engine FORD C MAX HYBRID 2015 2.G Repair Manual

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 upwind and
uphill from the vehicle fire.
• 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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C-MAX (CCG) Mexico/United States of America/Canada, enUSA, CPE Review Roadside Emergencies

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
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
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:
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C-MAX (CCG) Mexico/United States of America/Canada, enUSA, CPE Review 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 219).
Lift the release lever at the rear of the cover
to remove it. 200
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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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C-MAX (CCG) Mexico/United States of America/Canada, enUSA, CPE Review Fuses

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
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
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C-MAX (CCG) Mexico/United States of America/Canada, enUSA, CPE Review Fuses

Protected components
Fuse amp rating
Fuse or relay number
Heater blower.
Mini relay
R13
Engine control relay.
Mini relay
R14
*Mini fuses **Cartridge fuses
Passenger Compartment Fuse
Panel
The fuse panel is located on the right-hand
side below the glove box. You may need
to remove a trim panel to access it. 203
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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.
To help you service your vehicle, we
provide scheduled maintenance
information which makes tracking routine
service easy. See Scheduled
Maintenance (page 426).
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 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.
2. Go to the front of the vehicle and locate the secondary release lever,
which is located under the front of the
hood, to your right of the center of the
vehicle (driver's side), near the
headlight.
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Engine coolant reservoir cap. See Engine Coolant Check (page 214).
A
Engine oil filler cap. See
Engine Oil Check (page 213).
B
Engine oil dipstick. See
Engine Oil Dipstick (page 213).
C
Engine air filter cover. See
Changing the Engine Air Filter (page 230).
D
Inverter system controller.
E
Brake fluid reservoir cap. See
Brake Fluid Check (page 218).
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 218).
I
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HIE162485

UNDER HOOD OVERVIEW -
PLUG-IN HYBRID ELECTRIC
VEHICLE (PHEV)
WARNING
The inverter system controller
contains various high-voltage
components that can cause serious
bodily harm or death. The inverter system
controller is not serviceable and should
never be touched, probed, or tampered
with. Note:
Do not attempt to service any of the
high-voltage components or wiring. For
easier identification, the high-voltage wiring
insulation is color coated orange. Engine coolant reservoir cap. See Engine Coolant Check (page 214).
A
Engine oil filler cap. See
Engine Oil Check (page 213).
B
Engine oil dipstick. See
Engine Oil Dipstick (page 213).
C
Engine air filter cover. See
Changing the Engine Air Filter (page 230).
D
Inverter system controller.
E
Brake fluid reservoir cap. See
Brake Fluid Check (page 218).
F
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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 218).
I
ENGINE OIL DIPSTICK MINA
MAX
B
ENGINE OIL CHECK
Check the level before starting the engine
and make sure that the level is between
the MIN and the MAX marks.
1. Make sure that your vehicle is on level ground.
2. Switch 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 oil level is at the minimum 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 266).
3. Wipe off any spilled oil.
4. Replace the filler cap. Turn it until you feel a strong resistance.
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