicalattention. If acid is swallowed, call aphysician immediately.
Battery posts, terminals and relatedaccessories contain lead and leadcompounds. Wash hands afterhandling.
Your vehicle has a Motorcraft®maintenance-free battery which normallydoes not require additional water duringits life of service.
Note:If your vehicle's battery has a coveror shield, make sure it is reinstalled after thebattery has been cleaned or replaced.
Note:See an authorized dealer for lowvoltage battery access, testing, orreplacement.
When a low voltage battery replacementis necessary, see an authorized dealer toreplace the low voltage battery with a Fordrecommended replacement low voltagebattery that matches the electricalrequirements of the vehicle.
To ensure proper operation of the batterymanagement system (BMS), do not allowa technician to connect any electricaldevice ground connection directly to thelow voltage battery negative post. Aconnection at the low voltage batterynegative post can cause inaccuratemeasurements of the battery conditionand potential incorrect system operation.
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Maintenance

Run the tip of your fingers over the edge ofthe blade to check for roughness.
Clean the wiper blades with washer fluidor water applied with a soft sponge orcloth.
CHANGING THE WIPER
BLADES
Replace the wiper blades at least annuallyfor optimum performance.
You can improve poor wiper quality bycleaning the wiper blades and thewindshield.
Note: The windshield wiper blades aredifferent in length. If you install wiperblades of the wrong length, the wiper bladescan clash damaging the wiper system.
Service Position
Set the windshield wipers in the serviceposition to change the wiper blades.
Note:You can use the service position toprovide easier access to the wiper bladesfor freeing them from snow and ice.
Note:Make sure the windshield is free fromsnow and ice before you switch the ignitionon.
1. Switch the ignition on.
2. Switch the ignition off.
3. Press and hold the wiper lever inposition A within three seconds.
4. Release the wiper lever when thewindshield wipers reach the serviceposition.
Note:The wipers remain in the serviceposition when you switch the ignition on.Press and release the wiper lever to returnthem to the park position.
Changing the Windshield WiperBlades
Note:Do not hold the wiper blade whenlifting the wiper arm.
Note:Make sure that the wiper arm doesnot spring back against the glass when thewiper blade is not attached.
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REMOVING A HEADLAMP
1.Switch all of the lamps and the ignitionoff.
2. Remove the screws that secure thelamp assembly.
3. Pull the headlamp toward the front ofyour vehicle to disengage it from itslocating points and then lift theheadlamp up.
4. Disconnect the electrical connector.
CHANGING A BULB
Replacing Headlamp Bulbs
WARNING
Handle a halogen headlamp bulbcarefully and keep out of children’sreach. Grasp the bulb by only itsplastic base and do not touch the glass.The oil from your hand could cause thebulb to break the next time the headlampsare operated.
Note:If the bulb is accidentally touched, itshould be cleaned with rubbing alcoholbefore being used.
Locating the headlamp bulbs:
Direction indicator lamp.A
Low beam headlamp.B
High beam headlamp.C
Replacing the High Beam HeadlampBulb:
1. Remove the headlamp assembly.
2. Remove service cap.
3. Disconnect the electrical connector.
4. Remove bulb from the headlampassembly by turning itcounterclockwise, then pull it straightout.
Replacing the Low Beam HeadlampBulb:
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2
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1. Remove the headlamp assembly.
2. Remove service cap.
3. Disconnect the electrical connector.
4. Remove bulb from the headlampassembly by turning itcounterclockwise, then pull it straightout.
Install the new bulbs in reverse order.
Replacing Side Marker Bulbs:
1. Remove the headlamp assembly.
2. Remove service cap.
3. Remove the bulb holder.
4. Remove bulb from the headlampassembly.
Install the new bulb in reverse order.
Replacing Fog, Park and DirectionIndicator Bulbs
Note:You cannot separate the fog lampbulb from the bulb holder.
1. Remove the fog lamp cover.
2. Remove the 2 screws.
3. Remove the lamp.
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CHANGING THE ENGINE AIR
FILTER
WARNING
To reduce the risk of vehicle damageand personal burn injuries, do notstart your engine with the air cleanerremoved and do not remove it while theengine is running.
Change the air filter element at the correctinterval.
Note:When changing the air filter element,use only the air filter element listed. SeeCapacities and Specifications (page 282).
Note: Failure to use the correct air filterelement may result in severe enginedamage. Resulting component damagemay not be covered by the vehicle Warranty.
Note:Failure to re-install the air cleanerassembly properly by fully seating on themounting studs in five places and securingwith the two bolts may result in air cleanerassembly dislodgement from engine anddamage to the air cleaner assembly andother engine components. Therefore werecommend that the air filter be serviced ata Ford dealer.
Air Cleaner Assembly Components
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MaintenanceE162533
ACD
E
B

Alloy wheels and wheel covers are coatedwith a clear coat paint finish. To maintaintheir condition we recommend that you:
•Clean them weekly with therecommended wheel and tire cleaner.
•Use a sponge to remove heavydeposits of dirt and brake dustaccumulation.
•Rinse them thoroughly with apressurized stream of water when youhave completed the cleaning process.
We recommend that you use Ford servicewheel cleaner. Make sure that you readand follow the manufacturer’s instructions.
Using other non-recommended cleaningproducts can result in severe andpermanent cosmetic damage.
VEHICLE STORAGE
If you plan on storing your vehicle for 30days or more, read the followingmaintenance recommendations to makesure your vehicle stays in good operatingcondition.
We engineer and test all motor vehiclesand their components for reliable, regulardriving. Under various conditions,long-term storage may lead to degradedengine performance or failure unless youuse specific precautions to preserve enginecomponents.
General
•Store all vehicles in a dry, ventilatedplace.
•Protect from sunlight, if possible.
•If you store vehicles outside, theyrequire regular maintenance to protectagainst rust and damage.
Body
•Wash your vehicle thoroughly toremove dirt, grease, oil, tar or mud fromexterior surfaces, rear-wheel housingand the underside of front fenders.
•Periodically wash your vehicle if youstore it in exposed locations.
•Touch-up exposed or primed metal toprevent rust.
•Cover chrome and stainless steel partswith a thick coat of auto wax to preventdiscoloration. Re-wax as necessarywhen you wash your vehicle.
•Lubricate all hood, door and luggagecompartment hinges and latches witha light grade oil.
•Cover interior trim to prevent fading.
•Keep all rubber parts free from oil andsolvents.
Engine
•Change the engine oil and filter prior tostorage because used engine oilcontains contaminates which maycause engine damage.
•Start the engine every 15 days for aminimum of 15 minutes. Run at fast idlewith the climate controls set to defrostuntil the engine reaches normaloperating temperature.
•With your foot on the brake, shiftthrough all the gears while the engineis running.
•We recommend that you change theengine oil before you use your vehicleagain.
Fuel System
•Fill the fuel tank with high-quality fueluntil the first automatic shutoff of thefuel pump nozzle.
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Vehicle Care