warning FORD FUSION/HYBRID 2020 Owners Manual

CHANGING THE ENGINE AIR
FILTER
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.
When changing the air filter element, use
only the air filter element listed. See
Capacities and Specifications
(page
310).
Change the air filter element at the proper
interval. See
Scheduled Maintenance
(page 421).
Note: Failure to use the correct air filter
element may result in severe engine
damage. The customer warranty may be
void for any damage to the engine if the
correct air filter element is not used. 1. Loosen the 5 bolts on the air cleaner
cover.
2. Remove the air cleaner cover.
3. Remove the engine air filter element from the engine air cleaner assembly. 4.
Wipe any dirt or debris from the air filter
housing and cover to make sure no dirt
gets in the engine and to make sure you
have a good seal.
5. Install the new engine air filter element
to the engine air cleaner assembly.
6. Install the air cleaner cover.
7. Tighten the 5 bolts to the air cleaner cover.
ENGINE COOLANT CHECK WARNING:
Do not remove the
coolant reservoir cap when the engine is
on or the cooling system is hot. Wait 10
minutes for the cooling system to cool
down. Cover the coolant reservoir cap
with a thick cloth to prevent the
possibility of scalding and slowly remove
the cap. Failure to follow this instruction
could result in personal injury. WARNING:
Do not put coolant in
the windshield washer reservoir. If
sprayed on the windshield, coolant could
make it difficult to see through the
windshield. WARNING:
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 you loosen
the cap slightly. WARNING:
Do not add coolant
further than the MAX mark.
260
Fusion Energi (CC7) Hybrid Electric Vehicle (HEV)/Plug-In Hybrid Electric Vehicle (PHEV), Canada/United States of America, enUSA, Edition date: 201905, Second-Printing MaintenanceE146048

Your vehicle has two separate cooling
systems. One for cooling the engine and a
separate system 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.
When the engine is cold, check the
concentration and level of the coolant at
the intervals listed in the scheduled
maintenance information. See Scheduled
Maintenance (page 421).
Note: Make sure that the coolant level is
between the
MIN and the MAX marks on
the coolant reservoir.
Note: Coolant expands when it is hot. The
level may extend beyond the
MAX mark.
Maintain coolant concentration within
48% to 50%, which equates to a freeze
point between -30°F (-34°C) and -34°F
(-37°C). Coolant concentration should be
checked using a refractometer. We do not
recommend the use of hydrometers or
coolant test strips for measuring coolant
concentration.
Adding Coolant WARNING:
Do not remove the
coolant reservoir cap when the engine is
on or the cooling system is hot. Wait 10
minutes for the cooling system to cool
down. Cover the coolant reservoir cap
with a thick cloth to prevent the
possibility of scalding and slowly remove
the cap. Failure to follow this instruction
could result in personal injury. WARNING:
Do not add engine
coolant when the engine is on or the
cooling system is hot. Failure to follow
this instruction could result in personal
injury. Note:
Automotive fluids are not
interchangeable. Do not use coolant or
windshield washer fluid outside of its
specified function and vehicle location.
Note: Do not use stop leak pellets, cooling
system sealants, or non-specified additives
as they can cause damage to the engine
cooling or heating systems. Resulting
component damage may not be covered by
the vehicle Warranty.
It is very important to use prediluted
coolant approved to the correct
specification in order to avoid plugging the
small passageways in the engine cooling
system. See
Capacities and
Specifications (page 314). Do not mix
different colors or types of coolant in your
vehicle. Mixing of engine coolants or using
an incorrect coolant may harm the engine
or cooling system components and may
not be covered by the vehicle Warranty.
Note: If prediluted coolant is not available,
use the approved concentrated coolant
diluting it to 50/50 with distilled water. See
Capacities and Specifications (page 310).
Using water that has not been deionized
may contribute to deposit formation,
corrosion and plugging of the small cooling
system passageways.
Note: Coolants marketed for all makes and
models may not be approved to Ford
specifications and may cause damage to
the cooling system. Resulting component
damage may not be covered by the vehicle
Warranty.
If the coolant level is at or below the
minimum mark, add prediluted coolant
immediately.
To top up the coolant level do the
following:
1. Unscrew the cap slowly. Any pressure escapes as you unscrew the cap.
261
Fusion Energi (CC7) Hybrid Electric Vehicle (HEV)/Plug-In Hybrid Electric Vehicle (PHEV), Canada/United States of America, enUSA, Edition date: 201905, Second-Printing Maintenance

Coolant Change
At specific mileage intervals, as listed in
the scheduled maintenance information,
the coolant should be changed. Add
prediluted coolant approved to the correct
specification. See Capacities and
Specifications (page 310).
Fail-Safe Cooling
Fail-safe cooling allows you to temporarily
drive your vehicle before any incremental
component damage occurs. The fail-safe
distance depends on ambient
temperature, vehicle load and terrain.
How Fail-Safe Cooling Works
If the engine begins to overheat, the
coolant temperature gauge moves toward
the red zone: A warning lamp illuminates and
a message may appear in the
information display.
If the engine reaches a preset
over-temperature condition, the engine
automatically switches to alternating
cylinder operation. Each disabled cylinder
acts as an air pump and cools the engine.
When this occurs, your vehicle still
operates, however:
• Engine power is limited.
• The air conditioning system turns off.
Continued operation increases the engine
temperature, causing the engine to
completely shut down. Your steering and
braking effort increases in this situation.
When the engine temperature cools, you
can re-start the engine. Have your vehicle
checked as soon as possible to minimize
engine damage. When Fail-Safe Mode Is Activated WARNING:
Fail-safe mode is for
use during emergencies only. Operate
your vehicle in fail-safe mode only as
long as necessary to bring your vehicle
to rest in a safe location and seek
immediate repairs. When in fail-safe
mode, your vehicle will have limited
power, will not be able to maintain
high-speed operation, and may
completely shut down without warning,
potentially losing engine power, power
steering assist, and power brake assist,
which may increase the possibility of a
crash resulting in serious injury. WARNING:
Do not remove the
coolant reservoir cap when the engine is
on or the cooling system is hot. Wait 10
minutes for the cooling system to cool
down. Cover the coolant reservoir cap
with a thick cloth to prevent the
possibility of scalding and slowly remove
the cap. Failure to follow this instruction
could result in personal injury.
Your vehicle has limited engine power
when in the fail-safe mode, drive your
vehicle with caution. Your vehicle does not
maintain high-speed operation and the
engine may operate poorly.
Remember that the engine is capable of
automatically shutting down to prevent
engine damage. In this situation:
1. Pull off the road as soon as safely possible and switch the engine off.
2. If you are a member of a roadside assistance program, we recommend
that you contact your roadside
assistance service provider.
3. If this is not possible, wait a short period for the engine to cool.
263
Fusion Energi (CC7) Hybrid Electric Vehicle (HEV)/Plug-In Hybrid Electric Vehicle (PHEV), Canada/United States of America, enUSA, Edition date: 201905, Second-Printing Maintenance

4. Check the coolant level. If the coolant
level is at or below the minimum mark,
add prediluted coolant immediately.
5. When the engine temperature cools, you can re-start the engine. Have your
vehicle checked as soon as possible to
minimize engine damage.
Note: Driving your vehicle without repair
increases the chance of engine damage.
Engine Coolant Temperature
Management (If Equipped) WARNING:
To reduce the risk of
crash and injury, be prepared that the
vehicle speed may reduce and the
vehicle may not be able to accelerate
with full power until the coolant
temperature reduces.
If you tow a trailer with your vehicle, the
engine may temporarily reach a higher
temperature during severe operating
conditions, for example ascending a long
or steep grade in high ambient
temperatures.
At this time, you may notice the coolant
temperature gauge moves toward the red
zone and a message may appear in the
information display.
You may notice a reduction in vehicle
speed caused by reduced engine power in
order to manage the engine coolant
temperature. Your vehicle may enter this
mode if certain high-temperature and
high-load conditions take place. The
amount of speed reduction depends on
vehicle loading, grade and ambient
temperature. If this occurs, there is no need
to pull off the road. You can continue to
drive your vehicle. The air conditioning may automatically
turn on and off during severe operating
conditions to protect the engine from
overheating. When the coolant
temperature decreases to the normal
operating temperature, the air conditioning
turns on.
If the coolant temperature gauge moves
fully into the red zone, or if the coolant
temperature warning or service engine
soon messages appear in your information
display, do the following:
1. Pull off the road as soon as safely
possible and shift the transmission into
park (P).
2. Leave the engine running until the coolant temperature gauge needle
returns to the normal position. If the
temperature does not drop after
several minutes, follow the remaining
steps.
3. Switch the engine off and wait for it to
cool. Check the coolant level.
4. If the coolant level is at or below the minimum mark, add prediluted coolant
immediately.
5. If the coolant level is normal, restart the engine and continue.
AUTOMATIC TRANSMISSION
FLUID CHECK
Note: Transmission fluid should be checked
by an authorized dealer. If required, fluid
should be added by an authorized dealer.
264
Fusion Energi (CC7) Hybrid Electric Vehicle (HEV)/Plug-In Hybrid Electric Vehicle (PHEV), Canada/United States of America, enUSA, Edition date: 201905, Second-Printing Maintenance

Have an authorized dealer check and
change the transmission fluid at the
correct service interval. See Scheduled
Maintenance (page 421). Your
transmission does not consume fluid.
However, the fluid level should be checked
if the transmission is not working properly,
(i.e., if the transmission slips or shifts
slowly) or if you notice some sign of fluid
leakage.
Do not use supplemental transmission
fluid additives, treatments or cleaning
agents. The use of these materials may
affect transmission operation and result
in damage to internal transmission
components.
BRAKE FLUID CHECK WARNING:
Do not use any fluid
other than the recommended brake fluid
as this will reduce brake efficiency. Use
of incorrect fluid could result in the loss
of vehicle control, serious personal injury
or death. WARNING:
Only use brake fluid
from a sealed container. Contamination
with dirt, water, petroleum products or
other materials may result in brake
system damage or failure. Failure to
adhere to this warning could result in the
loss of vehicle control, serious personal
injury or death. WARNING:
Do not allow the fluid
to touch your skin or eyes. If this
happens, rinse the affected areas
immediately with plenty of water and
contact your physician. WARNING:
The brake system
could be affected if the brake fluid level
is below the MIN mark or above the MAX
mark on the brake fluid reservoir. 1. Park your vehicle on a level surface.
2. Look at the brake fluid reservoir to see
where the brake fluid level is relative
to the
MIN and the MAX marks on the
reservoir.
Note: If the brake fluid level is between the
MIN
and the MAX marks on the reservoir, it
is acceptable.
Note: If the brake fluid level is below the
MIN
mark or above the MAX mark, have
your vehicle checked as soon as possible.
Note: To avoid fluid contamination, the
reservoir cap must remain in place and fully
tight, unless you are adding fluid.
Only use fluid that meets our
specifications. See
Capacities and
Specifications (page 310).
Brake Fluid Service Interval
Brake fluid absorbs water over time which
degrades the effectiveness of the brake
fluid. Change the brake fluid at the
specified intervals to prevent degraded
braking performance.
265
Fusion Energi (CC7) Hybrid Electric Vehicle (HEV)/Plug-In Hybrid Electric Vehicle (PHEV), Canada/United States of America, enUSA, Edition date: 201905, Second-Printing MaintenanceE170684

For detailed interval information, see
Scheduled Maintenance in your Owner's
Manual or your local maintenance guide.
CHANGING THE 12V BATTERY
WARNING: Batteries normally
produce explosive gases which can
cause personal injury. Therefore, do not
allow flames, sparks or lighted
substances to come near the battery.
When working near the battery, always
shield your face and protect your eyes.
Always provide correct ventilation. WARNING:
When lifting a
plastic-cased battery, excessive pressure
on the end walls could cause acid to flow
through the vent caps, resulting in
personal injury and damage to the
vehicle or battery. Lift the battery with a
battery carrier or with your hands on
opposite corners. WARNING:
Keep batteries out of
reach of children. Batteries contain
sulfuric acid. Avoid contact with skin,
eyes or clothing. Shield your eyes when
working near the battery to protect
against possible splashing of acid
solution. In case of acid contact with skin
or eyes, flush immediately with water for
a minimum of 15 minutes and get prompt
medical attention. If acid is swallowed,
call a physician immediately. WARNING:
Battery posts,
terminals and related accessories
contain lead and lead compounds,
chemicals known to the State of
California to cause cancer and
reproductive harm. Wash your hands
after handling
. The 12V battery is located in the left-hand
side of the luggage compartment. Remove
the door to gain access to the battery.
Your vehicle is fitted with a Motorcraft
maintenance-free battery which normally
does not require additional water.
Note:
After cleaning or replacing the
battery, make sure you reinstall the battery
cover or shield.
When a battery replacement is required,
you must use a recommended
replacement battery that matches the
electrical requirements of the vehicle.
Note: Contact an authorized dealer for low
voltage battery access, testing or
replacement.
To make sure the battery management
system works correctly, do not connect an
electrical device ground connection
directly to the low voltage battery negative
post. This can cause inaccurate
measurements of the battery condition
and potential incorrect system operation.
Note: If you add electrical accessories or
components to the vehicle, it may adversely
affect the low voltage battery performance
and durability. This may also affect the
performance of other electrical systems in
the vehicle.
For longer, trouble-free operation, keep the
top of the battery clean and dry.
266
Fusion Energi (CC7) Hybrid Electric Vehicle (HEV)/Plug-In Hybrid Electric Vehicle (PHEV), Canada/United States of America, enUSA, Edition date: 201905, Second-Printing MaintenanceE168357

Vertical Aim Adjustment Procedure
1. Park the vehicle directly in front of a
wall or screen on a level surface,
approximately 25 ft (7.6 m) away.
2. Measure the height of the headlamp bulb center from the ground and mark
an
8 ft (2.4 m) horizontal reference line
on the vertical wall or screen at this
height.
Note: To see a clearer light pattern for
adjusting, you may want to block the light
from one headlamp while adjusting the
other.
3. Turn on the low beam headlamps to illuminate the wall or screen and open
the hood. 4. On the wall or screen you will observe
a flat zone of high intensity light
located at the top of the right hand
portion of the beam pattern. If the top
edge of the high intensity light zone is
not at the horizontal reference line, the
headlamp will need to be adjusted. 5. Locate the vertical adjuster on each
headlamp. Using a Phillips #2
screwdriver, turn the adjuster either
clockwise or counterclockwise in order
to adjust the vertical aim of the
headlamp. The horizontal edge of the
brighter light should touch the
horizontal reference line.
6. Close the hood and turn off the lamps.
Horizontal Aim Adjustment
Horizontal aim is not required for this
vehicle and is not adjustable.
WASHER FLUID CHECK WARNING:
If you operate your
vehicle in temperatures below 40°F
(5°C), use washer fluid with antifreeze
protection. Failure to use washer fluid
with antifreeze protection in cold
weather could result in impaired
windshield vision and increase the risk
of injury or accident.
Add fluid to fill the reservoir if the level is
low. Only use a washer fluid that meets
Ford specifications. See
Capacities and
Specifications (page 310).
268
Fusion Energi (CC7) Hybrid Electric Vehicle (HEV)/Plug-In Hybrid Electric Vehicle (PHEV), Canada/United States of America, enUSA, Edition date: 201905, Second-Printing MaintenanceE142465 E145594

7.
Remove the two outmost front bumper
cover lower fasteners, only on the side
of the headlamp you are servicing, by
turning them counterclockwise. 8.
Separate the front bumper cover from
the fender by gently pulling the front
bumper cover to the outside of the
vehicle 1.2 in (3 cm). 9. From the front of the vehicle, gently
pull the front bumper cover forward
4 in (10 cm)
by grasping it next to the
headlamp to be serviced and in the
lower front of the wheel opening. 10. Gently pull the headlamp assembly
outward to disengage it from the
lower fixing point.
11. Carefully lift the headlamp and remove it from the vehicle.
12. Disconnect the electrical connector from the headlamp assembly by
pushing the release tab on the
connector.
CHANGING A BULB WARNING:
Switch the lamps and
the ignition off. Failure to follow this
warning could result in serious personal
injury. WARNING: Bulbs can become hot.
Let the bulb cool down before removing
it. Failure to do so could result in
personal injury.
Use the correct specification bulb. See
Bulb Specification Chart
(page 319).
Install in the reverse order unless otherwise
stated.
271
Fusion Energi (CC7) Hybrid Electric Vehicle (HEV)/Plug-In Hybrid Electric Vehicle (PHEV), Canada/United States of America, enUSA, Edition date: 201905, Second-Printing MaintenanceE159696 E159697 E159698 E159699

To clean the windshield and wiper blades:
•
Clean the windshield with a
non-abrasive glass cleaner. When
cleaning the interior of the windshield,
avoid getting any glass cleaner on the
instrument panel or door panels. Wipe
any glass cleaner off these surfaces
immediately.
• For windshields contaminated with
tree sap, chemicals, wax or bugs, clean
the entire windshield using steel wool
(no greater than 0000 grade) in a
circular motion and rinse with water.
• Clean the wiper blades with isopropyl
rubbing alcohol or windshield washer
concentrate.
Note: Do not use razor blades or other
sharp objects to clean or remove decals
from the inside of the heated rear window.
The vehicle warranty does not cover
damage caused to the heated rear window
grid lines.
CLEANING THE INTERIOR WARNING: Do not use cleaning
solvents, bleach or dye on the vehicle's
seatbelts, as these actions may weaken
the belt webbing. WARNING:
On vehicles equipped
with seat-mounted airbags, do not use
chemical solvents or strong detergents.
Such products could contaminate the
side airbag system and affect
performance of the side airbag in a crash.
For fabric, carpets, cloth seats and seats
equipped with side airbags:
• Remove dust and loose dirt with a
vacuum cleaner.
• Remove light stains and soil with
Motorcraft Professional Strength
Carpet & Upholstery Cleaner. •
If grease or tar is present on the
material, spot-clean the area first with
Motorcraft Spot and Stain Remover. In
Canada, use Motorcraft Multi-Purpose
Cleaner.
• If a ring forms on the fabric after spot
cleaning, clean the entire area
immediately (but do not oversaturate)
or the ring will set.
• Do not use household cleaning
products or glass cleaners, which can
stain and discolor the fabric and affect
the flame retardant abilities of the seat
materials.
Mirrors
Do not clean the housing or glass of any
mirror with harsh abrasives, fuel or other
petroleum or ammonia-based cleaning
products.
CLEANING THE INSTRUMENT
PANEL AND INSTRUMENT
CLUSTER LENS WARNING:
Do not use chemical
solvents or strong detergents when
cleaning the steering wheel or
instrument panel to avoid contamination
of the airbag system.
Note: Follow the same procedure as
cleaning leather seats for cleaning leather
instrument panels and leather interior trim
surfaces. See
Cleaning Leather Seats
(page 279).
Clean the instrument panel and cluster
lens with a clean, damp and soft cloth,
then use a clean, dry and soft cloth to dry
these areas.
278
Fusion Energi (CC7) Hybrid Electric Vehicle (HEV)/Plug-In Hybrid Electric Vehicle (PHEV), Canada/United States of America, enUSA, Edition date: 201905, Second-Printing Vehicle Care

General Information
WARNING: Failure to follow these
guidelines could result in an increased
risk of loss of vehicle control, injury or
death.
Note: Do not use the kit if a tire has become
severely damaged. Only punctures located
within the tire tread can be sealed with the
kit.
Do not attempt to repair punctures larger
than 0.24 in (6 mm) or damage to the tire's
sidewall. The tire may not completely seal.
Loss of air pressure may adversely affect
tire performance. For this reason:
Note: Do not drive the vehicle above
50 mph (80 km/h)
.
Note: Do not drive further than
120 mi
(200 km). Drive only to the closest
authorized Ford dealer or tire repair shop to
have your tire inspected.
• Drive carefully and avoid abrupt
steering maneuvers.
• Periodically monitor tire inflation
pressure in the affected tire; if the tire
is losing pressure, have the vehicle
towed.
• Read the information in the Tips for
Use of the Kit section to make sure safe
operation of the kit and your vehicle.
Tips for Use of the Kit
To ensure safe operation of the kit:
• Read all instructions and cautions fully.
• Before operating the kit, make sure
your vehicle is safely off the road and
away from moving traffic. Turn on the
hazard lights.
• Always set the parking brake to ensure
the vehicle doesn't move unexpectedly. •
Do not remove any foreign objects,
such as nails or screws, from the tire.
• When using the kit, leave the engine
running (only if the vehicle is outdoors
or in a well-ventilated area) so the
compressor does not drain the
vehicle's battery.
• Do not allow the compressor to
operate continuously for more than 15
minutes. This will help prevent the
compressor from overheating.
• Never leave the kit unattended during
operation.
• Sealant compound contains latex.
Those with latex sensitivities should
use appropriate precautions to avoid
an allergic reaction.
• Keep the kit away from children.
• Only use the kit when the ambient
temperature is between -22°F (-30°C)
and 158°F (70°C).
• Only use the sealing compound before
the use-by date. The use-by date is on
a label on the sealant canister and can
be seen through the rectangular
viewing window on the bottom of the
compressor. Check the use-by date
regularly and replace the canister when
the sealant expires.
• Do not store the kit unsecured inside
the passenger compartment of the
vehicle as it may cause injury during a
sudden stop or crash. Always store the
kit in its original location.
• After sealant use, the tire pressure
monitoring system sensor and valve
stem on the wheel must be replaced
by an authorized Ford dealer.
• Operating the kit could cause an
electrical disturbance in radio, CD, and
DVD player operation.
284
Fusion Energi (CC7) Hybrid Electric Vehicle (HEV)/Plug-In Hybrid Electric Vehicle (PHEV), Canada/United States of America, enUSA, Edition date: 201905, Second-Printing Wheels and Tires