service FORD C MAX 2016 Service Manual

4.
Open the hood. Support the hood with
the strut.
Closing the Hood
1. Remove the hood strut from the catch
and secure it correctly after use. 2. Lower the hood and allow it to drop
under its own weight for the last 8-12
in (20-30 cm).
Note: Make sure that the hood is correctly
closed.
UNDER HOOD OVERVIEW -
HYBRID ELECTRIC VEHICLE
(HEV) 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.
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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 223).
A
Engine oil filler cap. See
Engine Oil Check (page 222).
B
Engine oil dipstick. See
Engine Oil Dipstick (page 222).
C
Engine air filter cover. See
Changing the Engine Air Filter (page 238).
D
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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 348).
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 coolant
immediately. See
Adding Inverter System
Controller Coolant in this chapter.
The coolant concentration should be
maintained 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 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 276).
• 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 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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Vehicles driven year-round in non-extreme
climates should use 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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AUTOMATIC TRANSMISSION
FLUID CHECK
If required, have an authorized dealer check
and change the transmission fluid at the
correct service interval. See Scheduled
Maintenance (page 348).
The automatic transmission does not have
a transmission fluid dipstick. Your
transmission does not consume fluid.
An authorized dealer should check the
fluid:
• If the transmission is not working
properly.
• If you notice signs of fluid leakage.
Do not use supplemental transmission
fluid additives, treatments or cleaning
agents. The use of these materials may
affect transmission operation and result
in damage to internal transmission
components.
BRAKE FLUID CHECK
Fluid levels between the MIN and MAX
lines are within the normal operating range;
there is no need to add fluid. If the fluid
levels are outside of the normal operating
range, the performance of the system
could be compromised; seek service from
your authorized dealer immediately.
POWER STEERING FLUID
CHECK
Your vehicle is equipped with an electric
power steering (EPS) system. There is no
fluid reservoir to check or fill. WASHER FLUID CHECK WARNING
If you operate your vehicle in
temperatures below 40°F (5°C), use
washer fluid with antifreeze
protection. Failure to use washer fluid with
antifreeze protection in cold weather could
result in impaired windshield vision and
increase the risk of injury or accident. Note:
The front and rear washer systems
are supplied from the same reservoir.
Add fluid to fill the reservoir if the level is
low. Only use a washer fluid that meets
Ford specifications. See
Capacities and
Specifications (page 276).
State or local regulations on volatile
organic compounds may restrict the use
of methanol, a common windshield washer
antifreeze additive. Washer fluids
containing non-methanol antifreeze
agents should be used only if they provide
cold weather protection without damaging
the vehicle ’s paint finish, wiper blades or
washer system.
FUEL FILTER
Your vehicle is equipped with a lifetime
fuel filter that is integrated with the fuel
tank. Regular maintenance or replacement
is not needed.
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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 283). Reset the power
windows bounce-back feature. See
Windows and Mirrors
(page 80).
Reset the radio station presets. See
Audio System
(page 283).
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
Replace the wiper blades at least annually
for optimum performance.
You can improve poor wiper quality by
cleaning the wiper blades and the
windshield.
Note:
The windshield wiper blades are
different in length. If you install wiper
blades of the wrong length, the wiper blades
can clash damaging the wiper system.
Service Position
Set the windshield wipers in the service
position to change the wiper blades.
Note: You can use the service position to
provide easier access to the wiper blades
for freeing them from snow and ice.
Note: Make sure the windshield is free from
snow and ice before you switch the ignition
on.
1. Switch the ignition on.
2. Switch the ignition off.
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3. Press and hold the wiper lever in
position A within three seconds. 4. Release the wiper lever when the
windshield wipers reach the service
position.
Note: The wipers remain in the service
position when you switch the ignition on.
Press and release the wiper lever to return
them to the park position.
Changing the Windshield Wiper
Blades
Note: Do not hold the wiper blade when
lifting the wiper arm.
Note: Make sure that the wiper arm does
not spring back against the glass when the
wiper blade is not attached. Note:
Make sure the windshield is clean
before using new wiper blades. 1. Lift the wiper arm and then press the
wiper blade locking buttons together.
2. Slightly rotate the wiper blade.
3. Remove the wiper blade.
4. Install in the reverse order.
Note: Make sure that the wiper blade locks
into place.
Changing the Rear Window Wiper
Blade
Note: Do not hold the wiper blade when
lifting the wiper arm.
Note: Make sure that the wiper arm does
not spring back against the glass when the
wiper blade is not attached.
1. Lift the wiper arm.
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Locating the headlamp bulbs:
Direction indicator lamp.
A
Low beam headlamp.
B
High beam headlamp.
C
Replacing the High Beam Headlamp
Bulb: 1. Remove the headlamp assembly.
2. Remove service cap.
3. Disconnect the electrical connector.
4. Remove bulb from the headlamp
assembly by turning it
counterclockwise, then pull it straight
out.
Replacing the Low Beam Headlamp
Bulb: 1. Remove the headlamp assembly.
2. Remove service cap.
3. Disconnect the electrical connector.
4. Remove bulb from the headlamp
assembly by turning it
counterclockwise, then pull it straight
out.
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 headlamp
assembly.
Install the new bulb in reverse order.
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CHANGING THE ENGINE AIR
FILTER
WARNING
To reduce the risk of vehicle damage
and personal burn injuries, do not
start your engine with the air cleaner
removed and do not remove it while the
engine is running. Change the air filter element at the correct
interval.
Note:
When changing the air filter element,
use only the air filter element listed. See
Capacities and Specifications (page 276).
Note: Failure to use the correct air filter
element may result in severe engine
damage. Resulting component damage
may not be covered by the vehicle Warranty.
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.
Air Cleaner Assembly Components 238
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B