engine FORD FUSION HYBRID 2017 Service Manual

SAFETY PRECAUTIONS
WARNINGS
Do not overfill the fuel tank. Thepressure in an overfilled tank maycause leakage and lead to fuel sprayand fire.
The fuel system may be underpressure. If you hear a hissing soundnear the fuel filler inlet, do not refueluntil the sound stops. Otherwise, fuel mayspray out, which could cause seriouspersonal injury.
Fuels can cause serious injury ordeath if misused or mishandled.
Flow of fuel through a fuel pumpnozzle can produce static electricity.This can cause a fire if you are fillingan ungrounded fuel container.
Fuel may contain benzene, which isa cancer-causing agent.
When refueling always shut theengine off and never allow sparks oropen flames near the fuel tank fillervalve. Never smoke or use a cell phonewhile refueling. Fuel vapor is extremelyhazardous under certain conditions. Avoidinhaling excess fumes.
Observe the following guidelines whenhandling automotive fuel:
•Extinguish all smoking materials andany open flames before refueling yourvehicle.
•Always turn off the vehicle beforerefueling.
•Automotive fuels can be harmful orfatal if swallowed. Fuel such asgasoline is highly toxic and ifswallowed can cause death orpermanent injury. If fuel is swallowed,call a physician immediately, even if nosymptoms are immediately apparent.The toxic effects of fuel may not bevisible for hours.
•Avoid inhaling fuel vapors. Inhaling toomuch fuel vapor of any kind can leadto eye and respiratory tract irritation.In severe cases, excessive or prolongedbreathing of fuel vapor can causeserious illness and permanent injury.
•Avoid getting fuel liquid in your eyes. Iffuel is splashed in the eyes, removecontact lenses (if worn), flush withwater for 15 minutes and seek medicalattention. Failure to seek propermedical attention could lead topermanent injury.
•Fuels can also be harmful if absorbedthrough the skin. If fuel is splashed onthe skin, clothing or both, promptlyremove contaminated clothing andwash skin thoroughly with soap andwater. Repeated or prolonged skincontact with fuel liquid or vapor causesskin irritation.
•Be particularly careful if you are takingAntabuse or other forms of Disulfiramfor the treatment of alcoholism.Breathing gasoline vapors could causean adverse reaction, serious personalinjury or sickness. If fuel is splashed onthe skin, wash the affected areasimmediately with plenty of soap andwater. Consult a physician immediatelyif you experience any adverse reactions.
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Fuel and Refueling

FUEL QUALITY
Choosing the Right Fuel
We recommend regular unleaded gasolinewith a minimum pump (R+M)/2 octanerating of 87. Some fuel stations offer fuelsposted as regular unleaded gasoline withan octane rating below 87, particularly inhigh altitude areas. We do not recommendfuels with an octane rating below 87.
Do not use any fuel other than thoserecommended because they could lead toengine damage that may not be coveredby the vehicle Warranty.
Note:Use of any fuel other than thoserecommended can impair the emissioncontrol system and cause a loss of vehicleperformance.
Do not use:
•Diesel fuel.
•Fuels containing kerosene or paraffin.
•Fuel containing more than 15% ethanolor E85 fuel.
•Fuels containing methanol.
•Fuels containing metallic-basedadditives, including manganese-basedcompounds.
•Fuels containing the octane boosteradditive, methylcyclopentadienylmanganese tricarbonyl (MMT).
•Leaded fuel (using leaded fuel isprohibited by law).
The use of fuels with metallic compoundssuch as methylcyclopentadienylmanganese tricarbonyl (commonly knownas MMT), which is a manganese-basedfuel additive, will impair engineperformance and affect the emissioncontrol system.
Do not be concerned if the enginesometimes knocks lightly. However, if theengine knocks heavily while using fuel withthe recommended octane rating, contactan authorized dealer to prevent any enginedamage.
Fuel Freshness Mode (If Equipped)
This helps keep the fuel system functionaland the fuel fresh.
If you mainly use your vehicle in electricpower mode without refueling, the gasolinein the fuel tank may become stale due toaging. Stale gasoline can damage theengine and fuel system.
Your vehicle automatically switches to fuelfreshness mode if you do not refuel yourvehicle with fresh fuel within an 18-monthperiod. Fuel freshness mode protects yourvehicle from potential engine and fuelsystem damage caused by using stale fuel.
Note:If you do not add new fuel during an18-month period, fuel freshness mode willuse fuel until approximately 1.2 gal (4.5 L)of fuel remains in the fuel tank.
During fuel freshness mode:
•The information display will indicatefuel freshness mode is active.
•The vehicle will only run in hybrid mode.EV Now mode will not be available.
•Most of the plug-in power will bestored until fuel freshness mode iscompleted.
Note:EV Now mode resumes when lessthan 1.2 gal (4.5 L) of fuel remains in the fueltank.
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Note:When the fuel level is less thanone-quarter full, refueling your vehicle willend fuel freshness mode.
Note:We recommend you use a fuelstabilizer if you use less than a full tank offuel during an 18-month period.
FUEL FILLER FUNNEL
LOCATION
The fuel filler funnel is located under theluggage compartment floor covering.
RUNNING OUT OF FUEL
Running out of fuel can cause damage notcovered by the vehicle Warranty.
If your vehicle runs out of fuel:
•Add a minimum of 1.3 gal (5 L) of fuelto restart the engine. If your vehicle isout of fuel and on a steep slope, morefuel may be required.
•You may need to switch the ignitionfrom off to on several times afterrefueling to allow the fuel system topump the fuel from the tank to theengine. When restarting, cranking timetakes a few seconds longer thannormal.
Filling a Portable Fuel Container
Use the following guidelines to avoidelectrostatic charge build-up, which canproduce a spark, when filling anungrounded fuel container:
•Only use an approved fuel container totransfer fuel to your vehicle. Place thecontainer on the ground when filling it.
•Do not fill a fuel container when it isinside your vehicle (including the cargoarea).
•Keep the fuel pump nozzle in contactwith the fuel container when filling it.
•Do not use a device that holds the fuelpump nozzle lever in the fill position.
Adding Fuel From a Portable FuelContainer
WARNINGS
Do not insert the nozzle of a fuelcontainer or an aftermarket funnelinto the fuel system filler neck. Thismay damage the fuel system filler neck orits seal and cause fuel to run onto theground.
Do not try to pry open or push openthe capless fuel system with foreignobjects. This could damage the fuelsystem and its seal and cause injury to youor others.
Do not dispose of fuel in thehousehold refuse or the publicsewage system. Use an authorizedwaste disposal facility.
When refueling the vehicle fuel tank froma fuel container, use the plastic funnelincluded with your vehicle. See Fuel FillerFunnel Location (page 155).
Note:Do not use aftermarket funnels asthey will not work with the capless fuelsystem and can damage it.
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When refueling the vehicle fuel tank froma fuel container, do the following:
1.Fully open the fuel tank filler door untilit engages.
2. Fully insert the plastic funnel into thefuel tank filler pipe opening.
3. Add fuel to your vehicle from the fuelcontainer.
4. Remove the plastic funnel from thefuel tank filler pipe opening.
5. Fully close the fuel tank filler door.
6. Clean the plastic funnel and place itback in your vehicle or properly disposeof it.
Note:Extra funnels can be purchased froman authorized dealer if you choose todispose of the funnel.
REFUELING
WARNINGS
Do not overfill the fuel tank. Thepressure in an overfilled tank maycause leakage and lead to fuel sprayand fire.
WARNINGS
Do not try to pry open or push openthe capless fuel system with foreignobjects. This could damage the fuelsystem and its seal and cause injury to youor others.
Do not remove the fuel pump nozzlefrom its fully inserted position whenrefueling.
When refueling always shut theengine off and never allow sparks oropen flames near the fuel tank fillervalve. Never smoke or use a cell phonewhile refueling. Fuel vapor is extremelyhazardous under certain conditions. Avoidinhaling excess fumes.
Stop refueling when the fuel pumpnozzle automatically shuts off for thefirst time. Failure to follow this willfill the expansion space in the fuel tank andcould lead to fuel overflowing.
Wait at least 10 seconds beforeremoving the fuel pump nozzle toallow any residual fuel to drain intothe fuel tank.
The fuel system may be underpressure. If you hear a hissing soundnear the fuel filler door, do not refueluntil the sound stops. Otherwise, fuel mayspray out, which could cause seriouspersonal injury.
Read and follow all the instructionson the pump island.
1. When you stop your vehicle, shift intopark (P) or neutral (N) and switch theignition off.
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•Turn the ignition off before fueling; aninaccurate reading results if the engineis left running.
•Use the same fill rate(low-medium-high) each time the tankis filled.
•Allow no more than two automaticclick-offs when filling.
Results are most accurate when the fillingmethod is consistent.
Calculating Fuel Economy
Do not measure fuel economy during thefirst 1000 miles (1600 kilometers) ofdriving (this is your engine’s break-inperiod); a more accurate measurement isobtained after 2000 miles - 3000 miles(3200 kilometers - 4800 kilometers). Also,fuel expense, frequency of fill ups or fuelgauge readings are not accurate ways tomeasure fuel economy.
1.Fill the fuel tank completely and recordthe initial odometer reading.
2. Each time you fill the tank, record theamount of fuel added.
3. After at least three to five tank fill ups,fill the fuel tank and record the currentodometer reading.
4. Subtract your initial odometer readingfrom the current odometer reading.
5. Calculate fuel economy by dividingmiles traveled by gallons used (ForMetric: Multiply liters used by 100, thendivide by kilometers traveled).
Keep a record for at least one month andrecord the type of driving (city or highway).This provides an accurate estimate of thevehicle’s fuel economy under currentdriving conditions. Additionally, keepingrecords during summer and winter showhow temperature impacts fuel economy.In general, lower temperatures mean lowerfuel economy.
EMISSION CONTROL SYSTEM
WARNINGS
Do not park, idle, or drive your vehiclein dry grass or other dry ground cover.The emission system heats up theengine compartment and exhaust system,which can start a fire.
Exhaust leaks may result in entry ofharmful and potentially lethal fumesinto the passenger compartment. Ifyou smell exhaust fumes inside yourvehicle, have your dealer inspect yourvehicle immediately. Do not drive if yousmell exhaust fumes.
Your vehicle is equipped with variousemission control components and acatalytic converter that will enable yourvehicle to comply with applicable exhaustemission standards.
To make sure that the catalytic converterand other emission control componentscontinue to work properly:
•Use only the specified fuel listed.
•Avoid running out of fuel.
•Do not turn off the ignition while yourvehicle is moving, especially at highspeeds.
•Have the items listed in scheduledmaintenance information performedaccording to the specified schedule.
The scheduled maintenance items listedin scheduled maintenance information areessential to the life and performance ofyour vehicle and to its emissions system.
If you use anything other than Ford,Motorcraft or Ford-authorized parts formaintenance replacements or for serviceof components affecting emission control,such non-Ford parts should be equivalentto genuine Ford Motor Company parts inperformance and durability.
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Fuel and Refueling

Illumination of the service engine soonindicator, charging system warning light orthe temperature warning light, fluid leaks,strange odors, smoke or loss of enginepower could indicate that the emissioncontrol system is not working properly.
An improperly operating or damagedexhaust system may allow exhaust toenter the vehicle. Have a damaged orimproperly operating exhaust systeminspected and repaired immediately.
Do not make any unauthorized changes toyour vehicle or engine. By law, vehicleowners and anyone who manufactures,repairs, services, sells, leases, tradesvehicles, or supervises a fleet of vehiclesare not permitted to intentionally removean emission control device or prevent itfrom working. Information about yourvehicle’s emission system is on the VehicleEmission Control Information Decallocated on or near the engine. This decalalso lists engine displacement.
Please consult your warranty informationfor complete details.
On-Board Diagnostics (OBD-II)
Your vehicle has a computer known as theon-board diagnostics system (OBD-II) thatmonitors the engine’s emission controlsystem. The system protects theenvironment by making sure that yourvehicle continues to meet governmentemission standards. The OBD-II systemalso assists a service technician in properlyservicing your vehicle.
When the service engine soonindicator illuminates, the OBD-IIsystem has detected amalfunction. Temporary malfunctions maycause the service engine soon indicator toilluminate. Examples are:
1. Your vehicle has run out of fuel—theengine may misfire or run poorly.
2. Poor fuel quality or water in thefuel—the engine may misfire or runpoorly.
3. The fuel fill inlet may not have closedproperly. See Refueling (page 156).
4. Driving through deep water—theelectrical system may be wet.
You can correct these temporarymalfunctions by filling the fuel tank withgood quality fuel, properly closing the fuelfill inlet or letting the electrical system dryout. After three driving cycles without theseor any other temporary malfunctionspresent, the service engine soon indicatorshould stay off the next time you start theengine. A driving cycle consists of a coldengine startup followed by mixed city andhighway driving. No additional vehicleservice is required.
If the service engine soon indicator remainson, have your vehicle serviced at the firstavailable opportunity. Although somemalfunctions detected by the OBD-II maynot have symptoms that are apparent,continued driving with the service enginesoon indicator on can result in increasedemissions, lower fuel economy, reducedengine and transmission smoothness andlead to more costly repairs.
Readiness for Inspection andMaintenance (I/M) Testing
Some state and provincial and localgovernments may haveInspection/Maintenance (I/M) programsto inspect the emission control equipmenton your vehicle. Failure to pass thisinspection could prevent you from gettinga vehicle registration.
If the service engine soonindicator is on or the bulb doesnot work, your vehicle may needservice. See On-Board Diagnostics.
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Fuel and Refueling

Your vehicle may not pass the I/M test ifthe service engine soon indicator is on ornot working properly (bulb is burned out),or if the OBD-II system has determinedthat some of the emission control systemshave not been properly checked. In thiscase, the vehicle is not ready for I/Mtesting.
If the vehicle’s engine or transmission hasjust been serviced, or the battery hasrecently run down or been replaced, theOBD-II system may indicate that thevehicle is not ready for I/M testing. Todetermine if the vehicle is ready for I/Mtesting, turn the ignition key to the onposition for 15 seconds without crankingthe engine. If the service engine soonindicator blinks eight times, it means thatthe vehicle is not ready for I/M testing; ifthe service engine soon indicator stays onsolid, it means that your vehicle is readyfor I/M testing.
The OBD-II system checks the emissioncontrol system during normal driving. Acomplete check may take several days.
If the vehicle is not ready for I/M testing,you can perform the following driving cycleconsisting of mixed city and highwaydriving:
1. 15 minutes of steady driving on anexpressway or highway followed by 20minutes of stop-and-go driving with atleast four 30-second idle periods.
2. Allow your vehicle to sit for at leasteight hours with the ignition off. Then,start the vehicle and complete theabove driving cycle. The vehicle mustwarm up to its normal operatingtemperature. Once started, do not turnoff the vehicle until the above drivingcycle is complete.
If the vehicle is still not ready for I/Mtesting, you need to repeat the abovedriving cycle.
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Fuel and Refueling

AUTOMATIC TRANSMISSION
WARNINGS
Always set the parking brake fullyand make sure you shift the gearshiftlever to park (P). Switch the ignitionoff and remove the key whenever you leaveyour vehicle.
Do not apply the brake pedal andaccelerator pedal simultaneously.Applying both pedals simultaneouslyfor more than a few seconds will limitengine rpm, which may result in difficultymaintaining speed in traffic and could leadto serious injury.
Understanding the Shift Positionsof Your Automatic Transmission
Putting your vehicle in gear:
1. Fully press down the brake pedal.
2. Move the selector to the desired gear.
3. Come to a complete stop.
4. Move the selector to park (P).
Park (P)
With the transmission in park (P), yourvehicle locks the transmission andprevents the wheels from turning. Alwayscome to a complete stop before puttingyour vehicle into and out of park (P). Anaudible chime sounds once you select park(P).
When the ignition is turned off, your vehiclewill automatically shift into park (P). If theignition is turned off while the vehicle ismoving, it will first shift into neutral (N)until a slow enough speed is reached. Yourvehicle will then shift into park (P)automatically.
Automatic Return to Park
Note:This feature will not operate whenyour vehicle is in Stay in Neutral mode orneutral tow.
Your vehicle has a safety feature that willautomatically shift your vehicle into park(P) when any of the following conditionsoccur:
•You turn the vehicle off.
•You open the driver's door with yoursafety belt unlatched.
•Your safety belt is unlatched while thedriver's door is open.
If you turn your vehicle off while moving,your vehicle will first shift into neutral (N)until it slows down enough to shift intopark (P) automatically.
Note:If you have waited an extendedperiod of time (2-15 minutes) before startingyour vehicle, unlatching your safety belt willcause this feature to activate, even with thedriver's door closed.
Note:This feature may not work properlyif the door ajar switch is malfunctioning. Ifyour door ajar indicator does not illuminatewhen you open the driver’s door or theindicator illuminates with the driver’s doorclosed, see your authorized dealer.
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TransmissionE224178

Reverse (R)
With the selector in reverse (R), yourvehicle moves backward. Always come toa complete stop before shifting into andout of reverse (R).
Neutral (N)
With the selector in neutral (N), yourvehicle can be started and is free to roll.Hold the brake pedal down while in thisposition.
Stay in Neutral Mode
Note:Always put your vehicle in Stay inNeutral mode when entering an automaticcar wash. Failure to do this could result invehicle damage not covered by warranty.
Stay in Neutral mode allows your vehicleto stay in neutral when you exit yourvehicle. Your vehicle must be stationary toenter this mode.
To enter Stay in Neutral mode:
•Move the transmission selector toneutral (N).
•A message will appear in yourinformation display screen promptingyou to press the low (L) button.
•Press the low (L) button again to enterStay in Neutral mode.
To exit Stay in Neutral mode, select a gearother than low (L).
A message will appear in your informationdisplay screen when your vehicle hasentered Stay in Neutral mode.
Drive (D)
Drive (D) is the normal driving position forthe best fuel economy.
Grade Assist
Press the grade assist button to activategrade assist. The grade assist lamp willappear in the instrument cluster. Press thebutton again to switch the system off.
Grade assist:
•Provides additional grade braking witha combination of engine motoring andhigh-voltage battery charging to helpmaintain vehicle speed whendescending a grade.
•As your vehicle determines the amountof engine motoring and high-voltagebattery charging, you may notice theengine speed increasing anddecreasing to help maintain yourvehicle speed when descending agrade.
•The grade assist lamp in the instrumentcluster is illuminated.
Low (L)
•Provides maximum engine braking.
•The transmission may be shifted intolow (L) at any vehicle speed.
•Is not intended for use under extendedor normal driving conditions and resultsin lower fuel economy.
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Brake-Shift Interlock Override
WARNINGS
Do not drive your vehicle until youverify that the brake lamps areworking.
When doing this procedure, you needto take the transmission out of park(P) which means your vehicle canroll freely. To avoid unwanted vehiclemovement, always fully set the parkingbrake prior to doing this procedure. Usewheels chocks if appropriate.
If the parking brake is fully released,but the brake warning lamp remainsilluminated, the brakes may not beworking properly. Have your vehiclechecked as soon as possible.
Note:See your authorized dealer as soonas possible if this procedure is used.
Note:For some markets this feature isdisabled.
Note:This feature will only function if your12-volt battery has power. If vehicle batteryvoltage is not sufficient, an external 12-voltpower source (for example, jumper cables,battery charger or jump pack) may berequired to function the interlock overrideswitch.
Use the brake-shift interlock override tomove your transmission from the parkposition in the event of an electricalmalfunction. If your vehicle has a deadbattery, an external power source will berequired.
1. Apply the parking brake and turn yourignition off before performing thisprocedure.
2. Locate your brake-shift interlockaccess slot. The slot is located in yourcenter console storage bin. The accessslot does not have a label.
Note:Make sure that you correctly identifythe access hole as not to damage the mediahub.
3. Using a tool, press and hold the brakeshift interlock switch. The shift buttonson the instrument panel will flash whenyour vehicle is in override mode.
4.With the override switch still held, pressthe neutral button (N) to shift frompark.
5. Release the override button.
6. Your vehicle will remain in Stay inNeutral mode for wrecker towingpurposes or can be shifted to thedesired gear and driven (if possible).
7. Release the parking brake.
If Your Vehicle Gets Stuck In Mudor Snow
Note:Do not rock the vehicle if the engineis not at normal operating temperature ordamage to the transmission may occur.
Note:Do not rock the vehicle for more thana minute or damage to the transmission andtires may occur, or the engine may overheat.
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