light FORD C MAX ENERGI 2016 Repair Manual

1.Connect the positive (+) jumper cableto the positive (+) prong (A) of thedischarged battery.
2. Connect the other end of the positive(+) cable to the positive (+) terminalof the assisting battery.
3. Connect the negative (-) cable to thenegative (-) terminal of the assistingbattery.
4. Make the final connection of thenegative (-) cable to the negative (-)prong (B) of your vehicle.
Note:Do not attach the negative (-) cableto fuel lines, engine rocker covers, the intakemanifold or electrical components. Theseitems should not be considered groundingpoints.
WARNING
Never connect the negative end ofthe cable to the negative (-) terminalof the discharged battery. A sparkmay cause an explosion of the gases thatsurround the battery. Always use thenegative prong as a grounding point.
Make sure that the cables are clear of fanblades, belts, the moving parts of bothengines, or any fuel delivery system parts.
Jump Starting
1.Start the booster vehicle and press theaccelerator pedal moderately.
2. Start the disabled vehicle. Check theinstrument cluster for the Ready toDrive light as the gasoline engine maynot start, but the electric motor maybe running.
3.Once you start the disabled vehicle, runboth vehicles for an additional threeminutes before disconnecting thejumper cables.
Removing the Jumper Cables
Remove the jumper cables in the reverseorder that they were connected.
Note:In the illustration, the vehicle on thebottom is used to designate the assisting(boosting) battery.
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Roadside EmergenciesE148861

Crashes
A crash or impact significant enough torequire an emergency response forconventional vehicles would also requirethe same response for an electric orhybrid-electric vehicle.
If possible
•Move your car to a safe, nearbylocation and remain on the scene.
•Roll down the windows before shuttingyour vehicle off.
•Place your vehicle in Park, set theparking brake, turn off the vehicle,activate the hazard lights, and moveyour key(s) at least 16 feet (5 meters)away from the vehicle.
Always
•Call 911 if assistance is needed andadvise that an electric or hybrid-electricvehicle is involved.
•Do not touch exposed electricalcomponents or the enginecompartment, as a shock hazard mayexist.
•Avoid contact with leaking fluids andgases, and remain out of the way ofoncoming traffic until emergencyresponders arrive.
•When emergency responders arrive,tell them that the vehicle involved is anelectric vehicle or hybrid vehicle.
Fires
As with any vehicle, call 911 immediately ifyou see sparks, smoke or flames comingfrom the vehicle.
•Exit the vehicle immediately.
•Advise 911 that an electric orhybrid-electric vehicle is involved.
•As with any vehicle fire, do not inhalesmoke, vapors or gas from the vehicle,as they may be hazardous.
•Remain a safe distance from thevehicle and try to stay clear of thesmoke.
•Stay out of the roadway and stay outof the way of any oncoming trafficwhile awaiting the arrival of emergencyresponders.
Post-Incident
•Do not store a severely damagedvehicle with a lithium-ion battery insidea structure or within 50 feet (15meters) of any structure or vehicle.
•Make sure that passenger and cargocompartments remain ventilated (i.e.open window, door or trunk).
•For vehicles in the United States, notifyFord Motor Company 1-800-392-3673(then follow the prompts on the voiceresponse menu), an authorized Forddealer or service center as soon aspossible as there may be other stepsto secure and discharge thehigh-voltage battery.
•For vehicles in Canada, notify FordMotor Company 1-800-565-3673(then follow the prompts on the voiceresponse menu), an authorized Forddealer or service center as soon aspossible as there may be other stepsto secure and discharge thehigh-voltage battery.
•Call 911 if you observe leaking fluids,sparks, smoke or flames, or heargurgling or bubbling from thehigh-voltage battery.
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Roadside Emergencies

Protected componentsFuse amp ratingFuse or relay number
Cooling fan module.50A MidiF1
Electric water pump.50A MidiF2
Body control module supply 1.50A MidiF3
Body control module supply 2.50A MidiF4
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 electronicstability program module.5A*F19
Horn.15A*F20
Stop light switch.5A*F21
Vacuum pump monitoring.5A*F22
Engine control module 15.5A*F23Powertrain control module 15.Transmission oil pump 15.
Relay coils.5A*F24Light switch module.
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Fuses

Protected componentsFuse amp ratingFuse or relay number
Motor electronic cooling pump.10A*F25
Electronic power assist steering module15.5A*F26
Mass air flow sensor.5A*F27
Powertrain control module.15A*F28
Electronic air conditioning compressor.10A*F29Positive temperature coefficient heater.
Engine control module.10A*F30Powertrain 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 relayR1
Horn.Micro relayR2
Hybrid powertrain control.Micro relayR3
Front wiper.Micro relayR4
Vacuum pump.Micro relayR5
Front and rear wiper high-low.Micro relayR6
Not used.—R7
Ignition feed.Power relayR8
Not used.—R9
Not used.—R10
Not used.—R11
Cooling fan.Power relayR12
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Fuses

Protected componentsFuse amp ratingFuse or relay number
Fuel pump supply.20AF56
Not used.—F57
Not used (spare).5AF58
Passive anti-theft system.5AF59
Interior light.10AF60Driver door switch pack.Glove box illumination.Overhead console switch bank.
Cigar lighter.20AF61Second row power point.
Autowiper module.5AF62Autodimming rear view mirror.
Not used (spare).10AF63
Not used.—F64
Liftgate release.10AF65
Driver door unlock supply.20AF66
Cell phone passport (C-MAX Energi).7.5AF67Multi-function display.GPS module.Sync.
Not used (spare).15AF68
Instrument cluster.5AF69
Central lock and unlock supply.20AF70
Climate control module.7.5AF71
Steering wheel module.7.5AF72
Data link connector.7.5AF73OBD II supply.
Headlamp supply.15AF74
Fog lamp supply.15AF75
Reversing lamp supply.10AF76
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Fuses

Protected componentsFuse amp ratingFuse or relay number
Washer pump.20AF77
Ignition switch, Start button.5AF78
Radio.15AF79Hazard light switch.
Not used (spare).20AF80
Power sun shade.5AF81Remote receiver antenna.
Washer pump ground.20AF82
Central locking ground.20AF83
Drive door unlock ground.20AF84
Electronic 15 feed.7.5AF85
Restraints control module.10AF86Passenger air bag deactivation indicator.
Not used (spare).15AF87
Not used (spare).25AF88
Not used.—F89
Luggage Compartment Fuse Panel
The fuse panel is located in the luggagecompartment behind the left side wheelwell. Remove the fuse panel cover to gainaccess to the fuses.
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Fuses

GENERAL INFORMATION
Have your vehicle serviced regularly to helpmaintain its roadworthiness and resalevalue. There is a large network ofauthorized dealers that are there to helpyou with their professional servicingexpertise. We believe that their speciallytrained technicians are best qualified toservice your vehicle properly and expertly.They are supported by a wide range ofhighly specialized tools developedspecifically for servicing your vehicle.
If your vehicle requires professional service,an authorized dealer can provide thenecessary parts and service. Check yourwarranty information to find out whichparts and services are covered.
Use only recommended fuels, lubricants,fluids and service parts conforming tospecifications. Motorcraft® parts aredesigned and built to provide the bestperformance in your vehicle.
Precautions
•Do not work on a hot engine.
•Make sure that nothing gets caught inmoving parts.
•Do not work on a vehicle with theengine running in an enclosed space,unless you are sure you have enoughventilation.
•Keep all open flames and other burningmaterial (such as cigarettes) awayfrom the battery and all fuel relatedparts.
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 damageand/or personal burn injuries, do notstart your engine with the air cleanerremoved and do not remove it while theengine 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 releasehandle located under the left-handside of the instrument panel.
2. Slightly lift the hood.
3. Release the hood latch by pushing thesecondary release lever to yourleft-hand side.
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MaintenanceE142457

Low Engine Use (If Equipped)
The low engine use mode is equipped onEnergi models only. The low engine usemode keeps the engine oil quality in goodcondition when you drive your vehicle withlimited engine use. If your vehicle is in lowengine use mode when you start thevehicle, a message appears in theinformation display. When your vehicle isin low engine use mode, your vehicle runsthe engine as necessary.
Selecting EV Now mode when your vehicleis in the low engine use mode suspendsthe low engine use mode for as long as youcontinue driving your vehicle. The lowengine use mode resumes the next timeyou start your vehicle.
Changing the engine oil and resetting theoil life monitoring system suspends the lowengine use mode.
ENGINE COOLANT CHECK
WARNINGS
Do not add engine coolant when theengine is hot. Steam and scaldingliquids released from a hot coolingsystem can burn you badly. Also, you canbe burned if you spill coolant on hot engineparts.
Do not put engine coolant in thewindshield washer fluid container. Ifsprayed on the windshield, enginecoolant could make it difficult to seethrough the windshield.
To reduce the risk of personal injury,make sure the engine is cool beforeunscrewing the coolant pressurerelief cap. The cooling system is underpressure; steam and hot liquid can comeout forcefully when the cap is loosenedslightly.
Do not add coolant further than theMAX mark.
Engine Coolant and InverterSystem Controller Coolant
Your vehicle has two separate coolingsystems. One is for cooling the engine andone is for cooling the inverter systemcontroller that is specific to the hybridoperating system. The two systemsoperate similarly, with the inverter systemcontroller cooling system generallyoperating at a lower temperature andpressure.
Checking the Engine Coolant
When the engine is cold, check theconcentration and level of the enginecoolant at the intervals listed in thescheduled maintenance information. SeeScheduled Maintenance (page 348).
Note:Make sure that the level is betweenthe MIN and MAX marks on the enginecoolant 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 Engine Coolantin 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.
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Maintenance

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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Maintenance

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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Maintenance