engine FORD FUSION HYBRID 2014 Service Manual

SAFETY PRECAUTIONS WARNINGS
Do not overfill the fuel tank. The
pressure in an overfilled tank may
cause leakage and lead to fuel spray
and fire.
The fuel system may be under
pressure. If you hear a hissing sound
near the fuel filler door (Easy Fuel
capless fuel system), do not refuel until
the sound stops. Otherwise, fuel may spray
out, which could cause serious personal
injury.
Automotive fuels can cause serious
injury or death if misused or
mishandled.
The flow of fuel through a fuel pump
nozzle can produce static electricity,
which can cause a fire if fuel is
pumped into an ungrounded fuel container.
Fuel ethanol and gasoline may
contain benzene, which is a
cancer-causing agent.
When refueling always shut the
engine off and never allow sparks or
open flames near the filler neck.
Never smoke or use a cell phone while
refueling. Fuel vapor is extremely
hazardous under certain conditions. Avoid
inhaling excess fumes.
Observe the following guidelines when
handling automotive fuel:
• Extinguish all smoking materials and
any open flames before refueling your
vehicle.
• Always turn off the vehicle before
refueling. • Automotive fuels can be harmful or
fatal if swallowed. Fuel such as
gasoline is highly toxic and if
swallowed can cause death or
permanent injury. If fuel is swallowed,
call a physician immediately, even if no
symptoms are immediately apparent.
The toxic effects of fuel may not be
visible for hours.
• Avoid inhaling fuel vapors. Inhaling too
much fuel vapor of any kind can lead
to eye and respiratory tract irritation.
In severe cases, excessive or prolonged
breathing of fuel vapor can cause
serious illness and permanent injury.
• Avoid getting fuel liquid in your eyes. If
fuel is splashed in the eyes, remove
contact lenses (if worn), flush with
water for 15 minutes and seek medical
attention. Failure to seek proper
medical attention could lead to
permanent injury.
• Fuels can also be harmful if absorbed
through the skin. If fuel is splashed on
the skin, clothing or both, promptly
remove contaminated clothing and
wash skin thoroughly with soap and
water. Repeated or prolonged skin
contact with fuel liquid or vapor causes
skin irritation.
• Be particularly careful if you are taking
“Antabuse” or other forms of disulfiram
for the treatment of alcoholism.
Breathing gasoline vapors, or skin
contact could cause an adverse
reaction. In sensitive individuals, serious
personal injury or sickness may result.
If fuel is splashed on the skin, promptly
wash skin thoroughly with soap and
water. Consult a physician immediately
if you experience an adverse reaction.
148Fuel and Refueling

FUEL QUALITY Note: Use of any fuel other than those
recommended may cause powertrain
damage, a loss of vehicle performance and
repairs may not be covered under warranty.
Choosing the Right Fuel Use only UNLEADED fuel or UNLEADED
fuel blended with a maximum of 15%
ethanol. Do not use fuel ethanol (E85),
diesel fuel, fuel-methanol, leaded fuel or
any other fuel because it could damage or
impair the emission control system.
Your vehicle was not designed to use fuel
or fuel additives with metallic compounds,
including manganese-based additives. The
use of leaded fuel is prohibited by law.
Octane Recommendations Regular unleaded gasoline with a pump
(R+M)/2 octane rating of 87 is
recommended. Some fuel stations offer
fuels posted as regular with an octane
rating below 87, particularly in high altitude
areas. Fuels with octane levels below 87
are not recommended.
Do not be concerned if your engine
sometimes knocks lightly. However, if it
knocks heavily while you are using fuel with
the recommended octane rating, see your
authorized dealer to prevent any engine
damage.
Fuel Freshness Mode (Energi
Vehicles Only)
This feature helps keeps the fuel system
functional and the fuel fresh.
If you operate your vehicle mainly in plug-in
power mode using electricity from plugging
in without refueling, the gasoline in your
tank eventually becomes old. Old fuel can
damage the engine and fuel system. To prevent the fuel from becoming old,
your vehicle will automatically enter fuel
freshness mode. In fuel freshness mode
operates, your vehicle will operate in hybrid
mode causing the gasoline engine to run
in order to consume the fuel in the fuel
tank.
Note: If new fuel is not added during an 18
month period, fuel freshness mode will
consume fuel until about 1 gallon (3.8 liters)
is left in the tank.
During fuel freshness mode:
• The information display screen will
indicate that fuel freshness mode is
active.
• The vehicle will only run in hybrid mode.
EV Now will not be available.
• Most of the plug-in power will be
stored until fuel freshness mode is
completed.
Note: EV Now can resume if less than 1
gallon (3.8 liters) of fuel is left in the tank.
Note: In most cases, when the fuel level is
below 1/4 tank, refueling the vehicle will end
fuel freshness mode and EV Now will now
become available. Refueling after
consuming a full tank in fuel freshness mode
will end the mode.
Note: It is recommended to use a fuel
stabilizer if you consume less than a full
tank of fuel during an 18 month period.
REFUELING WARNINGS
Fuel vapor burns violently and a fuel
fire can cause severe injuries.
Read and follow all the instructions
on the pump island.
Turn off your vehicle when you are
refueling.
149Fuel and Refueling

Note: Allow about five to ten seconds after
pumping fuel before removing the fuel filler
nozzle. This allows residual fuel to drain
back into the fuel tank and not spill onto the
vehicle.
4. After you have stopped pumping fuel,
slowly remove the fuel filler nozzle.
Note: A fuel spillage concern may occur if
overfilling the fuel tank. Do not overfill the
tank to the point that the fuel is able to
bypass the fuel filler nozzle. The overfilled
fuel may run down the drain located below
and in front of the fuel filler door.
5. To close the fuel filler door, press the
center rear edge of the fuel filler door
and then release. The fuel door will
latch closed.
If the fuel fill inlet did not close properly, a
Check Fuel Fill Inlet message may
appear on the instrument cluster.
At the next opportunity, do the following:
1. Safely pull off the road.
2. Put the vehicle in position P and switch
the ignition off.
3. Open the fuel filler door and remove
any visible debris from the fuel fill
opening.
4. Insert the fuel fill nozzle, or the fuel fill
funnel provided with your vehicle,
several times to allow the inlet to close
properly. This will dislodge any debris
preventing the inlet from sealing.
If this action corrects the problem, the
message may not reset immediately. It
may take several driving cycles for the
message to turn off. A driving cycle
consists of an engine start-up (after four
or more hours with the engine off) followed
by city or highway driving. Continuing to
drive with the message on may cause the
service engine soon lamp to turn on as
well. Easy Fuel™ Capless System
(Energi Vehicles Only) WARNING
The fuel system may be under
pressure. If you hear a hissing sound
near the fuel filler door, do not refuel
until the sound stops. Otherwise, fuel may
spray out, which could cause serious
personal injury.
When fueling your vehicle:
1. Put the vehicle in position P and switch
the ignition off. E166527
2. Press the center-rear edge of the fuel
filler door and release to open.
E146221
3. Press the button located on the center
console to open the fuel filler door. It
could take up to 15 seconds for the fuel
door to pop open allowing you to insert
the fuel filler nozzle.
151Fuel and Refueling

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Note: Hold the handle of the fuel filler
nozzle higher while you insert the nozzle for
easier access.
4. Slowly insert the fuel filler nozzle fully
into the fuel system to open both
doors. Leave the nozzle fully inserted
until you have stopped pumping fuel. E154765
Note: Allow about five to ten seconds after
pumping fuel before removing the fuel filler
nozzle. This allows residual fuel to drain
back into the fuel tank and not spill onto the
vehicle.
5. After you have stopped pumping fuel,
slowly remove the fuel filler nozzle.
Note: A fuel spillage concern may occur if
overfilling the fuel tank. Do not overfill the
tank to the point that the fuel is able to
bypass the fuel filler nozzle. The overfilled
fuel may run down the drain located below
and in front of the fuel filler door. 6. To close the fuel filler door, press the
center rear edge of the fuel filler door
and then release. The fuel door will
latch closed.
If the fuel fill inlet did not close properly, a
Check Fuel Fill Inlet message may
appear on the instrument cluster.
At the next opportunity, do the following:
1. Safely pull off the road.
2. Put the vehicle in position P and switch
the ignition off.
3. Open the fuel filler door and remove
any visible debris from the fuel fill
opening.
4. Insert the fuel fill nozzle, or the fuel fill
funnel provided with the vehicle,
several times to allow the inlet to close
properly. This will dislodge any debris
preventing the inlet from sealing.
If this action corrects the problem, the
message may not reset immediately. It
may take several driving cycles for the
message to turn off. A driving cycle
consists of an engine start-up (after four
or more hours with the engine off) followed
by city or highway driving. Continuing to
drive with the message on may cause the
service engine soon lamp to turn on as
well.
Using the manual override lever
WARNING
The fuel system may be under
pressure. Insert the fuel nozzle
slowly. If you hear a hissing sound
near the fuel filler door, do not refuel until
the sound stops. Otherwise, fuel may spray
out, which could cause serious personal
injury.
Note: The vehicle must be in position P
when using the manual override feature.
152Fuel and Refueling

The manual override lever is located inside
of the trunk on the left rear-side panel.
When using the fuel door manual override
to access the fuel fill inlet:
1. Switch the ignition on prior using a
manual override. E156033
2. Pull the manual override mechanism
located in trunk.
3. Switch off and complete refueling
within 20 minutes. If more than 20
minutes is required, close fuel door, and
repeat the procedure.
This will enable you to refuel without any
issue.
Note: A fuel spillage concern may occur if
overfilling the fuel tank. Do not overfill the
tank to the point that the fuel is able to
bypass the fuel filler nozzle. The overfilled
fuel may run down the drain located below
and in front of the fuel filler door.
If you do not properly close the fuel fill
inlet, a Check Fuel Fill Inlet message may
appear on the instrument cluster. At the
next opportunity, do the following:
1. Safely pull off the road.
2. Put the vehicle in position P and switch
the ignition off.
3. Open the fuel filler door and remove
any visible debris from the fuel fill
opening. 4. Insert the fuel fill nozzle or the fuel fill
funnel provided with your vehicle
several times to allow the inlet to close
properly. This will dislodge any debris
preventing the inlet from sealing.
If this action corrects the problem, the
message may not reset immediately. It
may take several driving cycles for the
message to turn off. A driving cycle
consists of an engine start-up (after four
or more hours with the engine off) followed
by city/highway driving. Continuing to drive
with the message on may cause the service
engine soon lamp to turn on as well.
RUNNING OUT OF FUEL Avoid running out of fuel because this
situation may have an adverse effect on
vehicle components.
If you have run out of fuel:
• To start the vehicle with a keyless
ignition, just start the engine. Crank
time will be longer than usual.
• Normally, adding 1 gallon (3.8 liters) of
fuel is enough to restart the vehicle. If
the vehicle is out of fuel and on a steep
grade, more than 1 gallon (3.8 liters)
may be required.
• The service engine soon indicator may
come on.
Refilling With a Portable Fuel
Container (Except Energi
Vehicles)
WARNINGS
Do not insert the nozzle of portable
fuel containers or aftermarket
funnels into the capless fuel system.
This could damage the fuel system and its
seal, and may cause fuel to run onto the
ground instead of filling the tank, which
could result in serious personal injury.
153Fuel and Refueling

E146221
2. Press the fuel button located on the
center console. Wait up to 15 seconds
for the fuel door to open. A Ready to
Fuel message will appear in the
information display screen.
3. Locate the portable funnel that comes
with your vehicle.
E157279
4. Slowly insert the funnel into the
capless fuel system.
E157280 5. Fill the vehicle with fuel from the
portable fuel container.
6. Close the fuel door.
Note: If the fuel door is not closed and the
vehicle is driven, the check engine light in
the instrument cluster may come on.
7. When done, clean the funnel or
properly dispose of it. Extra funnels can
be purchased from your authorized
dealer if you choose to dispose of the
funnel.
FUEL CONSUMPTION Note: The amount of usable fuel in the
empty reserve varies and should not be
relied upon to increase driving range. When
refueling your vehicle after the fuel gauge
indicates empty, you might not be able to
refuel the full amount of the advertised
capacity of the fuel tank due to the empty
reserve still present in the tank.
Empty reserve is the amount of fuel
remaining in the tank after the fuel gauge
indicates empty. Do not rely on this fuel for
driving. The usable capacity of the fuel
tank is the amount of fuel that can be put
into the tank after the gauge indicates
empty. The advertised capacity is the total
fuel tank size – it is the combined usable
capacity plus the empty reserve.
Filling the Tank For consistent results when filling the fuel
tank:
• Turn the ignition off before fueling; an
inaccurate reading results if the engine
is left running.
• Use the same fill rate
(low-medium-high) each time the tank
is filled.
• Allow no more than two automatic
click-offs when filling.
156Fuel and Refueling

Results are most accurate when the filling
method is consistent.
Calculating Fuel Economy Do not measure fuel economy during the
first 1000 miles (1600 kilometers) of
driving (this is your engine’s break-in
period); a more accurate measurement is
obtained after 2000 miles - 3000 miles
(3200 kilometers - 4800 kilometers). Also,
fuel expense, frequency of fill ups or fuel
gauge readings are not accurate ways to
measure fuel economy.
1. Fill the fuel tank completely and record
the initial odometer reading.
2. Each time you fill the tank, record the
amount of fuel added.
3. After at least three to five tank fill ups,
fill the fuel tank and record the current
odometer reading.
4. Subtract your initial odometer reading
from the current odometer reading.
5. Calculate fuel economy by dividing
miles traveled by gallons used (For
Metric: Multiply liters used by 100, then
divide by kilometers traveled).
Keep a record for at least one month and
record the type of driving (city or highway).
This provides an accurate estimate of the
vehicle’s fuel economy under current
driving conditions. Additionally, keeping
records during summer and winter show
how temperature impacts fuel economy.
In general, lower temperatures mean lower
fuel economy.
EMISSION CONTROL SYSTEM WARNINGS
Do not park, idle, or drive your vehicle
in dry grass or other dry ground cover.
The emission system heats up the
engine compartment and exhaust system,
which can start a fire. WARNINGS
Exhaust leaks may result in entry of
harmful and potentially lethal fumes
into the passenger compartment. If
you smell exhaust fumes inside your
vehicle, have your dealer inspect your
vehicle immediately. Do not drive if you
smell exhaust fumes.
Your vehicle is equipped with various
emission control components and a
catalytic converter that will enable your
vehicle to comply with applicable exhaust
emission standards. To make sure that the
catalytic converter and other emission
control components continue to work
properly:
To make sure that the catalytic converter
and other emission control components
continue to work properly:
• Use only the specified fuel listed.
• Avoid running out of fuel.
• Do not turn off the ignition while your
vehicle is moving, especially at high
speeds.
• Have the items listed in scheduled
maintenance information performed
according to the specified schedule.
The scheduled maintenance items listed
in scheduled maintenance information are
essential to the life and performance of
your vehicle and to its emissions system
If other than Ford, Motorcraft or
Ford-authorized parts are used for
maintenance replacements or for service
of components affecting emission control,
such non-Ford parts should be equivalent
to genuine Ford Motor Company parts in
performance and durability.
157Fuel and Refueling

Illumination of the service engine soon
indicator, charging system warning light or
the temperature warning light, fluid leaks,
strange odors, smoke or loss of engine
power could indicate that the emission
control system is not working properly.
An improperly operating or damaged
exhaust system may allow exhaust to
enter the vehicle. Have a damaged or
improperly operating exhaust system
inspected and repaired immediately.
Do not make any unauthorized changes to
your vehicle or engine. By law, vehicle
owners and anyone who manufactures,
repairs, services, sells, leases, trades
vehicles, or supervises a fleet of vehicles
are not permitted to intentionally remove
an emission control device or prevent it
from working. Information about your
vehicle’s emission system is on the Vehicle
Emission Control Information Decal
located on or near the engine. This decal
also lists engine displacement
Please consult your warranty information
for complete details.
On-Board Diagnostics (OBD-II) Your vehicle is equipped with a computer
that monitors the engine’s emission control
system. This system is commonly known
as the on-board diagnostics system
(OBD-II). The OBD-II system protects the
environment by ensuring that your vehicle
continues to meet government emission
standards. The OBD-II system also assists
your authorized dealer in properly servicing
your vehicle.
When the service engine soon
indicator illuminates, the OBD-II
system has detected a
malfunction. Temporary malfunctions may
cause the service engine soon indicator to
illuminate. Examples are:
1. The vehicle has run out of fuel—the
engine may misfire or run poorly. 2. Poor fuel quality or water in the
fuel—the engine may misfire or run
poorly.
3. The fuel fill inlet may not have been
properly closed. See Refueling (page
149).
4. Driving through deep water—the
electrical system may be wet.
These temporary malfunctions can be
corrected by filling the fuel tank with good
quality fuel, properly closing the fuel fill
inlet or letting the electrical system dry out.
After three driving cycles without these or
any other temporary malfunctions present,
the service engine soon indicator should
stay off the next time the engine is started.
A driving cycle consists of a cold engine
startup followed by mixed city/highway
driving. No additional vehicle service is
required.
If the service engine soon indicator remains
on, have your vehicle serviced at the first
available opportunity. Although some
malfunctions detected by the OBD-II may
not have symptoms that are apparent,
continued driving with the service engine
soon indicator on can result in increased
emissions, lower fuel economy, reduced
engine and transmission smoothness, and
lead to more costly repairs.
Readiness for
Inspection/Maintenance (I/M)
Testing Some state/provincial and local
governments may have
Inspection/Maintenance (I/M) programs
to inspect the emission control equipment
on your vehicle. Failure to pass this
inspection could prevent you from getting
a vehicle registration.
If the service engine soon
indicator is on or the bulb does
not work, the vehicle may need
to be serviced. See On-Board Diagnostics.
158Fuel and Refueling

Your vehicle may not pass the I/M test if
the service engine soon indicator is on or
not working properly (bulb is burned out),
or if the OBD-II system has determined
that some of the emission control systems
have not been properly checked. In this
case, the vehicle is considered not ready
for I/M testing.
If the vehicle’s engine or transmission has
just been serviced, or the battery has
recently run down or been replaced, the
OBD-II system may indicate that the
vehicle is not ready for I/M testing. To
determine if the vehicle is ready for I/M
testing, turn the ignition key to the on
position for 15 seconds without cranking
the engine. If the service engine soon
indicator blinks eight times, it means that
the vehicle is not ready for I/M testing; if
the service engine soon indicator stays on
solid, it means that the vehicle is ready for
I/M testing.
The OBD-II system is designed to check
the emission control system during normal
driving. A complete check may take several
days. If the vehicle is not ready for I/M
testing, the following driving cycle
consisting of mixed city and highway
driving may be performed:
15 minutes of steady driving on an
expressway/highway followed by 20
minutes of stop-and-go driving with at
least four 30-second idle periods.
Allow the vehicle to sit for at least eight
hours with the ignition Off. Then, start the
vehicle and complete the above driving
cycle. The vehicle must warm up to its
normal operating temperature. Once
started, do not turn off the vehicle until the
above driving cycle is complete. If the
vehicle is still not ready for I/M testing, the
above driving cycle will have to be
repeated.
159Fuel and Refueling

AUTOMATIC TRANSMISSION WARNINGS
Always set the parking brake fully
and make sure the gearshift is
latched in P (Park). Turn the ignition
to the off position and remove the key
whenever you leave your vehicle.
Do not apply the brake pedal and
accelerator pedal simultaneously.
Applying both pedals simultaneously
for more than three seconds will limit
engine rpm, which may result in difficulty
maintaining speed in traffic and could lead
to serious injury.
Automatic Transmission Putting your vehicle in gear:
1. Fully press down the brake pedal.
2. Press and hold the button on the front
of the gearshift lever.
3. Move the gearshift lever into the
desired gear.
4. Release the button and your
transmission will remain in the selected
gear.
E144820 P (Park)
This position locks the transmission and
prevents the front wheels from turning.
Come to a complete stop before putting
your vehicle into and out of P (Park)
R (Reverse)
With the gearshift lever in R (Reverse), the
vehicle will move backward. Always come
to a complete stop before shifting into and
out of R (Reverse).
N (Neutral)
With the gearshift lever in N (Neutral), the
vehicle is free to roll; hold the brake pedal
down while in this position.
D (Drive)
The normal driving position for the best
fuel economy.
D (Drive) with Grade Assist (If
Equipped)
Press the transmission control switch on
the side of the gearshift lever to activate
grade assist.
E146092
166Transmission