service FORD C MAX ENERGI 2016 Service Manual

4.Open the hood. Support the hood withthe strut.
Closing the Hood
1.Remove the hood strut from the catchand secure it correctly after use.
2. Lower the hood and allow it to dropunder its own weight for the last 8-12in (20-30 cm).
Note:Make sure that the hood is correctlyclosed.
UNDER HOOD OVERVIEW -
HYBRID ELECTRIC VEHICLE
(HEV)
WARNING
The inverter system controllercontains various high-voltagecomponents that can cause seriousbodily harm or death. The inverter systemcontroller is not serviceable and shouldnever be touched, probed, or tamperedwith.
Note:Do not attempt to service any of thehigh-voltage components or wiring. Foreasier identification, the high-voltage wiringinsulation is color coated orange.
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UNDER HOOD OVERVIEW -
PLUG-IN HYBRID ELECTRIC
VEHICLE (PHEV)
WARNING
The inverter system controllercontains various high-voltagecomponents that can cause seriousbodily harm or death. The inverter systemcontroller is not serviceable and shouldnever be touched, probed, or tamperedwith.
Note:Do not attempt to service any of thehigh-voltage components or wiring. Foreasier identification, the high-voltage wiringinsulation 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 SystemController Coolant
When the engine is cold, check theconcentration and level of the invertersystem controller coolant at the intervalslisted in the scheduled maintenanceinformation. See ScheduledMaintenance (page 348).
Note:Make sure that the level is betweenthe MIN and MAX marks on the invertersystem controller coolant reservoir.
Note:Coolant expands when it is hot. Thelevel may extend beyond the MAX mark.
Note:If the level is at the MIN mark, belowthe MIN mark, or empty, add coolantimmediately. See Adding Inverter SystemController Coolant in this chapter.
The coolant concentration should bemaintained within 48% to 50%, whichequates to a freeze point between -30°F(-34°C) and -34°F (-37°C).
Note:For best results, coolantconcentration should be tested with arefractometer such as Robinair® Coolantand Battery Refractometer 75240. We donot recommend the use of hydrometers orcoolant test strips for measuring coolantconcentrations.
Note:Automotive fluids are notinterchangeable. Do not use engine coolantor antifreeze or windshield washer fluidoutside of its specified function and vehiclelocation.
Adding Coolant
Note:Do not use stop leak pellets, coolingsystem sealants, or additives as they cancause damage to the cooling or heatingsystems. This damage would not be coveredunder your vehicle’s warranty.
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:It is very important to use coolantmeeting the Ford specification in order toavoid plugging the small coolantpassageways. Use of concentrated coolantand water may cause coolant passagewayplugging and void the warranty. SeeCapacities and Specifications (page 276).
•Do not mix different colors or types ofcoolant in your vehicle. Make sure thecorrect coolant is used. Mixing ofcoolants may harm your coolingsystem. The use of an improper coolantmay harm the engine, inverter systemcontroller, and cooling systemcomponents and may void thewarranty.
•In case of emergency, a large amountof water without engine coolant maybe added to the engine cooling systemin order to reach a vehicle servicelocation. In this instance, the enginecooling system must be drained,chemically cleaned with MotorcraftPremium Cooling System Flush, andrefilled with engine coolant as soon aspossible. Water alone (without enginecoolant) can cause engine damagefrom corrosion, overheating, or freezing.DO NOT use this method for theinverter system controller coolingsystem. The inverter system controllercooling system operates close toambient temperature, and issusceptible to freezing in anysubfreezing environment in theabsence of coolant.
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Vehicles driven year-round in non-extremeclimates should use coolant meeting theFord specification for optimum coolingsystem 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 driventemporarily before incremental componentdamage is incurred. The “fail-safe”distance depends on ambienttemperatures, vehicle load and terrain.
How Fail-Safe Cooling Works
If the engine begins to overheat, the enginecoolant temperature gauge will move tothe red (hot) area and:
The coolant temperaturewarning light will illuminate.
The service engine soonindicator will illuminate.
If the engine reaches a presetover-temperature condition, the enginewill automatically switch to alternatingcylinder operation. Each disabled cylinderacts as an air pump and cools the engine.
When this occurs the vehicle will stilloperate. However:
•The engine power will be limited.
•The air conditioning system will bedisabled.
Continued operation will increase theengine temperature and the engine willcompletely shut down, causing steeringand braking effort to increase.
Once the engine temperature cools, theengine can be re-started. Take your vehicleto an authorized dealer as soon as possibleto minimize engine damage.
When Fail-Safe Mode Is Activated
WARNINGS
Fail-safe mode is for use duringemergencies only. Operate yourvehicle in fail-safe mode only as longas necessary to bring your vehicle to restin a safe location and seek immediaterepairs. When in fail-safe mode, yourvehicle will have limited power, will not beable to maintain high-speed operation, andmay completely shut down withoutwarning, potentially losing engine power,power steering assist, and power brakeassist, which may increase the possibilityof a crash resulting in serious injury.
Never remove the coolant reservoircap while the engine is running or hot.
Note:Driving the vehicle without repairingthe engine problem increases the chance ofengine damage. Take your vehicle to anauthorized dealer as soon as possible.
You have limited engine power when in thefail-safe mode, so drive the vehicle withcaution. The vehicle will not be able tomaintain high-speed operation and theengine will run rough. Remember that theengine is capable of completely shuttingdown automatically to prevent enginedamage, therefore:
1. Pull off the road as soon as safelypossible and turn off the engine.
2. Arrange for the vehicle to be taken toan authorized dealer.
3. If this is not possible, wait a shortperiod for the engine to cool.
4. Check the coolant level and replenishif low.
5. Re-start the engine and take yourvehicle to an authorized dealer.
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AUTOMATIC TRANSMISSION
FLUID CHECK
If required, have an authorized dealer checkand change the transmission fluid at thecorrect service interval. See ScheduledMaintenance (page 348).
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
Fluid levels between the MIN and MAXlines are within the normal operating range;there is no need to add fluid. If the fluidlevels are outside of the normal operatingrange, the performance of the systemcould be compromised; seek service fromyour authorized dealer immediately.
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 276).
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.
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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.
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.
Note:If a person adds electrical orelectronic accessories or components to thevehicle, the accessories or components mayadversely affect the low voltage batteryperformance and durability and may alsoaffect the performance of other electricalsystems in the vehicle.
For longer, trouble-free operation, keep thetop of the battery clean and dry. Also,make certain the battery cables are alwaystightly fastened to the battery terminals.
If you see any corrosion on the battery orterminals, remove the cables from theterminals and clean with a wire brush. Youcan neutralize the acid with a solution ofbaking soda and water.
When a battery replacement is required,the battery should only be replaced witha Ford recommended replacement batterythat matches the electrical requirementsof the vehicle.
Because your vehicle’s engine iselectronically-controlled by a computer,some engine control settings aremaintained by power from the low voltagebattery. Some engine computer settings,like the idle trim and fuel trim strategy,optimize the driveability and performanceof the engine. Some other computersettings, like the clock and radio station
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presets, are also maintained in memory bypower from the low voltage battery. Whena technician disconnects and connects thelow voltage battery, these settings areerased. Complete the following procedurein 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 startthe vehicle.
5. Run the engine until it reaches normaloperating temperature. While theengine is warming up, complete thefollowing: Reset the clock. See AudioSystem (page 283). Reset the powerwindows bounce-back feature. SeeWindows and Mirrors (page 80).Reset the radio station presets. SeeAudio System (page 283).
6.Allow the engine to idle for at least oneminute. If the engine turns off, pressthe accelerator pedal to start theengine.
7. While the engine is running, press thebrake pedal and shift into neutral (N).
8.Allow the engine to run for at least oneminute by pressing on the acceleratorpedal.
9.Drive the vehicle at least 12 mi (20 km)to completely relearn the idle and fueltrim strategy.
Note:If you do not allow the engine torelearn the idle and fuel trim strategy, theidle quality of your vehicle may be adverselyaffected until the engine computereventually relearns the idle trim and fueltrim strategy.
Make sure that you dispose of old batteriesin an environmentally friendly way. Seekadvice from your local authority aboutrecycling old batteries.
CHECKING THE WIPER
BLADES
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.
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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.
Note:Make sure the windshield is cleanbefore using new wiper blades.
1. Lift the wiper arm and then press thewiper 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 locksinto place.
Changing the Rear Window WiperBlade
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.
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 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:
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.
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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 276).
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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