engine FORD C MAX ENERGI 2016 Manual PDF

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
Heater blower.Mini relayR13
Engine control relay.Mini relayR14
*Mini fuses **Cartridge fuses
Passenger Compartment FusePanel
The fuse panel is located on the right-handside below the glove box. You may needto remove a trim panel to access it.
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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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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
Inverter system controller.E
Brake fluid reservoir cap. See Brake Fluid Check (page 227).F
Power distribution box. See Fuses (page 209).G
Inverter system controller coolant reservoir cap.H
Windshield washer fluid reservoir cap. See Washer Fluid Check (page 227).I
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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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Inverter system controller.E
Brake fluid reservoir cap. See Brake Fluid Check (page 227).F
Power distribution box. See Fuses (page 209).G
Inverter system controller coolant reservoir cap.H
Windshield washer fluid reservoir cap. See Washer Fluid Check (page 227).I
ENGINE OIL DIPSTICK
MINA
MAXB
ENGINE OIL CHECK
Check the level before starting the engineand make sure that the level is betweenthe MIN and the MAX marks.
1. Make sure that your vehicle is on levelground.
2. Switch the engine off and wait 10minutes for the oil to drain into the oilpan.
3. Remove the dipstick and wipe it witha clean, lint-free cloth. Replace thedipstick and remove it again to checkthe oil level.
If the oil level is at the minimum mark, addoil immediately.
Adding Engine Oil
Note:Do not remove the filler cap whenthe engine is running.
Note:Do not add oil further than the MAXmark. Oil levels above the MAX mark maycause engine damage.
Only use oils certified for gasoline enginesby the American Petroleum Institute (API).An oil with this trademark symbolconforms to the current engine andemission system protection standards andfuel economy requirements of theInternational Lubricants SpecificationAdvisory Council (ILSAC), comprised ofU.S. and Japanese automobilemanufacturers.
1. Remove the filler cap.
2. Add engine oil that meets the Fordspecifications. See Capacities andSpecifications (page 276).
3. Wipe off any spilled oil.
4. Replace the filler cap. Turn it until youfeel a strong resistance.
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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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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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•Do not use alcohol, methanol, brine orany engine coolants mixed with alcoholor methanol antifreeze (coolant).Alcohol and other liquids can causeengine damage from overheating orfreezing.
•Do not add extra inhibitors or additivesto the coolant. These can be harmfuland compromise the corrosionprotection of the engine coolant.
Adding Engine Coolant
1. Unscrew the engine coolant reservoircap slowly. Any pressure will escapeas you unscrew the cap.
2. Use a funnel to add engine coolant tothe engine coolant reservoir. Make surethat the level is between the MIN andMAX marks on the engine coolantreservoir. Use engine coolant meetingthe Ford specification. See Capacitiesand Specifications (page 276).
3.Close the engine coolant reservoir cap.
Whenever you add coolant, check thecoolant level in the engine coolant reservoirthe next few times you drive the vehicle. Ifnecessary, add enough engine coolant tobring the engine coolant level to the properlevel.
Adding Inverter System ControllerCoolant
1. Open the inverter system controllercoolant reservoir cap.
2. Use a funnel to add coolant to theinverter system controller coolantreservoir. Make sure that the level isbetween the MIN and MAX marks onthe inverter system controller coolantreservoir. Use coolant meeting the Fordspecification. See Capacities andSpecifications (page 276).
3. Close the inverter system controllercoolant reservoir cap.
Whenever you add coolant, check thecoolant level in the inverter systemcontroller coolant reservoir the next fewtimes you drive the vehicle. If necessary,add enough coolant to bring the invertersystem controller coolant level to theproper level.
Recycled Engine Coolant
Ford Motor Company does not recommendthe use of recycled engine coolant since aFord-approved recycling process is not yetavailable.
Used engine coolant should be disposedof in an appropriate manner. Follow yourcommunity’s regulations and standardsfor recycling and disposing of automotivefluids.
Severe Climates
If you drive in extremely cold climates:
•It may be necessary to have anauthorized Ford dealer increase thecoolant concentration above 50%.
•A coolant concentration of 60% willprovide improved freeze pointprotection. Engine coolantconcentrations above 60% willdecrease the overheat protectioncharacteristics of the engine coolantand may cause engine damage.
If you drive in extremely hot climates:
•It may be necessary to have anauthorized Ford dealer decrease thecoolant concentration to 40%.
•A coolant concentration of 40% willprovide improved overheat protection.Engine coolant concentrations below40% will decrease the freeze andcorrosion protection characteristics ofthe engine coolant and may causeengine damage.
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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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