light FORD C MAX 2016 Repair Manual

1.
Connect the positive (+) jumper cable
to the positive (+) prong (A) of the
discharged battery.
2. Connect the other end of the positive (+) cable to the positive (+) terminal
of the assisting battery.
3. Connect the negative (-) cable to the negative (-) terminal of the assisting
battery.
4. Make the final connection of the negative (-) cable to the negative (-)
prong (B) of your vehicle.
Note: Do not attach the negative (-) cable
to fuel lines, engine rocker covers, the intake
manifold or electrical components. These
items should not be considered grounding
points. WARNING
Never connect the negative end of
the cable to the negative (-) terminal
of the discharged battery. A spark
may cause an explosion of the gases that
surround the battery. Always use the
negative prong as a grounding point. Make sure that the cables are clear of fan
blades, belts, the moving parts of both
engines, or any fuel delivery system parts.
Jump Starting
1.
Start the booster vehicle and press the
accelerator pedal moderately.
2. Start the disabled vehicle. Check the instrument cluster for the Ready to
Drive light as the gasoline engine may
not start, but the electric motor may
be running.
3. Once you start the disabled vehicle, run
both vehicles for an additional three
minutes before disconnecting the
jumper cables.
Removing the Jumper Cables
Remove the jumper cables in the reverse
order that they were connected.
Note: In the illustration, the vehicle on the
bottom is used to designate the assisting
(boosting) battery.
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Crashes
A crash or impact significant enough to
require an emergency response for
conventional vehicles would also require
the same response for an electric or
hybrid-electric vehicle.
If possible
•
Move your car to a safe, nearby
location and remain on the scene.
• Roll down the windows before shutting
your vehicle off.
• Place your vehicle in Park, set the
parking brake, turn off the vehicle,
activate the hazard lights, and move
your key(s) at least 16 feet (5 meters)
away from the vehicle.
Always
• Call 911 if assistance is needed and
advise that an electric or hybrid-electric
vehicle is involved.
• Do not touch exposed electrical
components or the engine
compartment, as a shock hazard may
exist.
• Avoid contact with leaking fluids and
gases, and remain out of the way of
oncoming traffic until emergency
responders arrive.
• When emergency responders arrive,
tell them that the vehicle involved is an
electric vehicle or hybrid vehicle.
Fires
As with any vehicle, call 911 immediately if
you see sparks, smoke or flames coming
from the vehicle.
• Exit the vehicle immediately.
• Advise 911 that an electric or
hybrid-electric vehicle is involved. •
As with any vehicle fire, do not inhale
smoke, vapors or gas from the vehicle,
as they may be hazardous.
• Remain a safe distance from the
vehicle and try to stay clear of the
smoke.
• Stay out of the roadway and stay out
of the way of any oncoming traffic
while awaiting the arrival of emergency
responders.
Post-Incident
• Do not store a severely damaged
vehicle with a lithium-ion battery inside
a structure or within 50 feet (15
meters) of any structure or vehicle.
• Make sure that passenger and cargo
compartments remain ventilated (i.e.
open window, door or trunk).
• For vehicles in the United States, notify
Ford Motor Company 1-800-392-3673
(then follow the prompts on the voice
response menu), an authorized Ford
dealer or service center as soon as
possible as there may be other steps
to secure and discharge the
high-voltage battery.
• For vehicles in Canada, notify Ford
Motor Company 1-800-565-3673
(then follow the prompts on the voice
response menu), an authorized Ford
dealer or service center as soon as
possible as there may be other steps
to secure and discharge the
high-voltage battery.
• Call 911 if you observe leaking fluids,
sparks, smoke or flames, or hear
gurgling or bubbling from the
high-voltage battery.
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Protected components
Fuse amp rating
Fuse or relay number
Cooling fan module.
50A Midi
F1
Electric water pump.
50A Midi
F2
Body control module supply 1.
50A Midi
F3
Body control module supply 2.
50A Midi
F4
Not used.
—
F5
Not used.
—
F6
Anti-lock brake system pump.
40A**
F7
Anti-lock brake system valve.
30A**
F8
Vacuum pump.
40A**
F9
Heater blower motor.
40A**
F10
Engine management.
30A**
F11
Not used.
—
F12
Powertrain control module relay.
25A**
F13
Rear wiper.
20A**
F14
Body control module KL30 supply.
30A**
F15
Body control module 15 feed.
20A**
F16
Transmission oil pump (C-MAX Energi).
20A**
F17
Front wiper motor.
20A**
F18
Anti-lock brake system and electronic
stability program module.
5A*
F19
Horn.
15A*
F20
Stop light switch.
5A*
F21
Vacuum pump monitoring.
5A*
F22
Engine control module 15.
5A*
F23
Powertrain control module 15.
Transmission oil pump 15.
Relay coils.
5A*
F24
Light switch module.
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Protected components
Fuse amp rating
Fuse or relay number
Motor electronic cooling pump.
10A*
F25
Electronic power assist steering module
15.
5A*
F26
Mass air flow sensor.
5A*
F27
Powertrain control module.
15A*
F28
Electronic air conditioning compressor.
10A*
F29
Positive temperature coefficient heater.
Engine control module.
10A*
F30
Powertrain control module.
Charge port light ring (C-MAX Energi).
5A*
F31
Vehicle power 2.
20A*
F32
Vehicle power 4.
15A*
F33
Injectors.
10A*
F34
Vehicle power 3.
10A*
F35
Vehicle power 1.
20A*
F36
Vacuum pump.
Micro relay
R1
Horn.
Micro relay
R2
Hybrid powertrain control.
Micro relay
R3
Front wiper.
Micro relay
R4
Vacuum pump.
Micro relay
R5
Front and rear wiper high-low.
Micro relay
R6
Not used.
—
R7
Ignition feed.
Power relay
R8
Not used.
—
R9
Not used.
—
R10
Not used.
—
R11
Cooling fan.
Power relay
R12
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Protected components
Fuse amp rating
Fuse or relay number
Fuel pump supply.
20A
F56
Not used.
—
F57
Not used (spare).
5A
F58
Passive anti-theft system.
5A
F59
Interior light.
10A
F60
Driver door switch pack.
Glove box illumination.
Overhead console switch bank.
Cigar lighter.
20A
F61
Second row power point.
Autowiper module.
5A
F62
Autodimming rear view mirror.
Not used (spare).
10A
F63
Not used.
—
F64
Liftgate release.
10A
F65
Driver door unlock supply.
20A
F66
Cell phone passport (C-MAX Energi).
7.5A
F67
Multi-function display.
GPS module.
Sync.
Not used (spare).
15A
F68
Instrument cluster.
5A
F69
Central lock and unlock supply.
20A
F70
Climate control module.
7.5A
F71
Steering wheel module.
7.5A
F72
Data link connector.
7.5A
F73
OBD II supply.
Headlamp supply.
15A
F74
Fog lamp supply.
15A
F75
Reversing lamp supply.
10A
F76
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Protected components
Fuse amp rating
Fuse or relay number
Washer pump.
20A
F77
Ignition switch, Start button.
5A
F78
Radio.
15A
F79
Hazard light switch.
Not used (spare).
20A
F80
Power sun shade.
5A
F81
Remote receiver antenna.
Washer pump ground.
20A
F82
Central locking ground.
20A
F83
Drive door unlock ground.
20A
F84
Electronic 15 feed.
7.5A
F85
Restraints control module.
10A
F86
Passenger air bag deactivation indicator.
Not used (spare).
15A
F87
Not used (spare).
25A
F88
Not used.
—
F89
Luggage Compartment Fuse Panel
The fuse panel is located in the luggage
compartment behind the left side wheel
well. Remove the fuse panel cover to gain
access to the fuses.
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GENERAL INFORMATION
Have your vehicle serviced regularly to help
maintain its roadworthiness and resale
value. There is a large network of
authorized dealers that are there to help
you with their professional servicing
expertise. We believe that their specially
trained technicians are best qualified to
service your vehicle properly and expertly.
They are supported by a wide range of
highly specialized tools developed
specifically for servicing your vehicle.
If your vehicle requires professional service,
an authorized dealer can provide the
necessary parts and service. Check your
warranty information to find out which
parts and services are covered.
Use only recommended fuels, lubricants,
fluids and service parts conforming to
specifications. Motorcraft® parts are
designed and built to provide the best
performance in your vehicle.
Precautions
•
Do not work on a hot engine.
• Make sure that nothing gets caught in
moving parts.
• Do not work on a vehicle with the
engine running in an enclosed space,
unless you are sure you have enough
ventilation.
• Keep all open flames and other burning
material (such as cigarettes) away
from the battery and all fuel related
parts.
Working with the Engine Off
1. Set the parking brake and shift to park
(P).
2. Switch off the engine.
3. Block the wheels. Working with the Engine On 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. 1.
Set the parking brake and shift to park
(P).
2. Block the wheels.
OPENING AND CLOSING THE
HOOD
Opening the Hood 1.
Inside the vehicle, pull the hood release
handle located under the left-hand
side of the instrument panel.
2. Slightly lift the hood.
3. Release the hood latch by pushing the secondary release lever to your
left-hand side.
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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 348).
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 coolant
immediately. See
Adding Engine 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.
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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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