Ford FUSION HYBRID 2012 Modifiers Manual
  1. Manuals
  2. Brands
  3. Ford Manuals
  4. Automobile
  5. Fusion hybrid 2012
  6. Modifiers manual

Ford FUSION HYBRID 2012 Modifiers Manual

Hide thumbs Also See for FUSION HYBRID 2012:
Table of Contents

Advertisement

Quick Links

Download this manual See also: Owner's Manual
2012
FUSION HYBRID
MKZ
HYBRID
MODIFIERS GUIDE
FCS-15128-12

Advertisement

Table of Contents
loading

Related Manuals for Ford FUSION HYBRID 2012

Summary of Contents for Ford FUSION HYBRID 2012

  • Page 1 2012 FUSION HYBRID HYBRID MODIFIERS GUIDE FCS-15128-12...

  • Page 2: 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 any obligation.
  • Page 3 SECTION 0 Introduction Contents Introduction..................0-1 Genuine Ford Accessories For Your Vehicle ......0-1 Considerations When Using or Installing Accessories ....0-2 2012 Fusion Hybrid, MKZ Hybrid Modifiers Guide, 09/2011...
  • Page 4 Table of Contents Introduction Ford Motor Company has assembled this guide to assist vehicle modifiers in producing a safe and quality vehicle. Ford believes safety and quality come first. To achieve customer satisfaction, we want to assist modifiers in achieving the highest standards of safety and quality in their vehicles.
  • Page 5 Introduction Introduction Considerations When Using or Installing Accessories For maximum vehicle performance, keep the following information in mind when adding accessories or equipment to your vehicle: • When adding accessories, equipment, passengers and/or luggage to your vehicle, do not exceed the gross vehicle weight rating (GVWR) or gross axle weight rating (GAWR) as indicated on the Safety Compliance Certification Label.

  • Page 6: Table Of Contents

    SECTION 1 General Information Contents Section 1: General Information ............1-1 Important Safety Notice..............1-1 Warnings, Notices and Notes ...........1-2 Making Safety Devices and Elements Inoperative....1-3 Good Practices ................1-3 Process and Quality Assurance Systems ........1-3 Quality Assurance ..............1-3 Minimum and Maximum Screw Sizes ........1-4 Tires and Loading.................1-4 Tire Replacement Requirements ..........1-4 Using Snow Tires and Traction Devices ........1-4...
  • Page 7 SECTION 1 General Information Contents (Continued) Vehicle Storage — Fuel System ..........1-7 Vehicle Storage — Tires............1-7 2012 Fusion Hybrid, MKZ Hybrid Modifiers Guide, 09/2011...

  • Page 8: 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 9: Warnings, Notices And Notes

    General Information Section 1: General Information Warnings, Notices and Notes As you read through this guide, you will come across WARNINGS, NOTICES and NOTES. Each one is there for a specific purpose. WARNINGS remind you to be especially careful in those areas where carelessness can cause you personal injury.

  • Page 10: Making Safety Devices And Elements Inoperative

    All systems and functions that were provided by Ford should be checked to make sure that they function correctly after the build process. The modifier’s Process and Quality Assurance Systems should also make sure that appropriate training is provided to the employees.

  • Page 11: Minimum And Maximum Screw Sizes

    (such as P-metric versus LT-metric or all-season versus all-terrain) as those originally provided by Ford. Use of any tire or wheel not recommended by Ford can affect the safety and performance of your vehicle, which could result in an increased risk of the loss of vehicle control, vehicle rollover, personal injury or death.

  • Page 12: Vehicle Loading

    • 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 13: Vehicle Storage

    General Information Section 1: General Information • Subtract the combined weight of the driver and passengers from XXX kg or XXX lb. • The resulting figure equals the available amount of cargo and luggage load capacity. For example, if the ‘‘XXX’’ amount equals 1,400 lb and there will be five 150 lb passengers in your vehicle, the amount of available cargo and luggage load capacity is 650 lb (1400 - 750 (5 x 150) = 650 lb).

  • Page 14: Vehicle Storage - Engine

    General Information Section 1: General Information • Cover chrome and stainless steel parts with a thick coat of auto wax to prevent discoloration. Rewax as necessary when the vehicle is washed. • Lubricate the hood hinges, door hinges and latches with a light-grade oil. •...
  • Page 15 SECTION 2 Electrical Contents Section 2: Electrical .................2-1 Electrical Basics ................2-1 Electrical Terms ................2-1 Control Modules — Red Area ............2-2 Controller Area Network (CAN) Bus ..........2-2 General Electrical Considerations ..........2-2 Communication Equipment ............2-2 Vehicle Speed Signal..............2-2 Disabling Brake Lights ..............2-2 Disabling the A/C System............2-2 High and Low-Voltage Systems ...........2-3 12-Volt Battery ................2-3...
  • Page 16 SECTION 2 Electrical Contents (Continued) High-Voltage Traction Battery (HVTB) Systems Depowering .................2-6 Electrical Systems Management ..........2-9 Generator Output................2-9 Vehicle Component Electrical Loads ...........2-9 Typical Police/Taxi Equipment..........2-10 General Guidelines ..............2-10 Keep-Alive Memory (KAM) Power..........2-12 Equipment Grounding Guidelines...........2-12 Wire Insulation ................2-12 Terminals and Connectors............2-12 Circuit Protection and Electrical Load ........2-13 Wire Protection Requirements..........2-14 Electrical Protection ..............2-15...

  • Page 17: Section

    Splices and Repairs ..............2-20 Recommended Splicing Method — Solder (For 16 AWG and Smaller Diameter Wire Only) .......2-20 Heat Shrinkable Tubing (Heat Shrink) (Ford Specification ESB-M99D56-A2) ..........2-23 Recommended Splicing Method — Crimp (For 10 - 22 AWG Diameter Wire to Like Wire Diameter) ....2-23 Wiring Reference Information.............2-26...

  • Page 18: Section 2: Electrical

    Electrical Table of Contents Section 2: Electrical Electrical Basics Throughout a vehicle, electricity is supplied through ‘‘hot’’ wires, comparable to the pressurized supply pipes of a plumbing system. At various points along the wires are electrical loads in the form of lights, switches and receptacles. Turning on a light switch is somewhat like opening a faucet to let water run, electricity flows through the hot wire to make the light illuminate.

  • Page 19: Control Modules - Red Area

    Electrical Section 2: Electrical To figure the current needed for a device rated in watts, turn the equation around: Watts/volts = amperes. For example, if you have a piece of equipment, such as a communications radio, that uses 120 watts: 120 watts/12 volts = 10 amperes. Control Modules —...

  • Page 20: High And Low-Voltage Systems

    Electrical Section 2: Electrical High and Low-Voltage Systems NOTICE: Do not backprobe or splice into the high-voltage system. Voltage in the system is 275v DC. Damage may occur to equipment added to the system. The high-voltage system has a floating ground. When the engine is operating or the vehicle is moving, the high-voltage generator begins to generate high voltage, AC electricity.

  • Page 21: Dc/Dc Converter

    Electrical Section 2: Electrical Figure 1. 1. High-voltage service disconnect 2. High-voltage cover 3. High-voltage traction battery (HVTB) DC/DC Converter The DC/DC converter is a liquid-cooled component that converts high-voltage DC power to low-voltage DC power. It maintains an electrical isolation between the 2 DC power systems. This system converts the high voltage (275 volts) to low voltage (12 volts) that provides power to the vehicle low-voltage battery systems.

  • Page 22: Dc/Ac Inverter And Ac Power Point (Fusion Hybrid And Mkz Hybrid Only)

    Electrical Section 2: Electrical DC/AC Inverter and AC Power Point (Fusion Hybrid and MKZ Hybrid only) Note: Do not keep an electrical device plugged in the power point when the device is not in use. It is not recommended to use any extension cord with the 110V AC power point, since it will defeat the safety protection design provided by the cap and twist tab.

  • Page 23: High-Voltage Traction Battery (Hvtb) Systems Depowering

    Electrical Section 2: Electrical NOTICE: Power outlets are designed for accessory plugs only. Do not insert any other object in the power outlet as this will damage the outlet and blow the fuse. Do not hang any type of accessory or accessory bracket from the plug. Improper use of the power outlet can cause damage not covered by your warranty.
  • Page 24 Electrical Section 2: Electrical 4. Locate and slide the handle of the service disconnect toward the LH side of the vehicle. 2012 Fusion Hybrid, MKZ Hybrid Modifiers Guide, 09/2011...
  • Page 25 Electrical Section 2: Electrical 5. Rotate the handle upward. 6. Pull the service disconnect out and away from the HVTB. Make sure to store the service disconnect in a place where it cannot be accidentally re-installed while the vehicle is being serviced.

  • Page 26: Electrical Systems Management

    Electrical Section 2: Electrical Electrical Systems Management Care must be given in deciding what equipment should be installed into a vehicle given the power demands of the equipment and the power available from the vehicle. A power load strategy should be developed to minimize the risk of running out of power.

  • Page 27: Typical Police/Taxi Equipment

    2-10 Electrical Section 2: Electrical Component Amps Lighting Exterior and IP lamps (non-dimmable) Headlamps — low beam 10.0 Fog lamps Brake lights (with CHMSL) Heated Features Heated rear window (includes heated 14.0 mirrors) Heated front seat — LH Heated front seat — RH Other Radio DC/AC inverter...
  • Page 28 (male) connector on the electrical load side to reduce the possibility of a short circuit when disconnected. • Adherence to the above guidelines is not to be construed as approval by Ford Motor Company of any specific revisions or additions to the vehicle’s original electrical system.

  • Page 29: Keep-Alive Memory (Kam) Power

    • Cross-linked polyethylene (XPLPE or SXL) rated at 125°C (257°F) is the required insulation for underhood/underbody applications (Ford specification ESB-M1L123-A). • GXL can be used as an alternate wire (Ford specification ESB-M7L85B) as long as the concentricity specifications are met. To provide a water-resistant seal in conjunction with crimp connectors, a Duraseal crimp connector is recommended since it is designed to account for outside wire diameter that is smaller than the present SXL wire.

  • Page 30: Circuit Protection And Electrical Load

    Electrical 2-13 Section 2: Electrical When a connection is not defined (typical situation — harness-to-harness connectors), the following suggestions should be implemented: • Determine the connector type. If it will be located in a hostile environment, use a sealed connector; if not, use an open connector. A hostile environment is defined as being exposed to water and/or salt accumulation and/or high temperatures (that is;...

  • Page 31: Wire Protection Requirements

    2-14 Electrical Section 2: Electrical • When adding loads to a base vehicle-protected circuit, make sure that the total electrical load through the base vehicle fuse or circuit breaker is less than the device’s load rating. • Use 80% of the fuse rating to determine maximum steady state load to reduce nuisance fuse failures.

  • Page 32: Electrical 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 33: Grommets And Sealing Requirements

    2-16 Electrical Section 2: Electrical • Scroll — Similar to convolute, but without the ridges. Scroll is used where harness rigidity is required, especially for maintaining critical locator dimensions. Use scroll for short lengths only, as it is quite inflexible. Grommets and Sealing Requirements Any additional wiring routed through sheet metal must pass through a grommet that both seals the opening and locates the wire(s).
  • Page 34 Electrical 2-17 Section 2: Electrical • Route wires to avoid metal edges, screws, trim fasteners and abrasive surfaces. When such routing is not possible, use protective devices (shields, caps) to protect the wires. Cover metal edges with a protective shield and fasten the wiring within 76 mm (3 in) on each side of the edge (see figure below).

  • Page 35: Wire Retention And Routing

    • 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, new holes with proper wire protection and sealing must be used.
  • Page 36 Electrical 2-19 Section 2: Electrical For retainer screws, the following guidelines apply: • Avoid using fasteners that are too long for the application or are in an area which might damage vehicle components, including wiring, brake lines, fuel tank and lines, powertrain components, exhaust system and suspension.

  • Page 37: Splices And Repairs

    2-20 Electrical Section 2: Electrical Splices and Repairs WARNING: Do NOT splice into or repair high-voltage (orange) wiring/cables. The high voltage in this system is 275 volts DC. Failure to follow these instructions may result in severe personal injury or death. •...
  • Page 38 Electrical 2-21 Section 2: Electrical 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist the wires together. 5. Note: Use resin-core mildly-activated (RMA) solder. Do not use acid-core solder. Solder wires together. 6. Note: Wait for solder to cool before moving wires. Bend wire No.
  • Page 39 2-22 Electrical Section 2: Electrical 7. Note: Overlap tubing on both wires. Evenly position heat shrink tubing over wire repair. 8. Use a shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing.

  • Page 40: 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 41 2-24 Electrical Section 2: Electrical 4. Select the appropriate wire splice for the wires to be spliced from Rotunda Wire Splice Kit 164-R5903. 5. Note: Rotunda Pro-Crimper 164-R5901 supplied with the wire splice kit is the only tool that can be used with these splices. Identify the appropriate chamber on the Rotunda Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice.
  • Page 42 11. Reconnect the battery ground cable. 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.

  • Page 43: Wiring Reference Information

    To obtain information about ordering complete copies of Ford or Lincoln 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 44 Electrical 2-27 Section 2: Electrical 2012 Fusion Hybrid, MKZ Hybrid Modifiers Guide, 09/2011...
  • Page 45 2-28 Electrical Section 2: Electrical 2012 Fusion Hybrid, MKZ Hybrid Modifiers Guide, 09/2011...
  • Page 46 Electrical 2-29 Section 2: Electrical 2012 Fusion Hybrid, MKZ Hybrid Modifiers Guide, 09/2011...
  • Page 47 2-30 Electrical Section 2: Electrical 2012 Fusion Hybrid, MKZ Hybrid Modifiers Guide, 09/2011...
  • Page 48 Electrical 2-31 Section 2: Electrical Charging System 2012 Fusion Hybrid, MKZ Hybrid Modifiers Guide, 09/2011...
  • Page 49 2-32 Electrical Section 2: Electrical 2012 Fusion Hybrid, MKZ Hybrid Modifiers Guide, 09/2011...
  • Page 50 Electrical 2-33 Section 2: Electrical 2012 Fusion Hybrid, MKZ Hybrid Modifiers Guide, 09/2011...

  • Page 51: Connector End Views

    2-34 Electrical Section 2: Electrical Connector End Views 2012 Fusion Hybrid, MKZ Hybrid Modifiers Guide, 09/2011...

  • Page 52: Connector And Ground Locator

    Electrical 2-35 Section 2: Electrical Connector and Ground Locator 2012 Fusion Hybrid, MKZ Hybrid Modifiers Guide, 09/2011...
  • Page 53 2-36 Electrical Section 2: Electrical 2012 Fusion Hybrid, MKZ Hybrid Modifiers Guide, 09/2011...
  • Page 54 Electrical 2-37 Section 2: Electrical 2012 Fusion Hybrid, MKZ Hybrid Modifiers Guide, 09/2011...
  • Page 55 2-38 Electrical Section 2: Electrical 2012 Fusion Hybrid, MKZ Hybrid Modifiers Guide, 09/2011...
  • Page 56 SECTION 3 Mounting Contents Section 3: Mounting .................3-1 Push Bumpers ................3-1 Siren and Grille Lights..............3-1 Mounting Equipment to the Vehicle ..........3-1 Safety Belt Retractor..............3-2 Side Impact Sensor ..............3-3 Restraints Control Module (RCM) ..........3-3 Air Bag Deployment Interference ..........3-4 Seat Bolts..................3-5 2012 Fusion Hybrid, MKZ Hybrid Modifiers Guide, 09/2011...

  • Page 57: 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 The engine cooling system relies on proper airflow through the radiator to keep the engine at its proper operating temperature.

  • Page 58: Safety Belt Retractor

    Mounting Section 3: Mounting • 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. •...

  • Page 59: Side Impact Sensor

    Mounting Section 3: Mounting Side Impact Sensor Refer to the above illustration for locations that must not be used for partition mounting: The side impact sensor is located in the base of the B-pillar; one sensor in each pillar. They are positioned below the safety belt retractors.

  • Page 60: Air Bag Deployment Interference

    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 61: Seat Bolts

    Mounting Section 3: Mounting WARNING: To reduce risk of injury, do not obstruct or place objects in the deployment path of the inflatable Safety Canopy® System. NOTICE: The side impact sensor is tuned to excite based on its mass (including wiring), as well as the host sheet metal.
  • Page 62 SECTION 4 Reference Contents Section 4: Reference ...............4-1 Engineering Drawings ..............4-1 Air Bag Deployment Interference ..........4-1 Evaporative Emissions and Fuel Systems .......4-7 High-Voltage System ..............4-9 2012 Fusion Hybrid, MKZ Hybrid Modifiers Guide, 09/2011...

  • Page 63: Section 4: Reference

    WARNING: 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 64 Reference Section 4: Reference Note: The side impact sensor is tuned to excite based on its mass (including wiring), as well as the host sheet metal. Any alteration to these components must be avoided. Additions, such as padding, wire connectors, retainers, tape or fasteners of any kind should not be used. All fasteners in this predominantly sheet metal environment should be made of steel or a non-conductive plastic to guarantee retention and longevity.
  • Page 65 Reference Section 4: Reference Figure 1. Note: Do not mount equipment on the instrument panel between the driver and passenger air bags due to deployment variability. 1. 318 mm (12.5 in) from center of air bag door 2. 450 mm (17.7 in) from center of air bag door 3.
  • Page 66 Reference Section 4: Reference Figure 2. 1. 635 mm (25 in) from center of air bag door 2. 203 mm (8.0 in) from center of air bag door 2012 Fusion Hybrid, MKZ Hybrid Modifiers Guide, 09/2011...
  • Page 67 Reference Section 4: Reference Figure 3. 1. 730 mm (28.7 in) from center of air bag door 2. 650 mm (25.6 in) from center of air bag door 2012 Fusion Hybrid, MKZ Hybrid Modifiers Guide, 09/2011...
  • Page 68 Reference Section 4: Reference Figure 4. NOTICE: Any surfaces that could come into contact with side air curtain (Safety Canopy® System) during deployment must not damage the curtain. Sharp edges, corners or protrusions could damage the curtain and reduce the overall effectiveness of the side air curtain.

  • Page 69: Evaporative Emissions And Fuel Systems

    Reference Section 4: Reference Evaporative Emissions and Fuel Systems 2012 Fusion Hybrid, MKZ Hybrid Modifiers Guide, 09/2011...
  • Page 70 Reference Section 4: Reference 2012 Fusion Hybrid, MKZ Hybrid Modifiers Guide, 09/2011...

  • Page 71: High-Voltage System

    Reference Section 4: Reference High-Voltage System 2012 Fusion Hybrid, MKZ Hybrid Modifiers Guide, 09/2011...
  • Page 72 4-10 Reference Section 4: Reference 2012 Fusion Hybrid, MKZ Hybrid Modifiers Guide, 09/2011...

This manual is also suitable for:

Mkz hybrid 2012

Table of Contents