Ford FUSION HYBRID 2013 Modifiers Manual
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Ford FUSION HYBRID 2013 Modifiers Manual

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2013
FUSION HYBRID
MKZ HYBRID
FUSION ENERGI
MODIFIERS GUIDE
FCS-15128-13
March 2013

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Summary of Contents for Ford FUSION HYBRID 2013

  • Page 1 2013 FUSION HYBRID MKZ HYBRID FUSION ENERGI MODIFIERS GUIDE FCS-15128-13 March 2013...
  • Page 2 SECTION 0 Introduction Contents Introduction..................0-1 Genuine Ford Accessories For Your Vehicle ......0-1 Considerations When Using or Installing Accessories ....0-2 FCS-15128-13 March 2013...
  • Page 3 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 4 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 5 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 6: Section

    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 7 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 8 (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 9 • 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 10 General Information Section 1: General Information • 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 11 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 12: Table Of Contents

    SECTION 2 Electrical Contents (Continued) Generator Output................2-9 Vehicle Component Electrical Loads ...........2-9 Typical Police/Taxi Equipment..........2-10 General Guidelines ..............2-11 Keep-Alive Memory (KAM) Power..........2-12 Equipment Grounding Guidelines...........2-12 Wire Insulation ................2-12 Terminals and Connectors............2-13 Circuit Protection and Electrical Load ........2-14 Wire Protection Requirements..........2-15 Electrical Protection ..............2-16 Mechanical/Environmental Protection........2-16 Grommets and Sealing Requirements ........2-17...
  • Page 13 SECTION 2 Electrical Contents (Continued) Heat Shrinkable Tubing (Heat Shrink) (Ford Specification ESB-M99D56-A2) ..........2-24 Recommended Splicing Method — Crimp (For 10 - 22 AWG Diameter Wire to Like Wire Diameter) ....2-24 Wiring Reference Information.............2-27 Wiring Diagrams ..............2-27 FCS-15128-13 March 2013...
  • Page 14 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 15 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 16 Electrical Section 2: Electrical 12 Volt Battery The 12 volt battery is a standard automotive battery. It is a DC source connected in a negative ground system. The battery case is sealed, with 2 vent holes to release gases. The battery has 3 major functions: •...
  • Page 17 Electrical Section 2: Electrical Figure 1. Note: FHEV (HYBRID) BATTERY SHOWN. • Pull Service Disconnect Handle towards the center of the vehicle to disengage the interlock. • Rotate the lever to it’s horizontal position. • Remove the High-Voltage Service Disconnect. FCS-15128-13 March 2013...
  • Page 18 Electrical Section 2: Electrical Note: The High-Voltage Service Disconnect is accessible by lowering the rear seatback on the driver side and removing the access cover located on the battery cover. Figure 2. Note: PHEV (ENERGI) BATTERY SHOWN. • Pull Service Disconnect Handle towards the center of the vehicle to disengage the interlock. •...
  • Page 19 Electrical Section 2: Electrical Note: The High-Voltage Service Disconnect is accessible by lowering the rear seatback on the passenger side and removing the access cover located on the battery cover. DC/DC Converter The DC/DC converter is an air-cooled component that converts high-voltage DC power to low-voltage DC power.
  • Page 20 Electrical Section 2: Electrical 3. Fold the appropriate backrest down. Note: 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. Figure 3.
  • Page 21 Electrical Section 2: Electrical Note: The High-Voltage Service Disconnect is accessible by lowering the rear seatback on the driver side and removing the access cover located on the battery cover. Figure 4. Note: PHEV (ENERGI) BATTERY SHOWN. • Pull Service Disconnect Handle towards the center of the vehicle to diengage the interlock. •...

  • Page 22: Generator Output

    Electrical Section 2: Electrical Note: The High-Voltage Service Disconnect is accessible by lowering the rear seatback on the passenger side and removing the access cover located on the battery cover. 4. Wait 5 minutes after the service disconnect has been removed before continuing service. This allows any residual voltage in the high-voltage system to dissipate.

  • Page 23: Typical Police/Taxi Equipment

    2-10 Electrical Section 2: Electrical Component Amps A/C fan to face — high speed 25.0 (recirculating air) A/C fan to face — M/H speed 16.0 (recirculating air) Heater fan to foot — M/H speed 16.0 (fresh air) Lighting Exterior and IP lamps (non-dimmable) Headlamps —...

  • Page 24: General Guidelines

    • Install the fuse panel so fuses are readily accessible. • Make sure that connections are easily accessible for assembly and service. • Inspect all Ford gauges, lights and switches for correct operation after instrument panel work is performed. • Make sure submersible connectors do not lose their seals under extreme assembly conditions such as bending wires 90 degrees immediately after the connector.

  • Page 25: Keep-Alive Memory (Kam) Power

    Electrical Section 2: Electrical • 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. • Document all revisions to the electrical system and place with the vehicle Owner’s Literature.

  • Page 26: Terminals And Connectors

    Electrical 2-13 Section 2: Electrical Terminals and Connectors Connector Types: • Submersible (sealed) — A connector that is capable of being immersed in water. • Weather-resistant — A connector that will retain its sealing and connection qualities while being exposed to adverse weather conditions. •...

  • Page 27: Circuit Protection And Electrical Load

    2-14 Electrical Section 2: Electrical • Determine the terminal type. Base your decision on wire gauge, current carrying capacity, connector type and insulation type. — Use non-detent low insertion force terminals whenever possible. — Do not use low insertion force female terminals in weather-resistant connectors. —...

  • Page 28: Wire Protection Requirements

    Electrical 2-15 Section 2: Electrical • Use 135% of the fuse rating when sizing wiring to protect the circuit in the event of an overload. Fuses will last for one hour at 135% of their rating. — Total current draw is the sum of the base vehicles circuit current requirement (measured with an ammeter) and the anticipated add-on component current requirements.

  • Page 29: 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 30: Grommets And Sealing Requirements

    Electrical 2-17 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 31 2-18 Electrical 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 32: 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 33 2-20 Electrical 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 34: Splices And Repairs

    Electrical 2-21 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 approximately 325 volts DC. Failure to follow these instructions may result in severe personal injury or death. •...
  • Page 35 2-22 Electrical 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 36 Electrical 2-23 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 37 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 38 Electrical 2-25 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 39 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 40 Ordering 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 41 2-28 Electrical Section 2: Electrical Figure 5. FCS-15128-13 March 2013...
  • Page 42 Electrical 2-29 Section 2: Electrical Figure 6. FCS-15128-13 March 2013...
  • Page 43 2-30 Electrical Section 2: Electrical Figure 7. FCS-15128-13 March 2013...
  • Page 44 Electrical 2-31 Section 2: Electrical Figure 8. FCS-15128-13 March 2013...
  • Page 45 2-32 Electrical Section 2: Electrical Figure 9. FCS-15128-13 March 2013...
  • Page 46 Electrical 2-33 Section 2: Electrical Figure 10. FCS-15128-13 March 2013...
  • Page 47 2-34 Electrical Section 2: Electrical Figure 11. FCS-15128-13 March 2013...
  • Page 48 Electrical 2-35 Section 2: Electrical Figure 12. FCS-15128-13 March 2013...
  • Page 49 2-36 Electrical Section 2: Electrical Figure 13. FCS-15128-13 March 2013...
  • Page 50 Electrical 2-37 Section 2: Electrical Figure 14. FCS-15128-13 March 2013...
  • Page 51 2-38 Electrical Section 2: Electrical Power Distribution Figure 15. FCS-15128-13 March 2013...
  • Page 52 Electrical 2-39 Section 2: Electrical Figure 16. FCS-15128-13 March 2013...
  • Page 53 2-40 Electrical Section 2: Electrical Figure 17. FCS-15128-13 March 2013...
  • Page 54 Electrical 2-41 Section 2: Electrical Figure 18. FCS-15128-13 March 2013...
  • Page 55 2-42 Electrical Section 2: Electrical Figure 19. FCS-15128-13 March 2013...
  • Page 56 Electrical 2-43 Section 2: Electrical Figure 20. FCS-15128-13 March 2013...
  • Page 57 2-44 Electrical Section 2: Electrical Figure 21. FCS-15128-13 March 2013...
  • Page 58 Electrical 2-45 Section 2: Electrical Figure 22. FCS-15128-13 March 2013...
  • Page 59 2-46 Electrical Section 2: Electrical Figure 23. FCS-15128-13 March 2013...
  • Page 60 Electrical 2-47 Section 2: Electrical Figure 24. FCS-15128-13 March 2013...
  • Page 61 2-48 Electrical Section 2: Electrical Figure 25. FCS-15128-13 March 2013...
  • Page 62 Electrical 2-49 Section 2: Electrical Figure 26. FCS-15128-13 March 2013...
  • Page 63 2-50 Electrical Section 2: Electrical Figure 27. FCS-15128-13 March 2013...
  • Page 64 Electrical 2-51 Section 2: Electrical Figure 28. FCS-15128-13 March 2013...
  • Page 65 2-52 Electrical Section 2: Electrical Figure 29. FCS-15128-13 March 2013...
  • Page 66 Electrical 2-53 Section 2: Electrical Figure 30. FCS-15128-13 March 2013...
  • Page 67 2-54 Electrical Section 2: Electrical Figure 31. FCS-15128-13 March 2013...
  • Page 68 Electrical 2-55 Section 2: Electrical Figure 32. FCS-15128-13 March 2013...
  • Page 69 2-56 Electrical Section 2: Electrical Figure 33. FCS-15128-13 March 2013...
  • Page 70 Electrical 2-57 Section 2: Electrical Figure 34. FCS-15128-13 March 2013...
  • Page 71 2-58 Electrical Section 2: Electrical Figure 35. FCS-15128-13 March 2013...
  • Page 72 Electrical 2-59 Section 2: Electrical Figure 36. FCS-15128-13 March 2013...
  • Page 73 2-60 Electrical Section 2: Electrical Figure 37. FCS-15128-13 March 2013...
  • Page 74 Electrical 2-61 Section 2: Electrical Figure 38. FCS-15128-13 March 2013...
  • Page 75 2-62 Electrical Section 2: Electrical Figure 39. FCS-15128-13 March 2013...
  • Page 76 Electrical 2-63 Section 2: Electrical Figure 40. FCS-15128-13 March 2013...
  • Page 77 2-64 Electrical Section 2: Electrical Figure 41. FCS-15128-13 March 2013...
  • Page 78 Electrical 2-65 Section 2: Electrical Figure 42. FCS-15128-13 March 2013...
  • Page 79 2-66 Electrical Section 2: Electrical Figure 43. FCS-15128-13 March 2013...
  • Page 80 Electrical 2-67 Section 2: Electrical Figure 44. FCS-15128-13 March 2013...
  • Page 81 2-68 Electrical Section 2: Electrical Figure 45. FCS-15128-13 March 2013...
  • Page 82 Electrical 2-69 Section 2: Electrical Figure 46. FCS-15128-13 March 2013...
  • Page 83 2-70 Electrical Section 2: Electrical Figure 47. FCS-15128-13 March 2013...
  • Page 84 Electrical 2-71 Section 2: Electrical Figure 48. FCS-15128-13 March 2013...
  • Page 85 2-72 Electrical Section 2: Electrical Figure 49. FCS-15128-13 March 2013...
  • Page 86 Electrical 2-73 Section 2: Electrical Figure 50. FCS-15128-13 March 2013...
  • Page 87 2-74 Electrical Section 2: Electrical Figure 51. FCS-15128-13 March 2013...
  • Page 88 Electrical 2-75 Section 2: Electrical Figure 52. FCS-15128-13 March 2013...
  • Page 89 2-76 Electrical Section 2: Electrical Figure 53. FCS-15128-13 March 2013...
  • Page 90 Electrical 2-77 Section 2: Electrical Figure 54. FCS-15128-13 March 2013...
  • Page 91 2-78 Electrical Section 2: Electrical Figure 55. FCS-15128-13 March 2013...
  • Page 92 Electrical 2-79 Section 2: Electrical Figure 56. FCS-15128-13 March 2013...
  • Page 93 2-80 Electrical Section 2: Electrical Figure 57. FCS-15128-13 March 2013...
  • Page 94 Electrical 2-81 Section 2: Electrical Figure 58. FCS-15128-13 March 2013...
  • Page 95 2-82 Electrical Section 2: Electrical Figure 59. FCS-15128-13 March 2013...
  • Page 96 Electrical 2-83 Section 2: Electrical Figure 60. FCS-15128-13 March 2013...
  • Page 97 2-84 Electrical Section 2: Electrical Figure 61. FCS-15128-13 March 2013...
  • Page 98 Electrical 2-85 Section 2: Electrical Figure 62. FCS-15128-13 March 2013...
  • Page 99 2-86 Electrical Section 2: Electrical Figure 63. FCS-15128-13 March 2013...
  • Page 100 Electrical 2-87 Section 2: Electrical Figure 64. FCS-15128-13 March 2013...
  • Page 101 Table of Contents 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 102 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 103 Mounting Section 3: Mounting • Clockspring • Collapsible steering column • Driver/passenger lower airbag • Passenger airbag • Passenger side airbag Figure 2. • Front passenger safety belt retractor (includes retractor pretensioner, adaptive load limiter and anchor pretensioner) • Front paasenger safety belt buckle (includes buckle switch and Belt Tension Sensor (BTS)) •...
  • Page 104 Mounting Section 3: Mounting • Driver safety belt buckle (includes buckle switch) • Driver front door side impact sensor • Seat position sensor • Occupant classification sensor (OCS) • Front impact severity sensor • Passenger Airbag Deactivation (PAD) Indicator • Passenger front door side impact sensor Safety Belt Retractor The safety belt retractors are located in the base of the B-pillars.
  • Page 105 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 106 Mounting Section 3: Mounting NOTICE: The side impact sensors are tuned to excite based on their 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.
  • Page 107 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 108 Reference Section 4: Reference NOTICE: The side impact sensors are tuned to excite based on their 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.
  • Page 109 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. 330 mm (13 in) from center of air bag door 2. 400 mm (15.7 in) from center of air bag door 3.
  • Page 110 Reference Section 4: Reference Figure 2. 1. 660 mm (26 in) from center of air bag door 2. 660 mm (26 in) from center of air bag door FCS-15128-13 March 2013...
  • Page 111 Reference Section 4: Reference Figure 3. 1. 690 mm (27.2 in) from center of air bag door 2. 500 mm (19.7 in) from center of air bag door FCS-15128-13 March 2013...
  • Page 112 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.

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