Ford C-MAX HYBRID 2013 Modifiers Manual
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Ford C-MAX HYBRID 2013 Modifiers Manual

Ford C-MAX HYBRID 2013 Modifiers Manual

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See also: Owner's Manual , Quick Reference Manual
2013
C-MAX HYBRID
C-MAX ENERGI
MODIFIER GUIDE
FCS-212235-13
March 2013

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Summary of Contents for Ford C-MAX HYBRID 2013

  • Page 1 2013 C-MAX HYBRID C-MAX ENERGI MODIFIER GUIDE FCS-212235-13 March 2013...

  • 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 FCS-212235-13 March 2013...
  • 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 SECTION 1 General Information Contents (Continued) Vehicle Storage — Fuel System ..........1-7 Vehicle Storage — Tires............1-7 FCS-212235-13 March 2013...
  • Page 7 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 8: 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 9 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 10 (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 11 • 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 12 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 13 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 14: Table Of Contents

    SECTION 2 Electrical Contents (Continued) High-Voltage Traction Battery (HVTB) Systems Depowering .................2-7 Electrical Systems Management ..........2-10 Vehicle Component Electrical Loads .........2-10 Typical Police/Taxi Equipment..........2-11 General Guidelines ..............2-11 Keep-Alive Memory (KAM) Power..........2-12 Equipment Grounding Guidelines...........2-13 Wire Insulation ................2-13 Terminals and Connectors............2-13 Circuit Protection and Electrical Load ........2-14 Wire Protection Requirements..........2-15 Electrical Protection ..............2-16...
  • Page 15 Contents (Continued) Recommended Splicing Method — Solder (For 16 AWG and Smaller Diameter Wire Only) .......2-21 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...
  • Page 16 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 17 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 18 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 approximately 300v 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 19 Electrical Section 2: Electrical Figure 1. Note: FHEV (HYBRID) BATTERY SHOWN. 1. Pull Service Disconnect Handle towards the center of the vehicle to disengage the interlock. 2. Rotate the lever to it’s horizontal position. 3. High-voltage traction battery (HVTB) FCS-212235-13 March 2013...
  • Page 20 Electrical Section 2: Electrical Figure 2. Note: PHEV (ENERGI) BATTERY SHOWN. 4. Pull Service Disconnect Handle towards the center of the vehicle to disengage the interlock. 5. Rotate the lever to it’s horizontal position. 6. High-voltage traction battery (HVTB) DC/DC Converter The DC/DC converter is an air-cooled component that converts high-voltage DC power to low-voltage DC power.
  • Page 21 Electrical Section 2: Electrical DC/AC Inverter and AC Power Point (C-Max Hybrid and C-Max Energi 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 22: 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 23 Electrical Section 2: Electrical Figure 3. 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-212235-13 March 2013...
  • Page 24 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 25: Electrical Systems Management

    2-10 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 26: 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 C-Max Hybrid/Energi Workshop Manual.

  • Page 27: Keep-Alive Memory (Kam) Power

    (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 vehicles original electrical system.

  • Page 28: Equipment Grounding Guidelines

    • 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®...

  • Page 29: Circuit Protection And Electrical Load

    2-14 Electrical 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 30: Wire Protection Requirements

    Electrical 2-15 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 devices load rating. • Use 80% of the fuse rating to determine maximum steady state load to reduce nuisance fuse failures.

  • Page 31: 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 32: 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 33: Wire Retention And Routing

    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 34 • 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 35 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 36: 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 300 volts DC. Failure to follow these instructions may result in severe personal injury or death. •...
  • Page 37 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 38 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 39: 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 40 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 41 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 42: Wiring Reference Information

    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 43 2-28 Electrical Section 2: Electrical FCS-212235-13 March 2013...
  • Page 44 Electrical 2-29 Section 2: Electrical FCS-212235-13 March 2013...
  • Page 45 2-30 Electrical Section 2: Electrical FCS-212235-13 March 2013...
  • Page 46 Electrical 2-31 Section 2: Electrical FCS-212235-13 March 2013...
  • Page 47 2-32 Electrical Section 2: Electrical FCS-212235-13 March 2013...
  • Page 48 Electrical 2-33 Section 2: Electrical FCS-212235-13 March 2013...
  • Page 49 2-34 Electrical Section 2: Electrical FCS-212235-13 March 2013...
  • Page 50 Electrical 2-35 Section 2: Electrical FCS-212235-13 March 2013...
  • Page 51 2-36 Electrical Section 2: Electrical FCS-212235-13 March 2013...
  • Page 52 Electrical 2-37 Section 2: Electrical FCS-212235-13 March 2013...
  • Page 53 2-38 Electrical Section 2: Electrical FCS-212235-13 March 2013...
  • Page 54 Electrical 2-39 Section 2: Electrical FCS-212235-13 March 2013...
  • Page 55 2-40 Electrical Section 2: Electrical FCS-212235-13 March 2013...
  • Page 56 Electrical 2-41 Section 2: Electrical FCS-212235-13 March 2013...

  • Page 57: Connector End Views

    2-42 Electrical Section 2: Electrical Connector End Views FCS-212235-13 March 2013...

  • Page 58: Ground

    Electrical 2-43 Section 2: Electrical Ground FCS-212235-13 March 2013...
  • Page 59 Table of Contents Section 3: Mounting Push Bumpers Ford Motor Company does not recommend the installation of any type of accessory bull bar/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 60 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 61 Mounting Section 3: Mounting Ocuupant Restraint Component Locations The following graphics illustrate the location of the airbag and restraint components. FCS-212235-13 March 2013...
  • Page 62 Mounting Section 3: Mounting FCS-212235-13 March 2013...
  • Page 63 Mounting Section 3: Mounting FCS-212235-13 March 2013...
  • Page 64 Mounting Section 3: Mounting Safety Belt Retractor The safety belt retractors are located in the base of the B-pillars. The pretensioner located in the retractor is referred to as the ‘‘safety belt retractor pretensioner’’. In the event the restraints control module (RCM) senses an impact, pretensioners provide improved occupant protection by rapidly removing slack from the safety belt.
  • Page 65 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 66 Mounting Section 3: Mounting Driver/passenger air bags affect the way equipment can be mounted in vehicles. Any surfaces that could come into contact with an air bag during deployment must not damage the air bag or alter its deployment path. Sharp edges, corners or protrusions could damage the nylon air bag material and reduce the effectiveness of the air bag.
  • Page 67 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 68 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 69 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 70 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-212235-13 March 2013...
  • Page 71 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-212235-13 March 2013...
  • Page 72 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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