🏷️ Basic Information

Make:

Ford

Model:

C-MAX

Year:

2016

Model Variants:

Hybrid, Energi

Chassis Code:

CD391

👋 Introduction

Market Segment:

Compact Hybrid/Plug-in Hybrid Hatchback

Primary Competitors:

Toyota Prius, Chevrolet Volt, Hyundai Ioniq (later models), Kia Niro (later models).

Unique Selling Points:

Stylish design for a hybrid, spacious interior, available Plug-in Hybrid (PHEV) variant (Energi) with extended electric range, Ford's reliable powertrain technology.

📋 Manual Details

Coverage Scope:

Complete Service & Repair Procedures A-Z

Estimated Page Count:

High (Detailed as per workshop standards)

Type:

Workshop Service Repair Manual

Language:

English

Delivery Format:

Digital Downloadable (PDF compatible)

📖 Manual Coverage

Powertrain:

2.0L Atkinson Cycle Hybrid Engine (Duratec HE), Hybrid Transaxle (eCVT), Electric Motor, Battery Pack (Li-ion), Power Split Device, Hybrid Control Systems.

Chassis:

Front Wheel Drive, Suspension (Front MacPherson Strut, Rear Independent Twist-Beam), Steering (Electric Power Assist), Brakes (Front Ventilated Discs, Rear Solid Discs, Regenerative Braking System), ABS, Traction Control, Stability Control.

Electrical:

12V Electrical System, High-Voltage Hybrid System, Charging System (for Energi Plug-in Hybrid), Lighting (Exterior & Interior), Instrument Cluster, Infotainment System, Body Control Module (BCM), Gateway Module, Powertrain Control Module (PCM), Hybrid Control Module (HCM), Battery Management System (BMS).

Body & Interior:

Body Structure, Doors, Hood, Liftgate, Bumpers, Glass, Interior Trim, Seats, HVAC System (including Hybrid A/C compressor), SRS Airbag System.

Scheduled Maintenance:

Oil Changes, Filter Replacements (Air, Cabin, Fuel - if applicable), Tire Rotation, Brake Inspections, Fluid Checks & Replacements (Coolant, Brake Fluid, Washer Fluid).

Engine Repair:

Engine Overhaul, Cylinder Head Removal/Installation, Piston/Connecting Rod Installation, Crankshaft/Bearing Replacement, Timing Chain/Belt Service, Component Replacement (Spark Plugs, Ignition Coils, Fuel Injectors, Sensors).

Hybrid System Repair:

High-Voltage Battery Service/Replacement (with safety precautions), Electric Motor Diagnostics/Repair, Power Split Device Servicing, Hybrid System Component Replacement, Hybrid System Troubleshooting.

Transmission Repair:

eCVT Disassembly/Assembly, Component Replacement, Fluid Change Procedures, Torque Converter Service.

Brake System Repair:

Brake Pad & Rotor Replacement, Brake Caliper Servicing, Brake Fluid Flush & Bleed, ABS Component Testing, Regenerative Braking System Diagnostics.

Electrical Diagnostics:

Wiring Diagrams, Connector Pinouts, Component Testing (using multimeter and oscilloscope), Troubleshooting of Powertrain Control Module (PCM), Hybrid Control Module (HCM), Body Control Module (BCM) and related systems. Diagnosis of warning lights and diagnostic trouble codes (DTCs).

HVAC Service:

Refrigerant Charging (including hybrid-specific AC systems), Component Replacement (Compressor, Evaporator, Condenser), Heater Core Service, Climate Control System Diagnostics.

Bodywork & Collision:

Panel Replacement, Door/Liftgate Adjustment, Glass Replacement, Bumper Repair/Replacement, Structural Repair Guidelines.

Depth:

Comprehensive (from basic maintenance to complete engine and hybrid system rebuilds, including detailed diagnostics).

📊 Manual Specifications

File Format:

PDF

Print Quality:

High-resolution, printable pages.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

Searchability:

Fully searchable text content for quick information retrieval.

Required Software:

Adobe Reader (or compatible PDF viewer)

⚙️ Engine Specifications

Engine Type:

2.0L DOHC Atkinson Cycle I-4 with Electric Motor Assist

Combined Horsepower:

188 hp (for Hybrid), 195 hp (for Energi - combined system output)

Engine Horsepower:

141 hp @ 6000 rpm

Engine Torque:

129 lb-ft @ 4000 rpm

Electric Motor Torque:

177 lb-ft (approximate, for Hybrid)

Fuel Type:

Unleaded Gasoline

Emission Control:

Catalytic Converter, On-Board Diagnostics (OBD-II), EVAP System

Coolant Type:

Motorcraft® Premium Gold Concentrated Engine Coolant (Orange)

Recommended Oil Viscosity:

SAE 0W-20

Oil Capacity:

4.5 US quarts (4.3 liters) with filter

High Voltage Battery Type:

Lithium-Ion (Li-ion)

Energi Battery Capacity:

7.6 kWh (for Energi Plug-in Hybrid)

🔧 Transmission

Transmission Type:

Electronic Continuously Variable Transmission (eCVT) with Power Split Device

Optional Transmission:

N/A

Transmission Features:

Integrated electric motor, seamless gear ratio changes, optimized for fuel efficiency and hybrid operation.

Transmission Fluid Type:

Motorcraft® MERCON® ULV Automatic Transmission Fluid (if specified for the eCVT unit, check manual for specifics).

📐 Dimensions

Length:

171.7 inches (4361 mm)

Width:

70.1 inches (1780 mm)

Height:

63.7 inches (1618 mm)

Wheelbase:

104.0 inches (2642 mm)

Cargo Volume Behind Second Row:

22.0 cu ft (Hybrid), 19.8 cu ft (Energi)

Curb Weight Hybrid:

Approx. 3,450 lbs (1,565 kg)

Curb Weight Energi:

Approx. 3,700 lbs (1,678 kg)

Standard Tire Size:

215/55R16

Standard Wheel Size:

16-inch alloy

Bolt Pattern:

5 x 108 mm

🛡️ Safety Features

NHTSA Overall Safety Rating:

5-Star (as typically achieved by Ford models of this era, consult NHTSA for specific VIN data)

ABS:

Yes (with EBD and Brake Assist)

Traction Control:

Yes (TCS)

Stability Control:

Yes (Electronic Stability Control - ESC)

Tire Pressure Monitoring:

Yes (TPMS)

Airbags:

Frontal, Side-Impact, Curtain Airbags

Seatbelts:

3-Point with Pretensioners and Load Limiters

💡 Technology Features

Infotainment System:

SYNC® (typically SYNC with MyFord Touch® or later SYNC 3)

Features:

Touchscreen display, Bluetooth connectivity, USB ports, voice commands, navigation (optional), smartphone integration (AppLink).

Optional Driver Assistance:

Rearview Camera, Rear Parking Sensors, Blind Spot Information System (BLIS), Cross-Traffic Alert.

Connectivity Features:

FordPass Connect (in later models/updates), Wi-Fi hotspot capability (optional).

Energi Charging Time:

Approximately 2.5 hours using a 240V outlet, 7 hours using a 120V outlet.

🔧 Maintenance

Engine Oil Change Interval:

Every 10,000 miles (16,000 km) or 12 months, whichever comes first.

Engine Air Filter Replacement:

Every 30,000 miles (48,000 km) or as needed.

Cabin Air Filter Replacement:

Every 20,000 miles (32,000 km) or as needed.

Coolant Flush Replacement:

First at 150,000 miles (240,000 km), then every 75,000 miles (120,000 km).

Brake Fluid Change:

Every 2 years or as needed.

Brake Fluid Type:

DOT 3 or DOT 4, meeting Ford specification WSS-M2C237-A

Windshield Washer Fluid:

Motorcraft® Premium Washer Fluid or equivalent

Common Complaints:

Hybrid battery degradation (over extended mileage), occasional HVAC system issues, potential for infotainment system glitches.

Powertrain Reliability:

Generally considered reliable, especially the hybrid powertrain which has proven durable in Ford's lineup.

📚 Vehicle History

Ford History:

Ford Motor Company, a pioneer in mass-produced automobiles since the early 20th century, has a long history of innovation and delivering reliable vehicles across various segments. Its commitment to electrification and hybrid technology has grown significantly in recent years.

C Max Heritage:

The Ford C-MAX, originally a compact MPV in Europe, was redesigned and introduced to North America in 2013 as a dedicated hybrid and plug-in hybrid model, replacing the defunct Ford Focus Electric in that role for many markets. It was known for its practical design and fuel efficiency.

Production Plant:

Wayne Assembly Plant, Wayne, Michigan, USA

Production Years:

2013-2018 (North America)

🏆 Awards & Recognition

Epa Fuel Economy:

Highly rated for fuel economy. (e.g., Hybrid: ~40 MPG combined city/highway; Energi: ~38 miles electric range, ~95 MPGe combined.)