2013-2021 Ford Fusion Hybrid Li-Ion Battery Service
0:00 Introduction
0:54 Battery kWh rating
Main battery components
1:32 Service Plug Grip
1:44 DC-DC Converter
1:52 Battery Energy Control Module (BECM)
1:59 Battery Junction Block
2:12 Battery Cells
2:26 Air-cooled battery airflow
2:30 Battery fan
2:50 Battery vent
3:00 Inlet air temperature sensor
3:06 Internal cell temperature sensors
4:00 High voltage (HV) disconnect procedure
4:45 Service plug grip removal warning
6:30 HV Interlock circuit
9:20 Removal of battery covers
10:00 Battery safety warning label
10:55 BECM electrical connections
13:40 BECM Warning label
14:02 **(see note below) Personal Protective Equipment needed
14:40 Service grip connector bracket removal
15:20 Cooling fan removal
15:36 Side and front cover removal
15:48 Rear cover removal
16:00 DC-DC converter electrical connections and operation
17:05 DC-DC converter cooling
18:40 HV Voltmeter checking
21:45 DC-DC converter output
23:22 Hybrid battery junction block harnesses and removal
27:20 Hybrid battery junction block connections and components
29:17 DC-DC converter fuse
30:30 Positive battery harness and connections
31:28 Positive battery harness and connections
32:00 Auxiliary harness connections
34:00 Li-Ion battery cover removal
35:20 Under the cover inspection
37:42 Tamper-resistant nuts
39:07 Cell stack voltages
29:50 Individual cell voltages
40:00 Cell pair voltage addition
41:31 Total cell stack and battery pack voltages
41:59 Battery vent system
The Li-Ion battery from a Ford Fusion Hybrid has 76 3.7V cells (281.2V) nominal and a ~5 Ah rating = 281.2 x 5 = 1406 Watt-hours or 1.406 kWh
**I failed to comply with three OSHA standards in this video:
- 1910.137(c)(2)(vii) - Protector gloves shall be worn over insulating gloves in this video.
- 1910.137(c)(2)(vii)(D) - Insulating gloves that have been used without protector gloves may not be reused until they have been tested under the provisions of paragraphs (c)(2)(viii) and (c)(2)(ix) of this section.
- 1910.137(c)(2)(vii)(A) - Protector gloves need not be used with Class 0 gloves, under limited-use conditions, when small equipment and parts manipulation necessitate unusually high finger dexterity.
I apologize for the error on my part. I was not aware of the requirement at that time. I now offer full updated training on PPE usage and following the proper OSHA regulations. See for more information.
Weber State University (WSU) - Department of Automotive Technology - Ardell Brown Technology Wing - Transmission Lab.
This episode covers High Voltage Hybrid Electrical Systems - Specifically the 2nd generation (2013-2016) Ford Fusion Hybrid 281.2 Volt Li-Ion battery system. Learn what is serviceable and how it works.
This topic is taught as part of our 4-year bachelor's degree program. For more information on the Weber Automotive program, visit:
This video was created and edited by Professor John D. Kelly at WSU. For a full biography, see