Ford Villager 2002 User Manual

Table of Contents

Introduction 4

Instrument Cluster 10

Warning and control lights 10 Gauges 15

Entertainment Systems 20

AM/FM stereo cassette (CD changer compatible) 20 AM/FM stereo cassette with CD 39 Rear seat controls 50 CD changer 53

Climate Controls 58

Manual heating and air conditioning 58 Electronic automatic temperature control 63

Lights 74

Headlamps 74 Turn signal control 76 Bulb replacement 77

Driver Controls 83

Windshield wiper/washer control 83 Steering wheel adjustment 85 Power windows 87 Mirrors 89 Speed control 90 Message center 99

Locks and Security 108

Keys 108 Locks 108 Anti-theft system 109

Table of Contents

Seating and Safety Restraints 115

Seating 115 Safety restraints 129 Air bags 136 Child restraints 141

Driving 155

Starting 155 Brakes 158 Transmission operation 162 Vehicle loading 167 Trailer towing 169 Recreational towing 172

Roadside Emergencies 173

Getting roadside assistance 173 Hazard flasher switch 174 Fuel pump shut-off switch 174 Fuses and relays 175 Changing tires 182 Jump starting 188 Wrecker towing 193

Customer Assistance 194

The dispute settlement board 197 Utilizing the mediation/arbitration 200 Getting assistance outside the U.S. and Canada 200 Ordering additional owner’s literature 201 Reporting safety defects (U.S. only) 202

Table of Contents

Cleaning 203

Maintenance and Specifications 209

Hood 210 Engine compartment 211 Engine oil 212 Battery 215 Fuel information 221 Air filter(s) 234 Part numbers 239 Refill capacities 239 Lubricant specifications 240 Engine data 241 Vehicle dimensions 242

Accessories 245

Index 248

All rights reserved. Reproduction by any means, electronic or mechanical including photocopying, recording or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from Ford Motor Company. Ford may change the contents without notice and without incurring obligation.

Introduction

The following warning may be required by California law:

CALIFORNIA Proposition 65 Warning

WARNING:

vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. In addition, certain fluids contained in vehicles and certain products of component wear contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

CONGRATULATIONS

Congratulations on acquiring your new Mercury. Please take the time to get well acquainted with your vehicle by reading this handbook. The more you know and understand about your vehicle the greater the safety and pleasure you will derive from driving it.

For more information on Ford Motor Company and its products visit the following website:

• In the United States: www.ford.com

• In Canada: www.ford.ca

• In Mexico: www.ford.com.mx

• In Australia: www.ford.com.au

Engine exhaust, some of its constituents, and certain

Introduction

Additional owner information is given in separate publications.

This Owner’s Guide describes every option and model variant available and therefore some of the items covered may not apply to your particular vehicle. Furthermore, due to printing cycles it may describe options before they are generally available.

Remember to pass on the Owner’s Guide when reselling the vehicle. It is an integral part of the vehicle.

Fuel pump shut-off switch In the event of an accident the

safety switch will automatically cut off the fuel supply to the engine. The switch can also be activated through sudden vibration (e.g. collision when parking). To reset the switch, refer to the Fuel pump shut-off switch in the Roadside emergencies chapter.

SAFETY AND ENVIRONMENT PROTECTION

Warning symbols in this guide

How can you reduce the risk of personal injury and prevent possible damage to others, your vehicle and its equipment? In this guide, answers to such questions are contained in comments highlighted by the warning triangle symbol. These comments should be read and observed.

Warning symbols on your vehicle

When you see this symbol, it is imperative that you consult the relevant section of this guide before touching or attempting adjustment of any kind.

Introduction

Protecting the environment

We must all play our part in protecting the environment. Correct vehicle usage and the authorized disposal of waste cleaning and lubrication materials are significant steps towards this aim. Information in this respect is highlighted in this guide with the tree symbol.

BREAKING-IN YOUR VEHICLE

There are no particular guidelines for breaking-in your vehicle. During the first 1 600 km (1 000 miles) of driving, vary speeds frequently. This is recommended to give the moving parts a chance to break in.

SPECIAL NOTICES

Emission warranty

The New Vehicle Limited Warranty includes Bumper-to-Bumper Coverage, Safety Restraint Coverage, Corrosion Coverage, and 7.3L Power Stroke Diesel Engine Coverage. In addition, your vehicle is eligible for Emissions Defect and Emissions Performance Warranties. For a detailed description of what is covered and what is not covered, refer to the Warranty Guide that is provided to you along with your Owner’s Guide.

Introduction

Special instructions

For your added safety, your vehicle is fitted with sophisticated electronic controls.

By operating other electronic equipment (e.g. mobile telephone

without exterior aerial) electromagnetic fields can occur which can cause malfunctions of the vehicle electronics. Therefore you should observe the instructions of the equipment manufacturers.

Please read the section Air bag in the Seating and safety

restraints chapter. Failure to follow the specific warnings and instructions could result in personal injury.

Front seat mounted rear-facing child or baby seats should

NEVER be used in front of a passenger side air bag.

Introduction

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

Vehicle Symbol Glossary

Safety Alert

Fasten Safety Belt Air Bag-Front

Air Bag-Side Child Seat

Child Seat Installation Warning

Brake System Anti-Lock Brake System

Brake Fluid Non-Petroleum Based

AdvanceTrac Master Lighting Switch

Hazard Warning Flasher Fog Lamps-Front

Fuse Compartment Fuel Pump Reset

See Owner’s Guide

Child Seat Tether Anchorage

Traction Control

Windshield Wash/Wipe

Rear Window Defrost/Demist

Windshield Defrost/Demist

Power Windows Front/Rear

Vehicle Symbol Glossary

Introduction

Power Window Lockout

Child Safety Door Lock/Unlock

Interior Luggage Compartment Release

Panic Alarm

Symbol

Engine Oil Engine Coolant

Engine Coolant Temperature

Battery

Do Not Open When Hot

Avoid Smoking, Flames, or Sparks

Battery Acid Explosive Gas

Fan Warning Power Steering Fluid

Maintain Correct Fluid Level

Engine Air Filter

MAX

MIN

Emission System

Passenger Compartment Air Filter

Jack Check fuel cap

Low tire warning

Instrument Cluster

WARNING LIGHTS AND CHIMES

Warning lights and gauges can alert you to a vehicle condition that may become serious enough to cause expensive repairs. A warning light may illuminate when a problem exists with one of your vehicle’s functions. Many lights will illuminate when you start your vehicle to make sure the bulb works. If any light remains on after starting the vehicle, have

the respective system inspected immediately.

Standard analog instrument cluster

RPM x 1000

MPH

100

TRIP A

120

140

160

100

km/h

CRUISE SET

Optional electronic instrument cluster

˚F ˚C MILES/BAL L/100 km

OUTSIDE TEMP INST ECONOMY AVG. ECONOMY TO EMPTY

AIR BAG

CRUISE

X 1000

BRAKE

TRIP 1 TRIP 2

RPM

PRND21

MPH km/h

FUEL DOOR UNLEADED FUEL ONLY

1/2

SERVICE ENGINE

SOON

O/D OFF

ABS

Service engine soon

Illuminates briefly to ensure the system is functional. If it comes on after the engine is started, one of the engine’s emission control

SERVICE

ENGINE

SOON

systems may be malfunctioning. The light may illuminate without a driveability concern being noted. The vehicle will usually be drivable and will not require towing.

Instrument Cluster

Light turns on solid:

Temporary malfunctions may cause the light to illuminate. Examples are:

1. The vehicle has run out of fuel.

2. Poor fuel quality or water in the fuel.

3. The fuel cap may not have been properly installed and securely tightened.

These temporary malfunctions can be corrected by filling the fuel tank with high quality fuel of the recommended octane and/or properly installing and securely tightening the fuel cap. After three driving cycles without these or any other temporary malfunctions present, the light should turn off. (A driving cycle consists of a cold engine startup followed by mixed city/highway driving.) No additional vehicle service is required.

If the light remains on, have your vehicle serviced at the first available opportunity.

Light is blinking:

Engine misfire is occurring which could damage your catalytic converter. You should drive in a moderate fashion (avoid heavy acceleration and deceleration) and have your vehicle serviced at the first available opportunity.

Under engine misfire conditions, excessive exhaust temperatures

could damage the catalytic converter, the fuel system, interior floor coverings or other vehicle components, possibly causing a fire.

Brake system warning

• Standard analog instrument cluster

• Optional electronic instrument cluster

BRAKE

Instrument Cluster

To confirm the brake system warning light is functional, it will momentarily illuminate when the ignition is turned to the ON position (alternatively for some vehicles when the ignition is moved from the ON position to START position, the light will momentarily illuminate prior to reaching the START position). It also illuminates if the parking brake is engaged. If the brake system warning light does not illuminate as described, seek service immediately. Illumination after the parking brake is released indicates low brake fluid level or a brake system malfunction and the brake system should be serviced immediately by a qualified technician. Refer to Brakes in the Driving chapter for more information.

Anti-lock brake system (ABS) (if equipped)

To confirm the anti-lock brake system (ABS) warning light is functional it will momentarily illuminate when the ignition is turned to the ON position (alternatively for some vehicles when the ignition is moved from the ON position to the START position, the light will momentarily illuminate just prior to reaching the START position). If the light remains on, continues to flash or fails to illuminate, have the ABS serviced immediately. If the ABS light remains on, it means the anti-lock brake system has malfunctioned and is disabled, however, the normal brake system will still function unless the brake warning light also remains illuminated and parking brake is off. Refer to Brakes in the Driving chapter for more information.

ABS

Safety belt

Illuminates to remind you to fasten your safety belts. For more information, refer to the Seating and safety restraints chapter.

Air bag readiness

• Standard analog instrument cluster

Instrument Cluster

• Optional electronic instrument cluster

AIR

BAG

Illuminates to confirm that the air bags are operational. If the light fails to illuminate, continues to flash or remains on, have the system serviced immediately.

Charging system

Illuminates when the battery is not charging properly.

Engine oil pressure

Illuminates when the oil pressure falls below the normal range. Check the oil level and add oil if needed. Refer to Engine oil in the Maintenance and specifications chapter.

Low fuel

Illuminates when the fuel level in the fuel tank is at, or near, empty (refer to Fuel gauge in this chapter for more information).

Low washer fluid

Illuminates when the windshield washer fluid is low.

Speed control

• Standard analog instrument cluster

The “CRUISE” light comes on when the ON control is pressed.

CRUISE SET

Instrument Cluster

The “SET” light comes on when either the COAST/SET or RES/ACCEL controls are pressed. The “SET” light turns off when the cruise cancel control is pressed or the brake is applied. Both the “CRUISE” and “SET” lights turn off when the OFF control is pressed or the ignition is turned to the OFF position.

• Optional electronic instrument cluster

This light comes on when either the COAST/SET or RES/ACCEL controls are pressed. It turns off when the cruise cancel control is pressed, the brake is applied or the ignition is turned to the OFF position.

O/D off

Illuminates when the overdrive function has been turned OFF using the Transmission Control Switch (TCS) on the gearshift. If the light does not come on or the light flashes steadily, have your vehicle serviced as soon as possible, damage to the transmission could occur.

Door ajar

• Standard analog instrument cluster

CRUISE

O/D

OFF

• Optional electronic instrument cluster

Illuminates when any door is open (or not fully closed).

Turn signals

Illuminates when the turn signals or the hazard lights are turned on. If the lights stay on continuously or flash faster, check for a burned-out bulb.

Instrument Cluster

High beams

Illuminates when the high beam headlamps are turned on.

Safety belt warning chime

Sounds to remind you to fasten your safety belts.

Headlamps on warning chime

Sounds when the headlamps or parking lamps are on, the key is removed from the ignition and the driver’s door is opened.

Key-in-ignition warning chime

Sounds when the key is left in the ignition and the driver’s door is opened.

GAUGES

Standard analog instrument cluster gauges

RPM x 1000

MPH

100

TRIP A

120

140

160

100

km/h

CRUISE SET

Instrument Cluster

Optional electronic instrument cluster gauges

CRUISE

˚F ˚C MILES/BAL L/100 km

OUTSIDE TEMP INST ECONOMY AVG. ECONOMY TO EMPTY

AIR BAG

BRAKE

X 1000

RPM

PRND21

TRIP 1 TRIP 2

Engine coolant temperature gauge

Indicates the temperature of the engine coolant. At normal operating temperature, the needle remains within the normal area (the area between the “H” and “C”). If it enters the red section, the engine is overheating. Stop the vehicle as soon as safely possible, switch off the ignition and let it cool. Refer to Engine coolant in the Maintenance and specifications chapter.

This gauge indicates the temperature of the engine coolant, not the coolant level. If the coolant is not at its proper level or mixture, the gauge indication will not be accurate.

Never remove the coolant reservoir cap while the engine is

running or hot. Steam and scalding liquid from a hot cooling system can burn you badly.

MPH km/h

FUEL DOOR UNLEADED FUEL ONLY

1/2

SERVICE ENGINE

SOON

O/D OFF

ABS

• Standard analog instrument cluster

Instrument Cluster

• Optional electronic instrument cluster

Fuel gauge

Displays approximately how much fuel is in the fuel tank. The fuel gauge may vary slightly when the vehicle is in motion or on a grade.

When refueling the vehicle from empty indication, the amount of fuel that can be added will be less than the advertised capacity due to the reserve fuel.

• Standard analog instrument cluster

• Optional electronic instrument cluster

1/2

Instrument Cluster

Speedometer

Indicates the current vehicle speed.

• Standard analog instrument cluster

MPH

100

120

140

160

100

km/h

TRIP A

• Optional electronic instrument

cluster

CRUISE

X 1000

TRIP 1 TRIP 2

RPM

MPH

km/h

Odometer

Registers the total kilometers (miles) of the vehicle.

• Standard analog instrument cluster

ODO

• Optional electronic instrument

cluster

CRUISE

X 1000

TRIP 1 TRIP 2

RPM

MPH

km/h

Refer to Electronic Message Center in the Driver controls chapter for information on how to switch the display from metric to English measurements.

Instrument Cluster

Trip odometer

Registers the kilometers (miles) of individual journeys.

• Standard analog instrument cluster

To reset, press and hold the control for one second.

• Optional electronic instrument cluster

Refer to Electronic Message Center in the Driver controls chapter for information on how to switch the display from Trip 1 and Trip 2

CRUISE

X 1000 RPM

features on the electronic instrument cluster.

Tachometer

Indicates the engine speed in revolutions per minute.

Driving with your tachometer pointer continuously at the top of the scale may damage the engine.

• Standard analog instrument cluster

TRIP 1 TRIP 2

RPM x 1000

TRIP A

MPH

km/h

• Optional electronic instrument cluster

CRUISE

MPH

km/h

X 1000

TRIP 1 TRIP 2

RPM

Entertainment Systems

AM/FM STEREO/CASSETTE (CD CHANGER COMPATIBLE)

VOL - PUSH ON

AM FM

BASS TREB BAL FADE

CLK

TAPE

AMS

SEEK

TUNE

DISCS

SCAN

321456

Volume/power control

Press the control to turn the audio system on or off.

Turn the control to raise or lower volume.

SIDE

REW

SHUFFLECOMPCD

VOL - PUSH ON

1 - 2

If the volume is set above a certain level and the ignition is turned off, the volume will come back on at a “nominal” listening level when the ignition switch is turned back on.

Bass adjust

The bass adjust control allows you to increase or decrease the audio system’s bass output.

Treble adjust

The treble adjust control allows you to increase or decrease the audio system’s treble output.

Speaker balance adjust

Speaker sound distribution can be adjusted between the right and left speakers.

Entertainment Systems

BASS

TREB

BAL

Entertainment Systems

Speaker fade adjust

Speaker sound can be adjusted between the front and rear speakers.

FADE

Seek function

The seek function control works in radio or CD changer mode.

Seek function in radio mode

• Press listenable station down the frequency band.

• Press listenable station up the frequency band.

Seek function for CD changer (if equipped)

• Press track of the current disc. If a selection has been playing for three seconds or more and you press replay that selection from the beginning.

• Press the last track has been completed, the first track of the current disc will automatically replay.

Scan function

The scan function works in radio or CD changer mode (if equipped).

to find the next

to seek to the previous

SEEK

TUNE

DISCS

SEEK

TUNE

DISCS

, the CD changer will

to seek forward to the next track of the current disc. After

SCAN

Scan function in radio mode

Press the SCAN control to hear a brief sampling of all listenable stations on the frequency band. Press the SCAN control again to stop the scan mode.

Entertainment Systems

Scan function in CD changer mode (if equipped)

Press the SCAN control to hear a brief sampling of all selections on the CD. (The CD scans in a forward direction, wrapping back to the first track at the end of the CD.) To stop on a particular selection, press the SCAN control again.

AM/FM select

The AM/FM select control works in radio, tape and CD changer modes (if equipped).

AM FM

AM/FM select in radio mode

This control allows you to select AM or FM frequency bands. Press the control to switch between AM, FM1 or FM2 memory preset stations.

AM/FM select in tape mode

Press this control to stop tape play and begin radio play.

AM/FM select in CD changer mode (if equipped)

Press this control to stop CD play and begin radio play.

Radio station memory preset

The radio is equipped with six station memory preset controls. These controls can be used to select up to six preset AM stations and twelve FM stations ( six in FM1 and six in FM2).

Setting memory preset stations

1. Select the frequency band with the AM/FM select control.

2. Select a station. Refer to Tune adjust or Seek function for more

information on selecting a station.

Entertainment Systems

3. Press and hold a memory preset control until the sound returns,

indicating the station is held in memory on the control you selected.

SHUFFLECOMPCDCD

321456

Setting the clock

Press CLK to toggle between listening frequencies and clock mode while in radio mode.

To set the hour, press and hold the CLK control and press the SEEK control:

CLK

TAPE

AMS

•

To set the minute, press and hold the CLK control and press the TUNE control:

to decrease hours and

to increase hours.

SEEK

TUNE

DISCS

CLK

TAPE

AMS

•

• to increase minutes.

The CLK control will allow you to switch between media display mode (radio station, stereo information, etc.) and clock display mode (time). When in clock mode, the media information will display for 10 seconds, when the radio is turned on, and then revert to clock information. Any time that the media is changed, (new radio station, etc.), the media information will again display for 10 seconds before reverting back to the clock. In media mode, the media information will always be displayed.

to decrease minutes and

SEEK

TUNE

DISCS

Entertainment Systems

Tune adjust

The tune control works in radio and CD changer modes (if equipped).

Tune adjust in radio mode

• Press frequency down the band (whether or not a listenable station is located there). Hold the control to move through the frequencies quickly.

• Press a listenable station is located there). Hold for quick movement.

Tune adjust for CD changer (if equipped)

• Press disc in the CD changer. (Play will begin on the first track of the disc unless the CD changer is in shuffle mode. Refer to Shuffle feature for more information. Hold the control to continue reversing through the disc.

• Press to fast-forward through the remaining discs.

to move to the next

SEEK

TUNE

DISCS

to move to the next frequency up the band (whether or not

to select the previous

SEEK

TUNE

DISCS

to select the next disc in the CD changer. Hold the control

Tape select

• To enter tape mode while in radio or CD changer mode, press the TAPE control.

• If no tape is found, NO TAPE appears in the display.

CLK

TAPE

AMS

Entertainment Systems

Automatic Music Search

The Automatic Music Search feature allows you to quickly locate the beginning of the tape selection being played or to skip to the next selection.

To activate the feature, momentarily depress the TAPE AMS button. Then, press either REW (for the beginning of the current selection) or FF (to advance to the next selection). The tape deck stops and returns to play mode when the AMS circuit senses a blank section on the tape.

In order to ensure proper operation of the AMS feature, the tape MUST have a blank section of at least four seconds duration between programs.

CD changer select (if equipped)

• To enter CD changer mode while in radio or tape mode, press the CD control.

CLK

TAPE

AMS

Rewind

The rewind control works in tape and CD changer (if equipped) modes.

To rewind in tape mode, press the SIDE/REW control.

SIDE

1 - 2

REW FF

Press the 1–2/FF control to stop rewinding the tape.

To rewind in CD changer mode, press the CD control.

Press the control again to deactivate rewind mode.

SIDE

1 - 2

REW FF

Entertainment Systems

Fast forward

The fast forward control works in tape and CD changer modes.

To fast forward in tape mode, press the 1–2/FF control.

Tape direction will automatically reverse when the end of the tape is reached.

Press the SIDE/REW control to stop the fast forward of the tape.

SIDE

1 - 2

REW FF

SIDE

1 - 2

REW FF

To fast forward in CD changer mode, press the CD control.

Press the control again to deactivate fast forward mode.

Tape direction select

Press SIDE and 1–2 at the same time to play the alternate side of a tape.

Eject function

Press the control to stop and eject a tape.

Compression feature (if equipped)

Compression adjust brings soft and loud CD passages together for a more consistent listening level.

Press the COMP control to activate and deactivate compression adjust.

SIDE

1 - 2

REW FF

COMP

Entertainment Systems

Shuffle feature (if equipped)

The shuffle feature operates in CD changer mode and plays all tracks on the current disc in random order. The shuffle feature continues to the next disc after all tracks are played.

Press the SHUFFLE control to start this feature. Random order play will continue until the SHUFFLE control is pressed again.

Dolby姞 noise reduction

Dolby威 noise reduction operates only in tape mode. Dolby威 noise reduction reduces the amount of hiss and static during tape playback.

Press the reduction.

Dolby威 noise reduction is manufactured under license from Dolby威 Laboratories Licensing Corporation. “Dolby威” and the double-D symbol are registered trademarks of Dolby Laboratories Licensing Corporation.

Rear audio controls (if equipped)

Your vehicle may be equipped with rear audio controls for the rear seat passengers. Refer to Rear Seat Controls in this Chapter for more information.

control to activate (and deactivate) Dolby威 noise

SHUFFLE

Entertainment Systems

PREMIUM AM/FM CASSETTE (CD CHANGER COMPATIBLE)

BAL

SEL

FADE

AUTO

VOL PUSH ON

MUTE

CD TAPE

FMAM

REW

SEEK

TUNE

SIDE 1.2

3 4

BASS

TREB

SCAN

COMP5SHUFF

RDS / CLK

Your audio system is equipped with selective lighting, a unique lighting strategy. This lighting feature is operable when the headlamps are illuminated. During the operation of any selected mode, lighting for the individual function controls will either illuminate or turn off. Those controls which have a function for the specific mode of operation selected will be lit, while the controls which have no function for that mode will be turned off.

Volume/power control

Press the control to turn the audio system on or off.

VOL PUSH ON

Entertainment Systems

Turn the control to raise or lower volume.

VOL PUSH ON

If the volume is set above a certain level and the ignition is turned off, the volume will come back on at a “nominal” listening level when the ignition switch is turned back on.

Bass adjust

The bass adjust control allows you to increase or decrease the audio system’s bass output.

Treble adjust

The treble adjust control allows you to increase or decrease the audio system’s treble output.

BASS

SEL

TREB

BASS

SEL

TREB

Speaker balance adjust

Speaker sound distribution can be adjusted between the right and left speakers.

BAL

SEL

FADE

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