Engine FORD C MAX HYBRID 2014 2.G Repair Manual

In the CAMVAP program, impartial
third-party arbitrators conduct hearings at
mutually convenient times and places in
an informal environment. These impartial
arbitrators review the positions of the
parties, make decisions and, when
appropriate, render awards to resolve
disputes. CAMVAP decisions are fast, fair,
and final as the arbitrator
’s award is
binding on both you and Ford of Canada.
CAMVAP services are available in all
Canadian territories and provinces. For
more information, without charge or
obligation, call your CAMVAP Provincial
Administrator directly at 1-800-207-0685
or visit www.camvap.ca.
GETTING ASSISTANCE
OUTSIDE THE U.S. AND
CANADA
Before exporting your vehicle to a foreign
country, contact the appropriate foreign
embassy or consulate. These officials can
inform you of local vehicle registration
regulations and where to find unleaded
fuel.
If you cannot find unleaded fuel or can only
get fuel with an anti-knock index lower
than is recommended for your vehicle,
contact our Customer Relationship Center.
The use of leaded fuel in your vehicle
without proper conversion may damage
the effectiveness of your emission control
system and may cause engine knocking or
serious engine damage. Ford Motor
Company or Ford of Canada is not
responsible for any damage caused by use
of improper fuel. Using leaded fuel may
also result in difficulty importing your
vehicle back into the United States. If your vehicle must be serviced while you
are traveling or living in Asia-Pacific Region,
Sub-Saharan Africa, U.S. Virgin Islands,
Central America, the Caribbean, and Israel,
contact the nearest authorized dealer. If
the authorized dealer cannot help you,
contact:
FORD MOTOR COMPANY
FORD EXPORT OPERATIONS & GLOBAL
INITIATIVES
Customer Relationship Center
1555 Fairlane Drive
Fairlane Business Park #3
Allen Park, Michigan 48101
U.S.A.
Telephone: (313) 594-4857
Fax: (313) 390-0804
Email: [email protected]
For customers in Guam, the
Commonwealth of the Northern Mariana
Islands (CNMI), America Samoa, and the
U.S. Virgin Islands, please feel free to call
our Toll-Free Number: (800) 841-FORD
(3673).
If your vehicle must be serviced while you
are traveling or living in Puerto Rico,
contact the nearest authorized dealer. If
the authorized dealer cannot help you,
contact:
FORD MOTOR COMPANY
FORD EXPORT OPERATIONS & GLOBAL
INITIATIVES
Customer Relationship Center
1555 Fairlane Drive
Fairlane Business Park #3
Allen Park, Michigan 48101
U.S.A.
Telephone: (800) 841-FORD (3673)
FAX: (313) 390-0804
Email: [email protected]
www.ford.com.pr
If your vehicle must be serviced while you
are traveling or living in the Middle East,
contact the nearest authorized dealer. If
the authorized dealer cannot help you,
contact:
197
C-MAX (CCG) Customer Assistance

FUSE SPECIFICATION CHART
Pre-Fuse Box
Your vehicle has a pre-fuse box attached
to the power distribution box. There is a
second pre-fuse box attached to the
12-volt battery terminal in the rear of your
vehicle. They contain high-current fuses.
If you need to replace one of these fuses,
see an authorized dealer.
Power Distribution Box
WARNINGS
Always disconnect the battery before
servicing high current fuses. WARNINGS
To reduce risk of electrical shock,
always replace the cover to the
power distribution box before
reconnecting the battery or refilling fluid
reservoirs. The power distribution box is located in
the engine compartment. It has
high-current fuses that protect your
vehicle's main electrical systems from
overloads.
If you disconnect and reconnect the
battery, you will need to reset some
features. See Changing the 12V Battery
(page 218).
Lift the release lever at the rear of the cover
to remove it. 200
C-MAX (CCG) FusesE162196

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 / Powertrain
control module 15 / Transmission oil pump
15
5A*
F23
Relay coils, Light switch module
5A*
F24
Motor electronic cooling pump
10A*
F25
201
C-MAX (CCG) Fuses

Protected components
Fuse amp rating
Fuse or relay number
Electronic power assist steering module 15
5A*
F26
Mass air flow sensor
5A*
F27
Powertrain control module
15A*
F28
Electronic air conditioning compressor /
Positive temperature coefficient heater
10A*
F29
Engine control module, Powertrain control
module
10A*
F30
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
Not used
—
R1
Horn
Micro relay
R2
Hybrid powertrain control
Micro relay
R3
Front wiper
Micro relay
R4
Not used
—
R5
Front and rear wiper high/low
Micro relay
R6
Vacuum pump
Power relay
R7
Ignition feed
Power relay
R8
Not used
—
R9
Vacuum pump sensor
Mini relay
R10
Not used
—
R11
Cooling fan
Power relay
R12
Heater blower
Mini relay
R13
Engine control relay
Mini relay
R14
*Mini fuses **Cartridge fuses
202
C-MAX (CCG) Fuses

GENERAL INFORMATION
Have your vehicle serviced regularly to help
maintain its roadworthiness and resale
value. There is a large network of Ford
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.
To help you service your vehicle, we
provide scheduled maintenance
information which makes tracking routine
service easy. See Scheduled
Maintenance (page 417).
If your vehicle requires professional service,
your 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
P
(Park).
2. Turn off the engine and remove the key
(if equipped).
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
P
(Park).
2. Block the wheels
OPENING AND CLOSING THE
HOOD 1.
To open the hood, go inside the vehicle
and pull the hood release handle
located under the left hand side of the
instrument panel.
209
C-MAX (CCG) MaintenanceE142457

Engine coolant reservoir cap. See Engine Coolant Check (page 213).
A
Engine oil filler cap. See
Engine Oil Check (page 212).
B
Engine oil dipstick. See
Engine Oil Dipstick (page 212).
C
Engine air filter cover. See
Changing the Engine Air Filter (page 229).
D
Inverter system controller.
E
Brake fluid reservoir cap. See
Brake Fluid Check (page 217).
F
Power distribution box. See
Fuses (page 200).
G
Inverter system controller coolant reservoir cap.
H
Windshield washer fluid reservoir cap. See
Washer Fluid Check (page 217).
I
211
C-MAX (CCG) MaintenanceABCDEFG
HIE162485

ENGINE OIL DIPSTICK
MINA
MAX
B
ENGINE OIL CHECK
Note: Check the level before starting the
engine.
Note: Make sure that the level is between
the MIN and the MAX marks.
1. Make sure that your vehicle is on level ground.
2. Turn the engine off and wait 10 minutes
for the oil to drain into the oil pan.
3. Remove the dipstick and wipe it with a clean, lint-free cloth. Replace the
dipstick and remove it again to check
the oil level.
If the level is at the MIN mark, add oil
immediately.
Adding Engine Oil
Note: Do not remove the filler cap when
the engine is running.
Note: Do not add oil further than the MAX
mark. Oil levels above the MAX mark may
cause engine damage. Only use oils certified for gasoline engines
by the American Petroleum Institute (API).
An oil with this trademark symbol
conforms to the current engine and
emission system protection standards and
fuel economy requirements of the
International Lubricants Specification
Advisory Council (ILSAC), comprised of
U.S. and Japanese automobile
manufacturers.
1. Remove the filler cap.
2. Add engine oil that meets the Ford
specifications. See Capacities and
Specifications (page 265).
3. Replace the filler cap. Turn it until you feel a strong resistance.
Resetting the Oil Life Monitoring
System
Note: Reset the oil life monitoring only after
an oil change.
1. Turn the ignition key to the on position.
Do not start the engine. For vehicles
with push-button start, press and hold
the start button for two seconds
without pressing the brake pedal. Do
not attempt to start the engine.
2. Press both the accelerator and brake pedals at the same time.
3. Keep both pedals fully pressed.
212
C-MAX (CCG) MaintenanceAB
E169062 E142732

4. After three seconds, the Service: Oil
reset in prog. message will be
displayed.
5. After 25 seconds, the Service: Oil reset
complete message will be displayed.
6. Release both the accelerator and brake
pedals.
7. The Service: Oil reset complete message will no longer be displayed.
8. Rotate the key to the off position. For vehicles with push-button start, press
the start button to turn the vehicle off
completely.
ENGINE COOLANT CHECK
Engine Coolant and Inverter
System Controller Coolant
Your vehicle is equipped with 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 417).
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 prediluted
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 Rotunda tool
300-ROB75240 available from your dealer.
Ford does 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.
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 417).
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 prediluted
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).
213
C-MAX (CCG) Maintenance

Note:
For best results, coolant
concentration should be tested with a
refractometer such as Rotunda tool
300-ROB75240 available from your dealer.
Ford does 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 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.
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 prediluted
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 265).
• 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
only 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 prediluted 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.
214
C-MAX (CCG) Maintenance

•
Do not use alcohol, methanol, brine or
any engine coolants mixed with alcohol
or methanol antifreeze (coolant).
Alcohol and other liquids can cause
engine damage from overheating or
freezing.
• Do not add extra inhibitors or additives
to the coolant. These can be harmful
and compromise the corrosion
protection of the engine coolant.
Adding Engine Coolant
1. Unscrew the engine coolant reservoir cap slowly. Any pressure will escape
as you unscrew the cap.
2. Use a funnel to add prediluted engine coolant to the engine coolant reservoir.
Make sure that the level is between the
MIN and MAX marks on the engine
coolant reservoir. Use prediluted engine
coolant meeting the Ford specification.
See Capacities and Specifications
(page 265).
3. Close the engine coolant reservoir cap.
Whenever you add coolant, check the
coolant level in the engine coolant reservoir
the next few times you drive the vehicle. If
necessary, add enough prediluted engine
coolant to bring the engine coolant level
to the proper level.
Adding Inverter System Controller
Coolant
1. Open the inverter system controller coolant reservoir cap.
2. Use a funnel to add prediluted coolant
to the inverter system controller
coolant reservoir. Make sure that the
level is between the MIN and MAX
marks on the inverter system controller
coolant reservoir. Use prediluted
coolant meeting the Ford specification.
See
Capacities and Specifications
(page 265). 3. Close the inverter system controller
coolant reservoir cap.
Whenever you add coolant, check the
coolant level in the inverter system
controller coolant reservoir the next few
times you drive the vehicle. If necessary,
add enough prediluted coolant to bring the
inverter system controller coolant level to
the proper level.
Recycled Engine Coolant
Ford Motor Company does not recommend
the use of recycled engine coolant since a
Ford-approved recycling process is not yet
available.
Used engine coolant should be disposed
of in an appropriate manner. Follow your
community ’s regulations and standards
for recycling and disposing of automotive
fluids.
Severe Climates
If you drive in extremely cold climates:
• It may be necessary to have an
authorized Ford dealer increase the
coolant concentration above 50%.
• A coolant concentration of 60% will
provide improved freeze point
protection. Engine coolant
concentrations above 60% will
decrease the overheat protection
characteristics of the engine coolant
and may cause engine damage.
If you drive in extremely hot climates:
• It may be necessary to have an
authorized Ford dealer decrease the
coolant concentration to 40%.
• A coolant concentration of 40% will
provide improved overheat protection.
Engine coolant concentrations below
40% will decrease the corrosion/freeze
protection characteristics of the engine
coolant and may cause engine
damage.
215
C-MAX (CCG) Maintenance