Technical Information |
Advantage Online: 2009 Archives
2010 FORD FUSION/MERCURY MILAN HYBRID Ford added the Fusion Hybrid and Mercury Milan Hybrid for the 2010 model year, doubling the size of their hybrid lineup. Compared to the system on the Ford Escape and Mercury Mariner hybrids, this “next-generation” hybrid system features a smaller, but more powerful high-voltage (HV) battery. Also featured is electric air conditioning, and an instrument panel gauge that coaches drivers how to optimize hybrid performance. For collision repairs, there are several partial replacement procedures available for the structure and the outer side panels. High Voltage (HV) Battery The 2010 Fusion/Milan Hybrids have a 275-volt nickel-metal hydride HV battery, compared to the 330-volt battery on the first generation hybrids, but the battery is optimized so it produces 20% more power. Improved chemistry allows the battery to be run at a higher temperature, so it can be cooled using only cabin air. The Escape/Mariner hybrids require an outside vent located in the driver side quarter window and a dedicated rear air conditioning system to cool the battery. The HV battery is mounted vertically behind the rear seat. Dropping the rear seat forward to access the front of the battery, and the service disconnect, requires accessing the back of the battery from the trunk (see Figure 1). There are two backrest latch release levers located under the package shelf, one for the right seat back and one for the left. Slide the latch release lever toward the outboard side of the vehicle to drop the seat forward (see Video). The service disconnect is the familiar slide, pull, and remove type (see Figure 2). Despite the battery being more resistant to higher temperatures than the Escape and Mariner Hybrids, Ford’s precautions for spraybooth bake temperature still applies. Those precautions are that the temperature setting should not exceed 60°C (140°F) and paint bake times should not exceed 45 minutes. If either of these parameters will be exceeded, Ford recommends removal of the HV battery before entering the spraybooth. Electric Air Conditioning Service Precautions Electric air conditioning (A/C) is standard equipment on the Fusion/Milan Hybrids. As with most hybrids, the electric A/C uses the full rated 275 volts of the HV battery. Also, as with other electric A/C systems, it is imperative to lubricate the electric compressor with the proper oil. Oil for electric A/C compressors functions as an electric insulator, preventing the compressor case from conducting the high voltage. Motorcraft Electric A/C Compressor Oil YN-32 is specified. Using standard PAG oil will damage the A/C compressor and contaminate the rest of the system. Ford states to only use clean manual oil injection tools. Injection of the YN-32 oil with R-134a recharging equipment previously used with PAG oil will contaminate and damage the hybrid A/C system. There is no equipment flushing procedure in the service information that would allow using the same equipment for hybrid and non-hybrid vehicles. Ford also states to not add liquid-based R-134a leak detection dye to the electric A/C system, as leak detection dyes are mixed with PAG oil and will damage and contaminate the system. When checking for leaks in the system, use an electronic refrigerant leak detector. Service electric A/C compressors are supplied with electric A/C compressor oil already installed. This is unlike the standard Fusion/Milan models, where the service A/C compressors are supplied without refrigerant oil.Sectioning Procedures Ford has sectioning procedures for the front rail tip and the rear rail end (see Figures 3 and 4). The procedures not only apply to the hybrids, but the standard Fusion and Milan, back to the 2006 model year. Service rail parts are available. The instructions call for open butt joints at each of the sectioning locations, spot welds or GMA (MIG) plug welds on the flanges, and plug welds to the floor pan for the rear rail procedure.
Instrument Cluster Information The Ford Fusion and Mercury Milan Hybrids feature a unique instrument cluster called SmartGauge with EcoGuide that helps coach drivers on how to optimize performance of their hybrid (see Figure 5). SmartGauge with EcoGuide features two liquid crystal display screens on either side of the analog speedometer that can be configured to show different levels of information, including fuel and battery power levels, and fuel efficiency data. The system “grows” leaves and vines on the screen to reward drivers for efficient driving. Conclusion With the 2010 Ford Fusion Hybrid and Mercury Milan Hybrid, Ford has doubled their hybrid line. These next generation hybrids differ from the Ford Escape/Mercury Mariner Hybrids in several respects. Ford has sectioning procedures and service parts for the front and rear rails and the outer side panels on these vehicles. For comments or suggestions on the Advantage Online, please contact I-CAR at |
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