Ford Neighbor 2002 Owner's Manual

Table of contents

Introduction Instrumentation Lights Driver controls Seating and safety restraints Driving Charging Roadside emergencies Cleaning Maintenance and specifications Customer assistance Warranty information Index

4 12 23 45 61 70 77 83 86 98

104 115

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Introduction

The following warning may be required by California law:

CALIFORNIA Proposition 65 Warning

Warning: This product contains or emits

chemicals known to state of California to cause cancer and birth defects or other reproductive harm. In addition, certain fluids or certain products of component wear contain or emit chemicals knot to the state of California to cause cancer and birth defects or other reproductive harm.

ICONS

Indicates a safety alert. Read the following section on warnings.

WARNINGS

Warnings provide information which may reduce the risk of personal injury to you and others.

BREAKING IN YOUR VEHICLE

There are no particular break-in schedules for the vehicle.

Proper charging and avoidance of over discharging of the batteries will enhance their lives and capacity. Make sure to read Battery charging in the Driving section of this manual and Batteries in the Maintenance and specifications section of this manual.

These are some of the symbols you may see on your vehicle.

Safety Alert

Introduction

Fasten Safety Belt

Brake System

Master Lighting Switch

INFORMATION ABOUT THIS GUIDE

The information found in this guide was in effect at the time of printing. Ford Motor Company and/or TH!NK Mobility, LLC may change the contents without notice and without incurring obligation.

Instrumentation

GAUGES

1 2

10 9 8 7

4 5

The instrument cluster LCD (liquid crystal display), referred to as the “gauge,” will be activated if any of the following conditions exist:

• Key switch is on

• Vehicle batteries are being recharged

1. Safety belt warning indicator

The safety belt warning icon will illuminate for 30 seconds after the vehicle is switched into D (Drive) mode.

2. Speedometer gauge LCD

A two-digit LCD gauge display shows the vehicle speed in either MPH or KPH, depending on the selected mode. Vehicle speed is shown while in R (Reverse), T (Turf), and D (Drive) modes. The top speed of your vehicle in Drive mode is 25 mph (40 km/h) and 15 mph (24 km/h) in Turf mode.

Instrumentation

3. Right turn signal indicator

The arrow will flash when the turn signal lever is pushed up. If the indicator flashes at a fast rate, it has a malfunction, such as a burned out bulb.

4. Odometer/trip counter display

A five-digit LCD display shows the total accumulated miles traveled. The display may be changed to measure a particular trip distance. The drive mode selector switch must be in the T (Turf) or D (Drive) mode for this function. When the vehicle is restarted, the display will return to the last mode manually set.

Changing and resetting the modes

The odometer/trip modes can be changed by pressing the Select/Reset button on the instrument cluster. The word “TRIP” will be displayed next to the five-digit display when in Trip mode. To measure a specific trip mileage, with the drive mode selector switch in T (Turf) or D (Drive) reset the trip odometer by pushing and holding the Select/Reset button down for three seconds.

5. Drive system over-temperature indicator

This icon will illuminate if the drive system overheats. The vehicle will drive normally 30 seconds, after which power will be limited and will remain limited until the drive system cools.

Instrumentation

6. Service required indicator

The icon will illuminate when the vehicle has a malfunction in the motor controller. Cycle the service disconnect switch off and then back on. The service disconnect switch is located below and behind the parking brake lever within the seat stanchion (battery cover). It is a black rubber switch and faces the front of the vehicle. To access the service disconnect switch, remove the seat stanchion front cover, refer to Flooded type batteries in Maintenance and specifications. If the service required indicator is still on, take your vehicle to an authorized Dealer for the required maintenance to maintain your full warranty coverge.

7. Battery water reminder indicator

This icon indicates that your vehicle’s batteries require a maintenance check of the battery fluid levels.

Distilled water or demineralized water must be added as needed. Your vehicle comes

equipped with one of two types of batteries: “flooded”, requiring water level checks and maintenance refills; or the optional sealed maintenance free, for which no maintenance is required. This indicator will be disabled if your vehicle is equipped with sealed batteries. If you change the type of battery in your vehicle, the TH!NK dealer will need to change the battery setting in the gauge.

Resetting the battery water reminder indicator Once the battery water has been checked, reset

the reminder by pressing and holding the Select/Reset button for over three seconds while in the R (Reverse) mode. The reminder will only be reset during the following conditions: R (Reverse) mode is selected with the drive mode

Instrumentation

selector switch; instrument cluster gauge is in flooded battery mode.

8. System Select/Reset button

This button is used to perform four functions.

a. Each time the Select/Reset button is pressed and released in less than three seconds, the odometer/trip counter will switch between odometer and trip function displays. The drive mode selector switch must be in the D (Drive) or T (Turf) mode for this function.

b. Pressing and holding the Select/Reset button, with the odometer in the trip mode, for over 3 seconds before releasing will reset the trip odometer to zero and return to the trip odometer function. The drive mode selector switch must be in the D (Drive) or T (Turf) mode for this function.

c. Pressing and holding the Select/Reset button for over three seconds will reset the battery water reminder indicator. The drive mode selector switch must be in the R (Reverse) mode and the instrument cluster must be in “battery flooded mode” for this function.

d. The Select/Reset button will allow you to display diagnostic code(s). To display the diagnostic code(s):

• With the key in the OFF position, press and hold the Select/Reset button.

• Select D (Drive) mode with the key.

• Release the Select/Reset button.

• Press and release the Select/Reset button to scroll

through the diagnostic codes and their corresponding odometer value.

• All codes will be deleted by holding the Select/Reset button for three seconds and releasing.

Instrumentation

• Exit Service mode by selecting the OFF mode with the key.

• Press and release the Select/Reset button.

The following is a list of diagnostic codes.

Fault Code

05 Start switch fails to close. 06 Accelerator potentiometer pedal is depressed with

08 Accelerator input voltage too low on power up after

09 Both forward and reverse direction switches are

11 Start switch closed on power up after initial drive

15 Battery voltage is too low at initial drive mode

16 Battery voltage is too high at initial drive mode

23 Motor field current is high on start up in the

24 Motor field current is high on start up in the

27 12V buss is too low. 41 Open thermal protector (TP) or transistor

42 Motor armature offset voltage is too high. 43 Motor armature offset voltage is too low. 44 Armature transistor did not turn off properly. 45 Armature transistor did not turn on properly. 46 “Look Ahead” test for A2 volts less than 12% of

49 Motor field current is too low during the run mode. 51 Capacitor voltage is low before the line contactor

57 Controller “motor current sensor” input too low

75 Capacitor (1C) voltage too high during motoring

Description

no direction selected.

initial drive mode selector switch closure.

closed at the same time.

mode selector switch closure

selector switch closure.

reverse direction.

forward direction.

over-temperature.

battery volts.

closes.

while running.

Instrumentation

Fault Code

76 Capacitor (1C) voltage too high during regenerative

90 Motor thermostat is open during control operation.

Description

braking.

9. Battery charge

indicator

The icon will illuminate when the vehicle is connected to an outside power source to charge the batteries. The drive mode selector switch should be in the OFF position while the battery is charging.

Note: If this indicator is illuminated without the vehicle being charged there is a charger problem. The vehicle should be taken to an authorized TH!NK dealer.

10. Battery level

indicator

The battery level indicator shows the power level remaining in the batteries. Be sure the vehicle is not charging when checking the battery state of charge or the reading may be incorrect. The battery level indicator shows full whenever the vehicle is charging. Five bars are illuminated when the batteries have a full charge. At one bar, the battery outline will begin to flash. The flashing frequency will increase as the state of charge decreases. At low pack voltage, you may see either five bars or zero bars with a flashing outline. To maximize battery life, charge the vehicle as soon as possible when the outline begins to flash. When there are zero bars showing, the batteries have been discharged to the point where additional operation of your vehicle will reduce battery life. Charge the vehicle batteries immediately. If left uncharged, the batteries could

Instrumentation

discharge to the point where the battery charger will not turn on and battery damage may occur.

After a partial charge, the level may read higher than it actually is. Driving a few miles will cause the battery gauge to settle to an accurate level.

11. Brake status

indicator

This icon will illuminate if the emergency brake handle is not fully released, or if the brake fluid level is low. It will also flash while the park brake reminder is sounding.

12. Electrical leakage

warning indicator

This icon will illuminate to warn that there is electrical “leakage” or short circuit to the vehicle frame. If the vehicle is wet or has recently been washed, allow the vehicle to fully dry and recheck for the indicator. If the indicator is still present, take your vehicle to an authorized TH!NK Dealer to correct the condition.

To avoid serious injury and/or death, never

perform any vehicle service or maintenance while the electrical leakage warning indicator is illuminated.

Instrumentation

This vehicle contains a high voltage

electrical system. Serious injury, death, and/or property damage may result if this vehicle is not properly used, charged or serviced as stated in this manual. Read this owner’s guide prior to use, charging, or servicing this vehicle. Do not drill, cut, or modify any part of this vehicle, as high voltage wiring is present. Do not use jumper cables. Only charge this vehicle with an approved GFCI cord as stated in Battery charging.

13. Left turn signal indicator

The arrow will flash when the turn signal lever is pushed down. If the indicator flashes at a fast rate, it has a malfunction, such as a burned out bulb.

Audible Indicators

Park brake reminder

The park brake reminder has a tone that sounds for 10 seconds when the drive mode selector switch is turned to the OFF position with the parking brake not set. It stops after 10 seconds or when the parking brake is engaged. During this time the vehicle is “active” with functional park brake reminder and the gauge will be active and backlit. After 10 seconds, the vehicle shuts down and park brake reminder is no longer functional.

To avoid serious injury, death, and/or

property damage, always engage the parking brake before leaving the vehicle.

Reverse alarm

When the vehicle is in R (Reverse), a tone is generated to alert the driver and pedestrians.

Lights

HEADLAMP CONTROL

The headlamps are the larger inboard lamps on the front panel of the vehicle. The smaller outboard lamps are the front turn signals.

The headlamp switch also controls the tail lights. The tail lights are the larger inboard lamps integrated into the rear bumper. The smaller outboard lamps are the rear turn signal lamps.

The headlamp switch is located on the lever on the left side of the steering column. The center section of the lever rotates to turn on the rear tail lamps, license plate lamps, and the headlamps.

The headlamp switch can be identified by the bright bulb symbol.

Lights

Always remember to turn on your

headlamps at dusk and dawn and during inclement weather. Failure to activate your headlamps under these conditions could result in a collision.

The OFF position is indicated on the lever by the O. When the switch arrowhead is aligned with the O symbol, the exterior lamps are off. The lights will not operate in the key OFF mode.

The first position above the OFF position is the rear tail lamps and license plate lamp.

The second position above the OFF position will illuminate the headlamps while the rear tail lamps and license plate lamps remain on.

Pulling the headlamp switch rearward while it is in the OFF position will cause the headlamps to turn on as long as the switch is held rearward. There are no high beams on this vehicle. Pulling the headlamp switch rearward while it is in the ON position will NOT change the performance of the headlamps.

Lights

TURN SIGNAL CONTROL

The headlamp switch lever also controls the turn signals. Push down to activate the left turn signal, and push up to activate the right turn signal. The arrow indicator will flash on the instrument cluster indicating that the turn signal is on.

AIMING THE HEADLAMPS

The headlamps on your vehicle are properly aimed at the assembly plant.

If your vehicle has been in an accident the alignment of your headlamps should be checked by a qualified service technician.

Vertical aim adjustment

1. Park the vehicle on a level surface approximately

7.6 meters (25 feet) from a vertical wall or screen directly in front of it.

• (A) 2.43 meters (8 feet)

• (B) Height of top of lamp beam to ground

• (C) 6.09 meters (25 feet)

• (D) Horizontal reference line

Lights

2. Turn on the headlamps to illuminate the wall or screen.

3. On the wall or screen you will observe an area of high intensity light. The top of the high intensity area should be between 0.61 meters (2 ft) and 0.69 meters (2 ft 3 in) above the ground. If not, the beam will need to be adjusted by a qualified TH!NK technician.

BULB REPLACEMENT Headlamps

To remove the headlamp bulb:

1. Remove the scrivet and the cowl tray panel.

Lights

2. Disconnect the headlamp electrical connector.

3. Rotate the headlamp bulb shield counterclockwise and flip down to access the bulb connectors.

4. Pull the flat connector attached to the white wire from the headlamp bulb shield.

Lights

5. Push and squeeze the two bulb retainer wires to disengage them from the headlamp housing. Remove the headlamp bulb.

To install the headlamp bulb:

Handle the halogen headlamp bulb carefully

and keep out of the children’s reach. Grasp the bulb only by its metal base and do not touch the glass. The oil from your hand could cause the bulb to break the next time the headlamps are operated.

1. Install the headlamp bulb. Squeeze and push the two bulb retainer wires to engage them to the headlamp housing.

2. Push the flat connector attached to the white wire into the headlamp bulb shield.

Lights

3. Install and rotate the headlamp bulb shield clockwise.

4. Connect the headlamp electrical connector.

5. Install the cowl tray panel and the scrivet.

Lights

Replacing the front turn signals

1. Remove the scrivet and cowl tray panel. (Driver side shown; the passenger side is similar.)

2. Twist counterclockwise and remove the front turn signal bulb retainer.

3. Remove the bulb.

4. Install the new bulb.

5. Install the removed components.

Replacing the rear high-mount stop and reverse lamp bulbs

1. Remove the two screws and pull out the lamp assembly to expose the bulb sockets on the back.

Lights

2. Rotate the bulb socket counterclockwise and pull out to access the bulb.

3. To remove the bulb, pull it straight out of the socket.

4. Insert a new bulb into the socket until it is fully seated.

5. Install the socket into the back of the lamp assembly and turn clockwise until it is locked into place.

6. Position the lamp assembly into the vehicle housing and install the two screws. Tighten the screws firmly, but do not over-tighten. Over-tightening can cause damage to the lamp.

Replacing the rear turn signals

1. Unlock and remove the decklid (if equipped).

2. From inside the rear wheel housings, remove the six rear bumper bolts and carefully lower the bumper.

3. Twist counterclockwise and remove the rear turn signal bulb retainer.

Lights

4. Remove the bulb.

5. Install the new bulb.

6. Install the removed parts. Tighten the rear bumper bolts to 8–10 N•m.

7. Install and lock the decklid.

Replacing the tail lights/brake lights

Note: The bulb in the tail light/brake light assembly is not serviceable. The entire assembly must be replaced.

1. Unlock and remove the decklid.

2. Disconnect the electrical connector.

3. Remove the three screws and the rear turn signal assembly.

4. Connect the electrical connector and install the new lamp assembly.

Lights

5. Tighten the screws firmly, but do not over-tighten.

6. Install and lock the decklid.

Using the right bulbs

Replacement bulbs are specified in the chart below.

Function Number of bulbs Trade number

Headlamp 2 H3 Backup lamp 2 906 License plate lamp 1 W5W High-mount stop lamp 1 922 Turn signal lamp 4 7507/PY21W All replacement bulbs are clear in color except where

noted. To replace all instrument panel lights - see your Dealer.

Driver controls

WINDSHIELD WIPER/WASHER Front wiper control

The front windshield wiper is controlled by the lever mounted on the right side of the steering column.

To operate the windshield wiper, with the drive mode selector switch in R (Reverse), T (Turf) or D (Drive), push the lever up.

Washer

To operate the windshield washer, turn the wiper on, push the end of the lever in toward the steering column and hold it in for the desired length of spray. Release the lever to stop the washer and turn the wiper off.

Driver controls

Checking windshield washer fluid

To check the windshield washer fluid level:

1. Unlock and remove the hood.

2. Observe the level of fluid in the reservoir on the right side of the compartment.

3. If necessary, unscrew the reservoir cap and fill with pre-mixed washer fluid.

4. Install the reservoir cap.

5. Install and lock the hood.

Checking the wiper blade

If the wiper operation results in streaky or obstructed vision, clean the blade with mild soap and water to remove any foreign material, grease or dirt. If the wiper operation still results in poor visibility, inspect the blade, the insert, and the arm.

• Confirm that the arm and blade are not bent or damaged. If any defect is found, the part must be replaced to assure proper operation.

• Confirm that the wiper blade insert is supple and pliable. If it has become hard, cracked, or split it must be replaced for proper operation.

Driver controls

SUN ROOF/ROOF VENT (IF EQUIPPED)

The sun roof/roof vent is located in the roof panel. Opening it increases air flow to the driver and front passenger.

FRONT

To open the sun roof/roof vent:

1. Pull down on the sun roof/roof vent handle to

unlock the sun roof/roof vent.

2. Rotate the handle rearward and swivel up until it

locks in one of the five raised positions. To close the sun roof/roof vent:

1. Pull down on the sun roof/roof vent handle to

unlock the sun roof/roof vent.

2. Rotate the handle forward and swivel up until it

locks in the closed position.

2–PASSENGER WAGON (IF EQUIPPED)

Your two-passenger wagon was designed for transporting loads of up to 226 kg (500 lbs) in the wagon bed.

Driver controls

Wagon bed

The wagon bed was designed for easy loading and unloading. Pressing the two latches inward toward the middle of the tailgate and pulling toward you will open the tailgate.

HEATER/DEFOGGER (IF EQUIPPED)

The heater/defogger system is a single speed fixed temperature system. There are no controls to adjust fan speed or outlet air temperature.

Air distribution

The air flow volume and direction can be regulated with the side registers.

Side registers

Adjust as necessary for comfort or to direct air to the windows for defogging.

Heater/defogger switch

Operating the heater/defogger switch will energize the heater/defogger system for approximately 5–10 minutes. After which it will automatically shut off. If required, the system can be reenergized by operating the switch again. Pressing the heater/defogger switch while the system is operating will turn the system off.

Note: Operating the heater/defogger system uses high amounts of energy and greatly reduces the vehicle range. Only operate the heater/defogger system when necessary.

Driver controls

HORN

To activate the horn, push one of the three horn contact points on the steering wheel.

CUPHOLDER

Your vehicle is equipped with a number of convenient cupholders, depending on which storage trays your vehicle has.

Driver side instrument panel storage tray with cupholder and storage compartments (Passenger side is similar.)

Optional cowl tray with sport package.

Driver controls

Rear cupholders (4-passenger only)

15 A POWER POINT (IF EQUIPPED)

The 15A power point is located on the passenger side of the instrument panel. The power point is operational at all times. For safety, there is a rubber plug protecting the power point. To use the power point, remove the rubber plug and insert the desired accessory plug. Always keep the rubber plug inserted into the power point when not in use.

Note: The power point should not be used during battery charging.

MIRRORS Interior rear view mirror

The interior rear view mirror is adjustable for both day and night use. To reduce the glare at night, use the manual switch at the base of the mirror to put the mirror in night mode.

Exterior mirror

The exterior rear view mirrors (right-hand mirror is optional) are adjusted manually. Your view should be

Driver controls

adjusted so that the vehicle’s rear tires are just visible in the bottom inside corner of the mirror. This will minimize any “blind spot” in your field of view.

Always confirm it is clear behind you before changing lanes or backing up to avoid a

collision.

GOLF RACK (IF EQUIPPED)

To mount golf bags in the golf rack:

1. Unlock the decklid. To remove the decklid, lift

and raise the decklid.

2. Pull rearward

on the bag belt webbing release/locking lever.

3. Pull the webbing out of the release/locking lever.

Note: The base of the golf bag should rest on the top of the golf bag tray.

Driver controls

4. Position the golf bag in the trunk area.

5. Route the webbing through the golf bag handle

and through the release/locking lever.

6. Remove any slack from the webbing and lock the

release/locking lever.

FLOOR MATS

The floor mats are fastened to the floor with scrivets that can be loosened and removed for cleaning under the floor mats.

SCORECARD HOLDER (IF EQUIPPED)

The scorecard holder is attached to the glove box door with magnets after attaching a magnetic disc to the glove box door.

STEREO (IF EQUIPPED)

For operating instructions for the stereo, please refer to the instructions provided with the unit.

SAND AND SEED BOTTLE AND HOLDER (IF EQUIPPED)

The sand and seed bottle holder is mounted to the left-hand side roof pillar.

+ 88 hidden pages

Ford Neighbor 2002 Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual