engine FORD C MAX 2015 Manual PDF

UNDER HOOD OVERVIEW -
PLUG-IN HYBRID ELECTRIC
VEHICLE (PHEV)
WARNING
The inverter system controller
contains various high-voltage
components that can cause serious
bodily harm or death. The inverter system
controller is not serviceable and should
never be touched, probed, or tampered
with. Note:
Do not attempt to service any of the
high-voltage components or wiring. For
easier identification, the high-voltage wiring
insulation is color coated orange. Engine coolant reservoir cap. See Engine Coolant Check (page 218).
A
Engine oil filler cap. See
Engine Oil Check (page 217).
B
Engine oil dipstick. See
Engine Oil Dipstick (page 217).
C
Engine air filter cover. See
Changing the Engine Air Filter (page 233).
D
Inverter system controller.
E
Brake fluid reservoir cap. See
Brake Fluid Check (page 222).
F
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Power distribution box. See Fuses (page 204).
G
Inverter system controller coolant reservoir cap.
H
Windshield washer fluid reservoir cap. See
Washer Fluid Check (page 222).
I
ENGINE OIL DIPSTICK MINA
MAX
B
ENGINE OIL CHECK
Check the level before starting the engine
and make sure that the level is between
the MIN and the MAX marks.
1. Make sure that your vehicle is on level ground.
2. Switch the engine off and wait 10 minutes for the oil to drain into the oil
pan.
3. Remove the dipstick and wipe it with a clean, lint-free cloth. Replace the
dipstick and remove it again to check
the oil level.
If the oil level is at the minimum mark, add
oil immediately. Adding Engine Oil
Note:
Do not remove the filler cap when
the engine is running.
Note: Do not add oil further than the MAX
mark. Oil levels above the MAX mark may
cause engine damage. Only use oils certified for gasoline engines
by the American Petroleum Institute (API).
An oil with this trademark symbol
conforms to the current engine and
emission system protection standards and
fuel economy requirements of the
International Lubricants Specification
Advisory Council (ILSAC), comprised of
U.S. and Japanese automobile
manufacturers.
1. Remove the filler cap.
2. Add engine oil that meets the Ford
specifications. See
Capacities and
Specifications (page 275).
3. Wipe off any spilled oil.
4. Replace the filler cap. Turn it until you feel a strong resistance.
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Low Engine Use (If Equipped)
The low engine use mode is equipped on
Energi models only. The low engine use
mode keeps the engine oil quality in good
condition when you drive your vehicle with
limited engine use. If your vehicle is in low
engine use mode when you start the
vehicle, a message appears in the
information display. When your vehicle is
in low engine use mode, your vehicle runs
the engine as necessary.
Selecting EV Now mode when your vehicle
is in the low engine use mode suspends
the low engine use mode for as long as you
continue driving your vehicle. The low
engine use mode resumes the next time
you start your vehicle.
Changing the engine oil and resetting the
oil life monitoring system suspends the low
engine use mode.
ENGINE COOLANT CHECK WARNINGS
Do not add engine coolant when the
engine is hot. Steam and scalding
liquids released from a hot cooling
system can burn you badly. Also, you can
be burned if you spill coolant on hot engine
parts. Do not put engine coolant in the
windshield washer fluid container. If
sprayed on the windshield, engine
coolant could make it difficult to see
through the windshield. To reduce the risk of personal injury,
make sure the engine is cool before
unscrewing the coolant pressure
relief cap. The cooling system is under
pressure; steam and hot liquid can come
out forcefully when the cap is loosened
slightly. Do not add coolant further than the
MAX
mark. Engine Coolant and Inverter
System Controller Coolant
Your vehicle has two separate cooling
systems. One is for cooling the engine and
one is for cooling the inverter system
controller that is specific to the hybrid
operating system. The two systems
operate similarly, with the inverter system
controller cooling system generally
operating at a lower temperature and
pressure.
Checking the Engine Coolant
When the engine is cold, check the
concentration and level of the engine
coolant at the intervals listed in the
scheduled maintenance information. See
Scheduled Maintenance
(page 420).
Note: Make sure that the level is between
the MIN and MAX marks on the engine
coolant reservoir.
Note: Coolant expands when it is hot. The
level may extend beyond the MAX mark.
Note: If the level is at the MIN mark, below
the MIN mark, or empty, add prediluted
coolant immediately. See
Adding Engine
Coolant in this chapter.
Maintain coolant concentration within
48% to 50%, which equates to a freeze
point between -30°F (-34°C) and -34°F
(-37°C).
Note: For best results, coolant
concentration should be tested with a
refractometer such as Robinair® Coolant
and Battery Refractometer 75240. We do
not recommend the use of hydrometers or
coolant test strips for measuring coolant
concentrations.
Note: Automotive fluids are not
interchangeable. Do not use engine coolant
or antifreeze or windshield washer fluid
outside of its specified function and vehicle
location.
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Checking the Inverter System
Controller Coolant
When the engine is cold, check the
concentration and level of the inverter
system controller coolant at the intervals
listed in the scheduled maintenance
information. See Scheduled
Maintenance (page 420).
Note: Make sure that the level is between
the MIN and MAX marks on the inverter
system controller coolant reservoir.
Note: Coolant expands when it is hot. The
level may extend beyond the MAX mark.
Note: If the level is at the MIN mark, below
the MIN mark, or empty, add prediluted
coolant immediately. See
Adding Inverter
System Controller Coolant in this chapter.
Maintain coolant concentration within
48% to 50%, which equates to a freeze
point between -30°F (-34°C) and -34°F
(-37°C).
Note: For best results, coolant
concentration should be tested with a
refractometer such as Robinair® Coolant
and Battery Refractometer 75240. We do
not recommend the use of hydrometers or
coolant test strips for measuring coolant
concentrations.
Note: Automotive fluids are not
interchangeable. Do not use engine coolant
or antifreeze or windshield washer fluid
outside of its specified function and vehicle
location.
Adding Coolant
Note: Do not use stop leak pellets, cooling
system sealants, or additives as they can
cause damage to the cooling or heating
systems. This damage would not be covered
under your vehicle ’s warranty. Note:
During normal vehicle operation, the
coolant may change color from orange to
pink or light red. As long as the coolant is
clear and uncontaminated, this color change
does not indicate the coolant has degraded
nor does it require the coolant to be drained,
the system to be flushed, or the coolant to
be replaced.
Note: It is very important to use prediluted
coolant meeting the Ford specification in
order to avoid plugging the small coolant
passageways. Use of concentrated coolant
and water may cause coolant passageway
plugging and void the warranty. See
Capacities and Specifications (page 275
).
• Do not mix different colors or types of
coolant in your vehicle. Make sure the
correct coolant is used. Mixing of
coolants may harm your cooling
system. The use of an improper coolant
may harm the engine, inverter system
controller, and cooling system
components and may void the
warranty.
• In case of emergency, a large amount
of water without engine coolant may
be added to the engine cooling system
in order to reach a vehicle service
location. In this instance, the engine
cooling system must be drained,
chemically cleaned with Motorcraft
Premium Cooling System Flush, and
refilled with prediluted engine coolant
as soon as possible. Water alone
(without engine coolant) can cause
engine damage from corrosion,
overheating, or freezing. DO NOT use
this method for the inverter system
controller cooling system. The inverter
system controller cooling system
operates close to ambient
temperature, and is susceptible to
freezing in any subfreezing environment
in the absence of coolant.
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•
Do not use alcohol, methanol, brine or
any engine coolants mixed with alcohol
or methanol antifreeze (coolant).
Alcohol and other liquids can cause
engine damage from overheating or
freezing.
• Do not add extra inhibitors or additives
to the coolant. These can be harmful
and compromise the corrosion
protection of the engine coolant.
Adding Engine Coolant
1. Unscrew the engine coolant reservoir cap slowly. Any pressure will escape
as you unscrew the cap.
2. Use a funnel to add prediluted engine coolant to the engine coolant reservoir.
Make sure that the level is between the
MIN and MAX marks on the engine
coolant reservoir. Use prediluted engine
coolant meeting the Ford specification.
See Capacities and Specifications
(page 275).
3. Close the engine coolant reservoir cap.
Whenever you add coolant, check the
coolant level in the engine coolant reservoir
the next few times you drive the vehicle. If
necessary, add enough prediluted engine
coolant to bring the engine coolant level
to the proper level.
Adding Inverter System Controller
Coolant
1. Open the inverter system controller coolant reservoir cap.
2. Use a funnel to add prediluted coolant
to the inverter system controller
coolant reservoir. Make sure that the
level is between the MIN and MAX
marks on the inverter system controller
coolant reservoir. Use prediluted
coolant meeting the Ford specification.
See
Capacities and Specifications
(page 275). 3. Close the inverter system controller
coolant reservoir cap.
Whenever you add coolant, check the
coolant level in the inverter system
controller coolant reservoir the next few
times you drive the vehicle. If necessary,
add enough prediluted coolant to bring the
inverter system controller coolant level to
the proper level.
Recycled Engine Coolant
Ford Motor Company does not recommend
the use of recycled engine coolant since a
Ford-approved recycling process is not yet
available.
Used engine coolant should be disposed
of in an appropriate manner. Follow your
community ’s regulations and standards
for recycling and disposing of automotive
fluids.
Severe Climates
If you drive in extremely cold climates:
• It may be necessary to have an
authorized Ford dealer increase the
coolant concentration above 50%.
• A coolant concentration of 60% will
provide improved freeze point
protection. Engine coolant
concentrations above 60% will
decrease the overheat protection
characteristics of the engine coolant
and may cause engine damage.
If you drive in extremely hot climates:
• It may be necessary to have an
authorized Ford dealer decrease the
coolant concentration to 40%.
• A coolant concentration of 40% will
provide improved overheat protection.
Engine coolant concentrations below
40% will decrease the freeze and
corrosion protection characteristics of
the engine coolant and may cause
engine damage.
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Vehicles driven year-round in non-extreme
climates should use prediluted coolant
meeting the Ford specification for
optimum cooling system and engine
protection.
What You Should Know About Fail-
Safe Cooling
If the engine coolant supply is depleted,
this feature allows the vehicle to be driven
temporarily before incremental component
damage is incurred. The
“fail-safe”
distance depends on ambient
temperatures, vehicle load and terrain.
How Fail-Safe Cooling Works
If the engine begins to overheat, the engine
coolant temperature gauge will move to
the red (hot) area and: The coolant temperature
warning light will illuminate.
The service engine soon
indicator will illuminate.
If the engine reaches a preset
over-temperature condition, the engine
will automatically switch to alternating
cylinder operation. Each disabled cylinder
acts as an air pump and cools the engine.
When this occurs the vehicle will still
operate. However:
• The engine power will be limited.
• The air conditioning system will be
disabled.
Continued operation will increase the
engine temperature and the engine will
completely shut down, causing steering
and braking effort to increase.
Once the engine temperature cools, the
engine can be re-started. Take your vehicle
to an authorized dealer as soon as possible
to minimize engine damage. When Fail-Safe Mode Is Activated WARNINGS
Fail-safe mode is for use during
emergencies only. Operate your
vehicle in fail-safe mode only as long
as necessary to bring your vehicle to rest
in a safe location and seek immediate
repairs. When in fail-safe mode, your
vehicle will have limited power, will not be
able to maintain high-speed operation, and
may completely shut down without
warning, potentially losing engine power,
power steering assist, and power brake
assist, which may increase the possibility
of a crash resulting in serious injury. Never remove the coolant reservoir
cap while the engine is running or hot.
Note:
Driving the vehicle without repairing
the engine problem increases the chance of
engine damage. Take your vehicle to an
authorized dealer as soon as possible.
You have limited engine power when in the
fail-safe mode, so drive the vehicle with
caution. The vehicle will not be able to
maintain high-speed operation and the
engine will run rough. Remember that the
engine is capable of completely shutting
down automatically to prevent engine
damage, therefore:
1. Pull off the road as soon as safely possible and turn off the engine.
2. Arrange for the vehicle to be taken to an authorized dealer.
3. If this is not possible, wait a short period for the engine to cool.
4. Check the coolant level and replenish if low.
5. Re-start the engine and take your vehicle to an authorized dealer.
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CHANGING THE 12V BATTERY
WARNINGS
Batteries normally produce explosive
gases which can cause personal
injury. Therefore, do not allow
flames, sparks or lighted substances to
come near the battery. When working near
the battery, always shield your face and
protect your eyes. Always provide correct
ventilation. When lifting a plastic-cased battery,
excessive pressure on the end walls
could cause acid to flow through the
vent caps, resulting in personal injury and
damage to the vehicle or battery. Lift the
battery with a battery carrier or with your
hands on opposite corners. Keep batteries out of reach of
children. Batteries contain sulfuric
acid. Avoid contact with skin, eyes or
clothing. Shield your eyes when working
near the battery to protect against possible
splashing of acid solution. In case of acid
contact with skin or eyes, flush
immediately with water for a minimum of
15 minutes and get prompt medical
attention. If acid is swallowed, call a
physician immediately. Battery posts, terminals and related
accessories contain lead and lead
compounds. Wash hands after
handling. Your vehicle has a Motorcraft®
maintenance-free battery which normally
does not require additional water during
its life of service.
Note:
If your vehicle's battery has a cover
or shield, make sure it is reinstalled after the
battery has been cleaned or replaced.
Note: See an authorized dealer for low
voltage battery access, testing, or
replacement. When a low voltage battery replacement
is necessary, see an authorized dealer to
replace the low voltage battery with a Ford
recommended replacement low voltage
battery that matches the electrical
requirements of the vehicle.
To ensure proper operation of the battery
management system (BMS), do not allow
a technician to connect any electrical
device ground connection directly to the
low voltage battery negative post. A
connection at the low voltage battery
negative post can cause inaccurate
measurements of the battery condition
and potential incorrect system operation.
Note:
If a person adds electrical or
electronic accessories or components to the
vehicle, the accessories or components may
adversely affect the low voltage battery
performance and durability and may also
affect the performance of other electrical
systems in the vehicle.
For longer, trouble-free operation, keep the
top of the battery clean and dry. Also,
make certain the battery cables are always
tightly fastened to the battery terminals.
If you see any corrosion on the battery or
terminals, remove the cables from the
terminals and clean with a wire brush. You
can neutralize the acid with a solution of
baking soda and water.
When a battery replacement is required,
the battery should only be replaced with
a Ford recommended replacement battery
that matches the electrical requirements
of the vehicle.
Because your vehicle ’s engine is
electronically-controlled by a computer,
some engine control settings are
maintained by power from the low voltage
battery. Some engine computer settings,
like the idle trim and fuel trim strategy,
optimize the driveability and performance
of the engine. Some other computer
settings, like the clock and radio station
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presets, are also maintained in memory by
power from the low voltage battery. When
a technician disconnects and connects the
low voltage battery, these settings are
erased. Complete the following procedure
in order to restore the settings:
1. With the vehicle at a complete stop,
set the parking brake.
2. Shift into park (P).
3. Switch off all accessories.
4. Fully press the brake pedal and start the vehicle.
5. Run the engine until it reaches normal operating temperature. While the
engine is warming up, complete the
following: Reset the clock. See Audio
System (page 282). Reset the power
windows bounce-back feature. See
Windows and Mirrors
(page 79).
Reset the radio station presets. See
Audio System
(page 282).
6. Allow the engine to idle for at least one
minute. If the engine turns off, press
the accelerator pedal to start the
engine.
7. While the engine is running, press the brake pedal and shift into neutral (N).
8. Allow the engine to run for at least one
minute by pressing on the accelerator
pedal.
9. Drive the vehicle at least 12 mi (20 km)
to completely relearn the idle and fuel
trim strategy.
Note: If you do not allow the engine to
relearn the idle and fuel trim strategy, the
idle quality of your vehicle may be adversely
affected until the engine computer
eventually relearns the idle trim and fuel
trim strategy.
Make sure that you dispose of old batteries
in an environmentally friendly way. Seek
advice from your local authority about
recycling old batteries. CHECKING THE WIPER
BLADES
Run the tip of your fingers over the edge of
the blade to check for roughness.
Clean the wiper blades with washer fluid
or water applied with a soft sponge or
cloth.
CHANGING THE WIPER
BLADES
Note:
Use the service position in winter to
provide easier access to the front wiper
blades for freeing them from snow and ice.
The front wipers will not return to their
normal position as soon as you switch on
the ignition. The front wipers will stay in the
service position when you switch the ignition
on or start the engine. Switch on the front
wipers to any mode, then switch off the
front wipers to bring the front wipers back
to the park position.
Note: The windshield wiper blades are
different in length. If you install wiper blades
of the wrong length, the wipers may not
work correctly. If equipped with autowipers,
the rain sensor may not work correctly.
Note: Make sure that the wiper blade locks
into place. Lower the wiper arm and blade
back to the windshield. The wiper arms will
automatically return to their normal position
when the ignition is turned on.
Note: Replace wiper blades at least once
per year for optimum performance.
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CHANGING THE ENGINE AIR
FILTER
WARNING
To reduce the risk of vehicle damage
and/or personal burn injuries do not
start your engine with the air cleaner
removed and do not remove it while the
engine is running. Note:
Failure to re-install the air cleaner
assembly properly by fully seating on the
mounting studs in five places and securing
with the two bolts may result in air cleaner
assembly dislodgement from engine and
damage to the air cleaner assembly and
other engine components. Therefore we
recommend that the air filter be serviced at
a Ford dealer.
Note: When changing the air filter element,
use only the air filter element listed. See
Capacities and Specifications (page 275).
Note: Change the air filter element at the
proper interval.
Note: Failure to use the correct air filter
element may result in severe engine
damage. The customer warranty may be
void for any damage to the engine if the
correct air filter element is not used.
Identifying Air Filter Element Components 233
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ACD
E
B

A. Air cleaner assembly
B. Air cleaner cover
C. Air cleaner outlet tube
D. Positive crankcase ventilation (PCV)
tube
E. Air cleaner intake tube
Removing the Engine Air Filter
Element 1.
Loosen the hose clamps for air cleaner
outlet tube (C). Disconnect the tube
from the air cleaner assembly (A).
2. Release the tabs and disconnect the PCV tube (D) from the air cleaner
outlet tube (C) and remove the tube.
3. Disconnect the air cleaner intake tube (E) from the air cleaner assembly (A). 4.
Remove the bolts from each side of the
air cleaner assembly (A) as shown with
arrows. 5. Lift the air cleaner assembly (A) from
the mounting studs, then rotate and
pull it towards the front of the vehicle. 6.
Loosen the 5 bolts from the air cleaner
cover (B).
7. Remove the air cleaner cover (B) from
the air cleaner assembly (A).
Installing the Engine Air Filter
Element
Note: Clean the inside of the air filter
assembly before installing a new air filter.
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