Ford MKZ HYBRID 2019 Modifiers Manual

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2019

FUSION HYBRID

MKZ HYBRID

FUSION ENERGI

MODIFIERS GUIDE

2019 Fusion Hybrid Modifiers Guide, 8/2018

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Page 3 SECTION 0: Introduction Table of Contents Contents PAGE Introduction ....................................Genuine Ford Accessories For Your Vehicle .......................... © Copyright Ford 2018 FoMoCo 2019 Fusion Hybrid Modifiers Guide, 8/2018...
Page 4: Genuine Ford Accessories For Your Vehicle
This means that genuine Ford accessories purchased along with your new vehicle and installed by the dealer are covered for the full length of your new vehicle's limited warranty — 3 years or 60,000 km (36,000 mi), whichever occurs first. Contact your dealer for details and a copy of the warranty.
Page 5 SECTION 1: General Information Table of Contents Contents PAGE Section 1: General Information ..............................Important Safety Notice ................................Good Practices ..................................Tires and Loading ................................... Vehicle Storage ..................................© Copyright Ford 2018 FoMoCo 2019 Fusion Hybrid Modifiers Guide, 8/2018...
Page 6: Section 1: General Information
NOTE: The descriptions and specifications contained in this guide were in effect at the time this guide was approved for printing. Ford Motor Company reserves the right to discontinue models at any time, or change specifications or design without notice and without incurring obligation.
Page 7: Quality Assurance
All appropriate systems should be checked for leaks. A road test should be performed to verify that all systems are operating correctly. All systems and functions that were provided by Ford should be checked to make sure that they function correctly after the build process.
Page 8: Vehicle Loading
Section 1: General Information Do not exceed 48 km/h (30 mph) with tire cables or chains on your vehicle. • Consult your dealer for information on other Ford approved methods of traction control. Vehicle Loading WARNING: The appropriate loading capacity of your vehicle can be limited either by volume capacity (how much space is available) or by payload capacity (how much weight the vehicle should carry).
Page 9: Vehicle Storage - Body
If the vehicle is stored for a period longer than 15 days, it should be moved several feet during each 15-day period. The vehicle should be parked after being moved so that a different portion of the tread contacts the ground. © Copyright Ford 2018 FoMoCo 2019 Fusion Hybrid Modifiers Guide, 8/2018...
Page 10 Electrical Systems Management ............................2-10 Generator Output .................................. 2-10 Vehicle Component Electrical Loads ............................ 2-10 General Guidelines ................................2-11 Splices and Repairs ................................2-17 Wiring Reference Information ............................... 2-22 © Copyright Ford 2018 FoMoCo 2019 Fusion Hybrid Modifiers Guide, 8/2018...
Page 11: Section 2: Electrical
The vehicle speed signal is sent from the BCM to other vehicle modules through the CAN bus. There is a specific wire/circuit that carries the vehicle speed signal pulses. © Copyright Ford 2018 FoMoCo 2019 Fusion Hybrid Modifiers Guide, 8/2018...
Page 12 If the center safety belt retractor locks and the safety belt webbing prevents the 60 percent backrest from lowering, raise the backrest upward to release the safety belt retractor and the belt webbing. NOTE: FHEV (HYBRID) BATTERY. Remove the high-voltage battery service disconnect cover. © Copyright Ford 2018 FoMoCo 2019 Fusion Hybrid Modifiers Guide, 8/2018...
Page 14 • P ull the Lever Position Assurance (LPA) tab toward the front of the vehicle to remove. • P ull the lever handle outward to disengage the interlock. • R otate the lever to horizontal and remove the battery high-voltage service disconnect. © Copyright Ford 2018 FoMoCo 2019 Fusion Hybrid Modifiers Guide, 8/2018...
Page 15 Electrical Section 2: Electrical NOTE: PHEV (ENERGI) BATTERY SHOWN. Remove the high-voltage battery service disconnect cover. © Copyright Ford 2018 FoMoCo 2019 Fusion Hybrid Modifiers Guide, 8/2018...
Page 17 • P ull the Lever Position Assurance (LPA) tab toward the front of the vehicle to remove. • P ull the lever handle outward to disengage the interlock. • R otate the lever to horizontal and remove the battery high-voltage service disconnect. © Copyright Ford 2018 FoMoCo 2019 Fusion Hybrid Modifiers Guide, 8/2018...
Page 18: Auxiliary Power Point - 12V
The nominal high-voltage traction battery (HVTB) voltage is 300 volts DC. WARNING: The high-voltage traction battery (HVTB) and charging system contains high-voltage components and wiring. High-voltage cables and wiring are orange in color. © Copyright Ford 2018 FoMoCo 2019 Fusion Hybrid Modifiers Guide, 8/2018...
Page 19: Electrical Systems Management
A/C fan to face — M/H speed (recirculating air) 16.0 Heater fan to foot — M/H speed (fresh air) 16.0 Lighting Exterior and instrument panel lamps (non-dimmable) Headlamps — low beam © Copyright Ford 2018 FoMoCo 2019 Fusion Hybrid Modifiers Guide, 8/2018...
Page 20: Typical Police/Taxi Equipment
Do not cut, weld or screw into the HVTB case or penetrate the batteries in any way. • Air bag restraint systems must remain intact as received from Ford Motor Company. Before modifications are done to the vehicle, the system must be depowered by following the instructions provided in the current Focus Electric Workshop Manual.
Page 21: Keep-Alive Memory (Kam) Power
• Adherence to the above guidelines is not to be construed as approval by Ford Motor Company of any specific revisions or additions to the vehicles original electrical system.
Page 22: Circuit Protection And Electrical Load
This prevents splice and terminal shorts to the shielding. Minimize the length of conductors which extend beyond the shield. Failure to do this reduces the effectiveness of the shield. © Copyright Ford 2018 FoMoCo 2019 Fusion Hybrid Modifiers Guide, 8/2018...
Page 23: Mechanical/Environmental Protection
Tape — Tape is the most basic means of protection. It contains the wires in a loose bundle and provides limited environmental protection. It does not protect against chafing and pinching. — Kendall polyken fiberglass base tape (Ford specification ESB-M3G38-A) is used for engine compartment applications. This durable tape provides protection against cut-through and abrasion commonly found in underhood applications. —...
Page 24: Wire Retention And Routing
• Wiring exposed to weather must provide a drip loop to prevent moisture from being conducted into the device through the wire connection (see figure below). © Copyright Ford 2018 FoMoCo 2019 Fusion Hybrid Modifiers Guide, 8/2018...
Page 25 • The wire retainers and grommets installed by the assembly plant are usually designed to accommodate only the Ford-installed wires. Additional wiring or tubing should be retained by additional clips. When added wires or tubes are routed through sheet metal panels, use new holes with proper wire protection and sealing.
Page 26: Splices And Repairs
Stagger the splices within a harness to reduce increased harness diameter. Splice only on straight areas as installed, not on bends. • Strip wire ends, making sure that individual conductor strands are not damaged. © Copyright Ford 2018 FoMoCo 2019 Fusion Hybrid Modifiers Guide, 8/2018...
Page 27: Recommended Splicing Method - Solder (For 16 Awg And Smaller Diameter Wire Only)
Disconnect the battery ground cable. Strip wires to appropriate length. Install heat shrink tubing. Twist the wires together. NOTE: Use resin-core mildly-activated (RMA) solder. Do not use acid-core solder. Solder wires together. © Copyright Ford 2018 FoMoCo 2019 Fusion Hybrid Modifiers Guide, 8/2018...
Page 28 Evenly position heat shrink tubing over wire repair. Use a shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. © Copyright Ford 2018 FoMoCo 2019 Fusion Hybrid Modifiers Guide, 8/2018...
Page 29: Heat Shrinkable Tubing (Heat Shrink) (Ford Specification Esb-M99D56-A2)
E6FZ-14488-C Butt Connector Gauge: 10-12, Color: Yellow Heat Shrinkable Tubing (Heat Shrink) (Ford Specification ESB-M99D56-A2) Heat shrinkable tubing is available in various diameters for different splice sizes and configurations. When shrunk, it forms a small, flexible hermetic seal. Other methods (tape, PVC mold) do not provide a hermetic seal and are not recommended. Splice balancing is critical with heat shrink insulation.
Page 30 (1) Crimp should be centered on each end of the butt splice. (2) Wire insulation does not enter butt splice. (3) Wire is visible through inspection hole of splices. © Copyright Ford 2018 FoMoCo 2019 Fusion Hybrid Modifiers Guide, 8/2018...
Page 31: Wiring Reference Information
To obtain information about ordering complete copies of Ford publications, call 1-800-782-4356. In addition, a publications order form can be obtained by writing to: Ford Publications, C/O Helm Inc., PO Box 07150, Detroit, MI 48207. Available publications include Workshop Manuals, Wiring Diagrams manual, PC/ED Manuals and Owner's Literature.
Page 40 SECTION 3: Mounting Table of Contents Contents PAGE Section 3: Mounting ..................................Push Bumpers ..................................Siren and Grille Lights ................................Mounting Equipment to the Vehicle ............................© Copyright Ford 2018 FoMoCo 2019 Fusion Hybrid Modifiers Guide, 8/2018...
Page 41: Section 3: Mounting
Section 3: Mounting Section 3: Mounting Push Bumpers Ford Motor Company does not recommend the installation of any type of push bumper. Siren and Grille Lights NOTICE: Do not modify the cooling system. High-voltage vehicle components may be damaged if any cooling system modifications are attempted.
Page 42 D - Driver airbag • E - Clockspring • F - Collapsible steering column • G - Driver/passenger lower airbag • H - Passenger airbag • I - Passenger side airbag © Copyright Ford 2018 FoMoCo 2019 Fusion Hybrid Modifiers Guide, 8/2018...
Page 43: Safety Belt Retractor
Do not mount any partition hardware on the inboard side of the B-pillar within the bottom 305 mm (12 in). Do not mount any partition hardware that will interfere with the proper sealing of the door. • © Copyright Ford 2018 FoMoCo 2019 Fusion Hybrid Modifiers Guide, 8/2018...
Page 44: Side Impact Sensor
Failure to follow this instruction may result in personal injury. WARNING: Do not attempt to service, repair or modify the air bag supplemental restraint systems (SRS) or its fuses. See your Ford or Lincoln dealer. Failure to follow this instruction may result in personal injury.
Page 45 If the safety belts are removed for any reason, all of the appropriate attaching hardware must be hand started and then tightened to the correct torque specifications as per the Workshop Manual. Proper operation must be verified before returning the vehicle to service. © Copyright Ford 2018 FoMoCo 2019 Fusion Hybrid Modifiers Guide, 8/2018...
Page 46 SECTION 4: Reference Table of Contents Contents PAGE Section 4: Reference ..................................Engineering Drawings ................................© Copyright Ford 2018 FoMoCo 2019 Fusion Hybrid Modifiers Guide, 8/2018...
Page 47: Section 4: Reference
Do not attempt to service, repair or modify the Safety Canopy® System, its fuses, the A, B or C-pillar trim, or the headliner on a vehicle containing a Safety Canopy® System. See your Ford or Lincoln dealer. Failure to follow these instructions may result in personal injury.
Page 48 1. 350 mm (13.779 in) from center of air bag door 2. 350 mm (13.779 in) from center of air bag door 3. 510 mm (20.078 in) 4. 150 mm (5.9 in) 5. 500 mm (19.7 in) © Copyright Ford 2018 FoMoCo 2019 Fusion Hybrid Modifiers Guide, 8/2018...
Page 49 Reference Section 4: Reference 1. 660 mm (25.984 in) from center of air bag door 2. 660 mm (25.984 in) from center of air bag door © Copyright Ford 2018 FoMoCo 2019 Fusion Hybrid Modifiers Guide, 8/2018...
Page 50 Do not mount equipment above the beltline within 200 mm (8 in) of the side glass from the A-pillar leading edge to the rear edge of the C- pillar. • Do not mount equipment on the headliner along the siderails. © Copyright Ford 2018 FoMoCo 2019 Fusion Hybrid Modifiers Guide, 8/2018...

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