Azure Dynamics Transit Connect Electric Specifications

Service Assistance And Supplemental Information
For Vehicle Owners And Operators
Azure Dynamics vehicles are sold and serviced through a network of authorized dealers who will
assist you with any periodic maintenance or service required for your vehicle.
The information contained in this publication
was current at time of publication,.
To ensure that you have the most up-to-date
reference on operation of your vehicle and its
systems, Azure Dynamics provides updated
and supplemental information on its Product Support website: AZDtec.com.
The information below contains both normal URL links and special electronic ―QR‖ links that may
be accessed through an appropriate reader on your web-enabled ―Smartphone‖.
Supplemental Update Information
http://azdtec.com/azdvehicles/ogs_updates/tce/
Or scan QR Bar Code at left.
Authorized Azure Dynamics Dealer Locations
http://azdtec.com/dealer/index.php
Or scan QR Bar Code at left.
Driver Orientation Video
http://www.youtube.com/watch?v=yjw8EVehflU
Or scan QR Bar Code at left.
P/N 107384-A,
9/8/2011
Introduction
INTRODUCTION
2
INSTRUMENT CLUSTER
6
CLIMATE CONTROLS
13
TIRES, WHEELS & LOADING
14
DRIVING
15
ROADSIDE EMERGENCIES
21
CLEANING
24
MAINTENANCE & SPECIFICATIONS
25
SCHEDULED MAINTENANCE
32
HIGH VOLTAGE BATTERY CHARGING
35
3
Introduction
OVERVIEW
The Transit Connect Electric is an electric vehicle produced by Azure Dynamics
Corporation and Ford Motor Company.
The vehicle is powered by a high voltage traction motor—mounted under the hood—
which drives the front wheels through a transmission. Power for the motor is supplied by
a high voltage battery pack which is mounted under the cargo area forward of the rear
wheels.
A junction box—mounted underneath the floor between the front seats—provides a
connection point between the high voltage battery and other system components. High
Voltage wiring is identified with distinctive orange cabling.
DRIVER CONTROLS
All Driver controls are used as they would be on a standard Transit Connect. This
includes power steering, power brakes, gear selection, and climate controls.
ELECTRICAL OPERATION
The Transit Connect Electric uses both High Voltage and Low Voltage systems. A
conventional 12 V battery maintains normal vehicle systems, however it is maintained by
the High Voltage Battery. All electrical power used comes from this High Voltage
Battery, which is maintained by recharging the vehicle from an external source.
See the High Voltage Battery Charging chapter at the back of this Supplement for
details.
4
Introduction
VEHICLE HIGH VOLTAGE BATTERY CHARGING
A charge port for external AC power is provided on the right side of the vehicle behind
the filler door.
An on-board charger is located under the hood and is electrically
connected to the charge port and the High Voltage Battery.
NOTE: Electric Vehicle Supply Equipment (EVSE) must be
properly and safely connected to the electrical grid to ensure
proper vehicle charging. Always have a certified Electrician install any EVSE or outlets
to support an EVSE.
See the High Voltage Battery Charging chapter at the back of this Supplement for
details.
5
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—as a
check—when you start your vehicle. If any
light remains on after starting the vehicle,
refer to the respective system warning light
for additional information.
The following warning lights are located on the left side of the instrument cluster on the
Range Indicator face.
Power Limit: This lamp will illuminate (solid) to indicate that the estimated
range is less than 0.5 kilometers (0.3miles), or that the vehicle power output is
being limited. The vehicle can continue to be driven with a solid Power Limit
lamp.
This lamp will flash to indicate a condition where the vehicle power output is being
significantly limited. If the Power Limit lamp is flashing, safely manoeuvre the vehicle
to the side of the road and have the vehicle towed to an authorized AZD repair
facility.
Anti-lock brake system: If the ABS light stays illuminated or continues to
flash, a malfunction has been detected, have the system serviced by your
authorized dealer. Normal braking is still functional unless the brake warning light also is
illuminated.
.
6
Instrument Cluster
Powertrain Service: This lamp will illuminate (solid) to indicate that the
vehicle has logged a fault requiring service. The vehicle can continue to be
driven; the Powertrain Service condition will be re-evaluated at the next keycycle. Contact your authorized dealer as soon as possible.
Charging Indicator: This lamp will illuminate while the High Voltage
Battery is being charged if the key is in the II position (on). The vehicle can
not be started while being charged.
Airbag readiness: If this light fails to illuminate when the ignition is turned to
on, continues to flash or remains on, have the system serviced immediately by
your authorized dealer. A Chime will sound when there is a malfunction in the
indicator light.
Speed Control: Refer to the Driver Controls chapter of the Ford Transit
Connect Owner’s Guide for more information.
Stop Safely Hazard Warning: This lamp will illuminate to indicate an high
voltage component fault/failure that will cause the vehicle to shutdown, fail
to start, or enter a limited operating mode.
Note: If the vehicle is still on, the vehicle may soon shutdown without
further warning and should be stopped safely. Safely maneuver the vehicle to the
side of the road and have the vehicle towed to an authorized AZD repair facility.
Low tire pressure warning: Illuminates when your tire pressure is low. If the light
remains on at start up or while driving, the tire pressure should be checked.
Refer to Inflating your tires in the Tires, Wheels and Loading chapter of this
Supplement.
When the ignition is first turned to on, the light will illuminate for three
seconds to ensure the bulb is working. If the light does not turn on or begins
to flash, have the system inspected by your authorized dealer.
For more information on this system, refer to Tire pressure monitoring
system (TPMS) in the Tires, Wheels and Loading chapter of the Ford Transit Connect
Owner’s Guide.
7
Instrument Cluster
WARNING LIGHTS AND CHIMES
The following warning lights are located
on the right side of the instrument cluster
on the Speedometer face.
AdvanceTrac® This lamp illuminates when the AdvanceTrac® is active. If
the light remains on, contact your authorized dealer as soon as possible.
Refer to the Driving chapter of the Ford Transit Connect Owner’s Guide for
more information.
Anti-theft system: Flashes when the SecuriLock® Passive Anti-theft
system has been activated.
High Voltage Battery (Layered Battery): This lamp illuminates (solid)
to indicate approximately 5 miles (8 km) of range. This lamp flashes to
indicate approximately 0 mile (0 km) of range.
Brake system warning light: To confirm the brake system warning light
is functional, it will momentarily illuminate when the ignition switch is
turned to the on position , or in a position between on and start, or by
applying the parking brake when the ignition is turned to the on position.
If the brake system warning light does not illuminate at this time, seek service
immediately from your authorized dealer. Illumination after releasing the parking brake
indicates low brake fluid level and the brake system should be inspected immediately by
your authorized dealer.
A chime will sound when there is a malfunction in the indicator light.
8
Instrument Cluster
WARNING: Driving a vehicle with the brake system warning
light on is dangerous. A significant decrease in braking performance may
occur. It will take you longer to stop the vehicle. Have the vehicle checked by
your authorized dealer. Driving extended distances with the parking brake engaged can
cause brake failure and the risk of personal injury.
DC/DC Charging system: Illuminates when the 12V battery has low voltage.
Headlamps: Illuminates when the low–beam headlamps are turned on.
High beams: Illuminates when the high-beam headlamps are turned on.
Door ajar: Illuminates when the ignition is in the on position and any door
is open.
Safety belt: Reminds you to fasten your front driver and passenger safety belt.
A Belt-Minder® chime will also sound to remind you to fasten your safety belt.
Refer to the Seating and Safety Restraints chapter of the Ford Transit Connect
Owner’s Guide to activate/deactivate the Belt-Minder® chime feature.
Turn signal: Illuminates when the left or right turn signal or the hazard
lights are turned on. If the indicators stay on or flash faster, check for a
burned out bulb.
Rear fog lamps: Illuminates when the rear fog lamps are turned on (if
equipped).
9
Instrument Cluster
Key-in-ignition warning chime: Sounds when the key is left in the ignition in
the off or accessory position and the driver’s door is opened.
Park warning chime: Sounds when the transmission is not in Park, the driver’s door is
opened and the ignition is off or in accessory position.
Headlamps on warning chime: Sounds when the headlamps or parking lamps are on
and the driver’s door is opened.
Seatbelt warning chime: The seatbelt chime sounds when the driver’s seatbelt is not
fastened. When the ignition is in run and the seatbelt is not fastened, the chime will
chime for 6 seconds. The chime will turn off if the driver’s seatbelt is fastened or if the
ignition returns to off or accessory position.
Belt minder warning chime: This chime periodically sounds to remind the driver and/
or passenger that their seatbelt is unbuckled. The seatbelt warning lamp in the cluster
will also illuminate once vehicle speed has exceeded 6 mph (10 km/h).
Airbag secondary warning chime: This chime sounds to indicate a fault with the supplemental restraint system in the event that the airbag readiness warning light is not operating.
Door ajar warning chime: The door ajar reminder chime informs the driver that one or
more doors are open while the ignition is in the run position.
Power Limit chime: A chime will sound to indicate the Power Limit lamp has been
turned on or off.
High Voltage Battery (Layered Battery): A chime will sound to indicate the High
Voltage Battery lamp has been turned on or off.
10
Instrument Cluster
GAUGES
Speedometer: Indicates the current vehicle
speed.
Range Gauge: Marked in increments showing
approximate range remaining in miles or kilometers based on stored vehicle usage history.
The range gauge is active after the vehicle has
been started.
NOTE:
The Range Gauge operates based on 400 miles of stored vehicle usage history. The
Gauge may not be at the maximum after charging if the vehicle 400 mile average is
lower. Your actual range may differ.
Vehicle range is affected by operating conditions.
For maximum range, avoid heavy acceleration and excessive vehicle speeds.
The use of any vehicle electrical equipment will affect range as well.
To maximize range, minimize use of heater and air conditioner whenever possible. See
State of Charge Gauge.
11
Instrument Cluster
Temperature Gauge: High Voltage electrical
components including the traction motor and High
Voltage Battery are liquid cooled. The coolant
temperature is maintained by the vehicle radiator
and electric fans.
At normal operating temperature, the needle will be
in the normal range, below the red line and the H
indicator.
If the Temperature Gauge indicates an over-temperature condition, the Power Limit lamp
will illuminate, and the vehicle will go into the Power Limit Mode to attempt to lower
the temperature.
The vehicle can still be driven in Power Limit Mode.
WARNING: Never remove the coolant reservoir cap while the
Vehicle is started or hot.
State of Charge Gauge: This shows the charge
level of the High Voltage Battery.
This gauge is used in conjunction with the Range
Gauge and High Voltage Battery Warning lamp to
inform the driver of the High Voltage Battery
charge level and of the estimated range before
charging is required.
After fully charging the HV Battery, this gauge will
read full.
With a full SOC reading, the vehicle can achieve the maximum range given the driving
style and electrical accessory loading (heater and air conditioning).
See Range Gauge.
12
Climate Controls
CLIMATE CONTROLS
Any operation of the heater or air conditioning systems during vehicle operation will
have an adverse effect on vehicle range. See Range Gauge and State of Charge Gauge.
If use is needed during normal vehicle operation, use the minimum amount of heating
and cooling consistent with occupant comfort.
See the Climate Controls chapter of the Ford Transit Connect Owner’s Guide for details
on heating and air conditioning controls and other general information.
13
Tires, Wheels & Loading
TIRE PRESSURES
Refer to the Tire and Loading Information sticker on the Driver’s door-jam for tire inflation information.
See the Tires, Wheels & Loading chapter in the Ford Transit Connect Owner’s Guide for
details and other general information.
14
Driving
STARTING PREPARATIONS
Positions of the ignition
0 (Off) — Locks the steering wheel and gearshift lever
and allows key removal.
This position also shuts off all the electrical accessories
and disconnects all high voltage components from the
high voltage battery pack.
I (Accessory) — Allows the electrical accessories
such as the radio to operate while the vehicle is not
started.
II (On) — Driving Mode: All vehicle control circuits are operational. Warning lights
illuminated. Key position when driving — after vehicle is started.
II (On) — Charging Mode: Used during vehicle charging to allow cabin preconditioning (if equipped).
III (Start) — Connects the high voltage system and readies the vehicle for operation.
Turn the key and release to start the vehicle.
Preparing to start your vehicle
This is an electric vehicle but is powered-up in the same way as a conventional vehicle is
started.
Since there are no typical engine sounds, your indications that the high voltage system is
ready for driving are the instrument cluster readings for the Range Indicator and State of
Charge Indicator (See Instrument Cluster Section).


Key to ON position—Range indicator moves up to OFF position from maximum
downscale; State of Charge Indicator moves to bottom indication.
Key to START position—Range indicator moves from off position up to indicate
available range. State of Charge Indicator moves up from bottom indication to show
current state of charge.
15
Driving
With key in II (on) position, Range
Indicator and State of Charge Indicators move to bottom of range
only.
VEHICLE IS NOT READY FOR
DRIVING
With the key in the III (start) position and released, both Range Indicator and State of Charge Indicator
move.
VEHICLE IS READY FOR
DRIVING
Before starting the vehicle:
1. Make sure all occupants buckle their safety belts. For
more information on safety belts and their proper usage,
refer to the Seating and Safety Restraints chapter in the
Transit Connect Owner’s Guide.
2. Make sure the headlamps and electrical accessories are
off.


16
Make sure the parking brake is set.
Make sure the gearshift is in P (Park).
Driving
STARTING UP—INITIALIZATION
1. Turn the key to II (On) without turning the key to III
(Start).
Some warning lights will briefly illuminate. See
Warning Lights and Chimes in the Instrument Cluster
chapter of this Supplement for more information
regarding the warning lights.
2. Turn the key to III (Start), then release the key when the Range Indicator and State of
Charge Indicator move up scale. This indicates that the vehicle has been started and is
ready to drive.
The vehicle is shut off by moving key switch to 0 (Off) position after bringing it to a
complete stop and shifting into Park.
3. After verifying normal instrument indications, use this procedure:



Depress brake pedal.
Shift out of park into Drive or Reverse.
Release parking brake and drive.
NOTE:
Maximum vehicle speed is limited to 75 mph (120 km/hr). This top-speed is maintained
by the vehicle software and indicates normal operation.
17
Driving
NOTE:
Vehicle range is affected by operating conditions. For maximum range, avoid heavy
acceleration and excessive vehicle speeds.
The use of any vehicle electrical equipment will affect range as well. To maximize
range, minimize use of heater and air conditioner whenever possible. See Range Gauge
and State of Charge Gauge.
To set the parking brake (1), pull the
parking brake handle up as far as possible.
The BRAKE warning lamp will illuminate
and will remain illuminated until the
parking brake is released.
To release, press and hold the button (2),
pull the handle up slightly,
then push the handle down.
WARNING: Always set the parking brake fully before putting the gearshift
into P (Park).
WARNING: If the parking brake is fully released, but the brake
warning lamp remains illuminated, the brakes may not be working properly.
See your authorized dealer as soon as possible
18
Driving
SHIFTER OPERATION
This vehicle does not have a conventional multi-speed transmission, instead it uses a
single-speed transmission to provide gear reduction and provide differential action for
the front wheels.
Driving the vehicle is the same as driving with an automatic transmission since the
electric traction motor provides sufficient speed range without the need for gear changes.
The shifter functions normally in the Park, Reverse, Neutral and Drive positions. The
2nd and 1st gear positions have the same function as Drive, but with progressively
higher levels of regenerative braking.
P (Park)
This position locks the transmission and prevents the front wheels
from turning.
To put your vehicle in gear:
• Start the vehicle.
• Press the brake pedal
• Press the shifter button and move the gearshift lever into the
desired position.
To put your vehicle in P (Park):
• Come to a complete stop With the brake pedal depressed, engage
the parking brake.
• Move the gearshift lever and securely latch it in P (Park)
WARNING: Always set the parking brake fully before putting the gearshift
into P (Park). Turn the ignition to the off position and remove the key
whenever you leave your vehicle.
19
Driving
R (Reverse)
With the gearshift lever in R (Reverse), the vehicle will move backward.
Always come to a complete stop before shifting into and out of R (Reverse).
N (Neutral)
With the gearshift lever in N (Neutral), the vehicle can be powered-up and is
free to roll. Apply the brakes when powering-up the vehicle in Neutral.
D (Drive)
The driving position for forward movement.
2, 1 (Drive)
These driving positions provide higher regenerative braking levels. This simulates the
engine-braking effect in a conventional vehicle when coasting in the 2 or 1 gear positions. The 2 position provides more regenerative braking than D (Drive), and 1 provides
more regenerative braking than 2.
DRIVING THROUGH WATER
If driving through deep or standing water is unavoidable, proceed very slowly until the
depth is known. Never drive through water that is higher than the bottom of the
wheel rims. Water can damage electrical components and mechanical systems by entering vents.
When driving through water, traction or brake capability may be limited.
Once through the water, always dry the brakes by moving your vehicle slowly while
applying light pressure on the brake pedal. Wet brakes do not stop the vehicle as
quickly as dry brakes.
20
Roadside Emergencies
HIGH VOLTAGE INERTIA SAFETY SWITCH
In the event of an accident the safety switch will automatically deactivate the vehicle high
voltage system—temporarily rendering the vehicle inoperative.
WARNING: In the event of an accident, do not reset the high voltage inertia
switch. Bring the vehicle to an authorized AZD repair facility to have the
high voltage system inspected and any necessary repairs conducted.
The switch can also be activated through sudden vibration (e.g.
collision when parking).
The switch is accessible from behind the glove box. The button
will be raised when the switch is activated.
To reset the switch:
1. Turn the key switch OFF.
2. Open the glove box then push in the sides and swing the
glove box down.
3. Reset the switch by pushing in the reset button.
4. Turn the key switch ON.
5. Wait a few seconds and return the key to off.
UNDERHOOD FUSE REPLACEMENT
The vehicle fuse box is found under the hood, between the firewall and 12V battery.
Refer to table on page 22 for fuse application.
21
Roadside Emergencies
FUSE / RELAY ALLOCATION
LOCATION
FUNCTION
SIZE
LOCATION
FUNCTION
SIZE
F1
---
---
F27
---
F2
---
---
F3
Vac Pump
Jcase-40a
--Hv Batt Pumps &
Cabin Htr Cool
Pump
F4
Low Pwr Loads,
Batt
Jcase-20a
F29
Electronics Cool
Pump
F5
Hv Batt Htr 1
Mini-20a
F32
Cool Fan Diode
---
F6
Hv Batt Htr 2
Mini-20a
F33
Start Signal
Mini-5a
F7
Start Switch Input
Mini-20a
F34
Hv Interlock
Mini-5a
F8
High Beam
Mini-15a
F35
Low Pwr Loads,
Batt
Mini-10a
F9
Central Junction
Box
Jcase-40a
K20
Hv Batt Htr 1
Ultra Mini-N/O
F10
Spare
Jcase-25a
K21a
---
---
F11
Start Switch Relay
Jcase-40a
K21b
---
---
F12
Abs
Jcase-30a
K21c
High Beam
Hi Current Micro
-N/C & N/O
F13
Blower Motor
Mini-30a
K21d
Start Switch
Hi Current Micro
-N/O
F14
Hv Batt Htr 3
Mini-20a
K30ab
Cool Fan High
Speed
Hi Current MiniN/O
F15
Abs
Jcase-20a
K30c
Cool Fan Low
Speed
Hi Current Micro
-N/O
F16
Cool Fan Low
Speed
Jcase-30a
K30d
Vac Pump Cutoff
Hi Current Micro
-N/O
F17
Cool Fan High
Speed
Jcase-50a
K31a
Rev Lamps
Ultra Mini-N/O
F18
Dtrl & Low Beam
Int
Jcase-25a
K31b
Hv Batt Htr 2
Ultra Mini-N/O
F19
Central Junction
Box
Jcase-50a
K31c
Dtrl
Ultra Mini-N/O
F22
Vac Pump Monitor
Mini-5a
K31d
Low Beam
Ultra Mini-N/O
F23
Rt Headlamp
Mini-10a
K31e
---
---
F24
Low Pwr Loads,
Start
Mini-10a
K31f
---
---
F25
Lft Headlamp
Mini-10a
K36
Hv Batt Htr 3
Ultra Mini-N/O
F26
Rev Lamps
Mini-5a
22
F28
Mini-7.5a
Mini-10a
Roadside Emergencies
FLAT TIRE SERVICING
This vehicle does not have a spare tire or a jack. If
a flat tire is encountered in service, use the supplied
tire inflator kit as a temporary repair.
This is located under either the left or right front
seat depending on vehicle configuration.
PUSH STARTING THE VEHICLE
Electric vehicles do not have push-starting capabilities, do not attempt with this vehicle.
TOWING THE VEHICLE
If towing with wheels on the ground, ensure that vehicle is placed in Neutral and that the
Parking Brake is released. When towing the Transit Connect Electric, make sure that no
tow chains or straps are allowed to make contact with, or hooked onto the High Voltage
components or cabling.
See the Roadside Emergencies chapter in the Ford Transit Connect Owner’s Guide for
general information about towing.
JACKING THE VEHICLE
The Lower Load Path (shown below) and the High Voltage Battery (shown below)
should never be used as support or jacking point when raising the vehicle.
23
Cleaning
UNDERBODY WASHING PRECAUTION

Never pressure wash or spray the underbody with water.

Clean only with a dry cloth after powering down and waiting for five minutes.

Keep body, door, and High Voltage Battery Pack drain holes free from packed
dirt.
UNDER HOOD AND CHARGE PORT
24

Never use a power washer to clean under the hood or in the charge port. The
high-pressure fluid could penetrate the sealed parts and cause significant damage and risk of personal injury.

Never spray water on any of the components under the hood or in the charge
port. Water ingress can damage electrical components and connections.

Use a dry cloth to remove any excess dirt that collects under the hood or in the
charge port. Always power-down the vehicle and wait five minutes before
touching any electrical components.
Maintenance & Specifications
SERVICE RECOMMENDATIONS
To help you service your vehicle, we provide scheduled maintenance
information which makes tracking routine service easy.
If your vehicle requires professional service, your authorized dealer can
provide the necessary parts and service.
Check your Warranty Guide/Customer Information Guide to find out which parts and
services are covered.
Use only recommended lubricants, fluids and service parts conforming to specifications.
Motorcraft parts are designed and built to provide the best performance in your vehicle.
PRECAUTIONS WHEN SERVICING YOUR VEHICLE

Make sure that nothing gets caught in moving parts.

Keep all open flames and other burning material (such as cigarettes) away from
the battery.
Working under the hood with the High Voltage system off:
1. Set the parking brake and ensure the gearshift is securely latched in P (Park).
2. Remove the key.
3. Block the wheels to prevent the vehicle from moving unexpectedly.
WARNING: Wait 5 minutes after key-off before touching any High voltage
electrical components.
WARNING: Exposure to high voltage may result in severe personal injury or
death. High voltage components must be serviced by a trained service
technician.
25
Maintenance and Specifications
IDENTIFYING COMPONENTS UNDER THE HOOD
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
26
Electronics Coolant Reservoir (Motorcraft® Specialty Orange Coolant only)
Cabin Heater Coolant Reservoir (Motorcraft® Specialty Orange Coolant only)
High Voltage Charger (Backside of Traction Motor)
Brake Fluid Reservoir
12V Battery
Vehicle Control Unit (VCU)
Power Steering Fluid Reservoir (Pentosin CHF11S Only)
Cabin Heater (Front of Traction Motor)
Traction Motor Inverter
Traction Motor
Maintenance and Specifications
When the vehicle is cold, check the level of the electronics coolant in the reservoir.
•

The coolant should be at the MAX level
as listed on the reservoir.
Refer to scheduled maintenance
information for service interval
schedules.
If the coolant has not been checked at the
recommended interval, the coolant reservoir
may become low or empty. If the reservoir
is low or empty, add coolant to the
reservoir. Refer to Adding Electronics
Coolant in this chapter.
Note: Automotive fluids are not interchangeable; do not use coolant/antifreeze or
windshield washer fluid outside of its specified function and vehicle location.
ADDING ELECTRONICS COOLANT
When adding coolant, make sure it is a 50/50 mixture of coolant and distilled water. Add
the mixture to the coolant reservoir, when the vehicle is cool, until the appropriate fill
level is obtained.
Use only Motorcraft® Specialty Orange Coolant (VC-3-B in U.S., CVC-3-B in
Canada) in the electronics cooling reservoir for this vehicle.
WARNING: Do not add electronics coolant when the vehicle is hot. Steam
and scalding liquids released from a hot cooling system can burn you badly.
Also, you can be burned if you spill coolant on hot components.
WARNING: Do not put electronics coolant in the windshield washer
fluid container. If sprayed on the windshield, electronics coolant
could make it difficult to see through the windshield.
27
Maintenance and Specifications
Do not mix coolants. Add the coolant type originally equipped in your vehicle. Refer
to Maintenance product specifications and capacities in this chapter.
Note: Do not use stop leak pellets or cooling system sealants/additives as they can cause
damage to the cooling system and electronic components. This damage would not be
covered under your vehicle’s warranty.
• A large amount of water without coolant may be added, in case of emergency, to reach
a vehicle service location. In this instance, the cooling system must be drained and
refilled with a 50/50 mixture of electronics coolant and distilled water as soon as
possible. Water alone (without electronics coolant) can cause damage from corrosion,
overheating or freezing.
• Do not use alcohol, methanol, brine or any coolants mixed with alcohol or
methanol. Alcohol and other liquids can cause overheating or freezing.
• Do not add extra inhibitors or additives to the coolant. These can be harmful and
compromise the corrosion protection of the coolant.
WARNING: To reduce the risk of personal injury, make sure the coolant is
cool before unscrewing the coolant pressure relief cap. The cooling system is
under pressure; steam and hot liquid can come out forcefully when the cap is loosened
28
Maintenance and Specifications
POWER STEERING FLUID
Check the fluid. Refer to scheduled maintenance
information.
1.
2.
3.
4.
Turn the steering wheel left and right several
times.
Power-down the vehicle.
Check the fluid level.
If the fluid is below the MIN line, add fluid
in small amounts until it reaches the correct
level (between the MIN and MAX lines).
NOTE: Use only Pentosin CHF11S power steering fluid in this vehicle.
See #7 in the Identifying Components Under the Hood section of this chapter in this
Supplement.
GEARBOX OIL
This vehicle uses a gearbox that is sealed and does not require any periodic checking and
filling by the vehicle owner or operator.
Periodic replacement of the gearbox oil by a qualified service technician is indicated by
the Maintenance Schedule (See Page 34).
STORING YOUR VEHICLE
Follow the recommendations in the Transit Connect Owner’s Guide for vehicle storage.
When removing the Electric Vehicle from storage, check the 12V and High Voltage
battery state of charge before driving the vehicle.
29
Maintenance and Specifications
CHARGING THE HIGH VOLTAGE BATTERY
See the High Voltage Battery Charging chapter in this Guide.
SERVICING HIGH VOLTAGE COMPONENTS
All high voltage components must be serviced by trained Technicians at an authorized
AZD repair facility.
WARNING: Exposure to high voltage may result in severe personal injury
or death. High voltage components must be serviced by a trained service
technician.
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Read and follow all instructions on the charging station.
Power-down the vehicle before charging the high voltage battery.
Keep children away from the charging station; never let children charge the high
voltage battery.
Maintenance and Specifications
IDENTIFYING YOUR VEHICLE
Safety Compliance Certification
Label
The National Highway Traffic Safety
Administration Regulations require
that a Safety Compliance
Certification Label be affixed to a
vehicle and prescribe where the
Safety Compliance Certification
Label may be located. The Safety
Compliance Certification Label is
located on the structure (B-Pillar)
by the trailing edge of the driver’s
door or the edge of the driver’s
door.
Vehicle identification number (VIN)
The vehicle identification number is
located on the driver side
instrument panel.
Please note that in the graphic,
XXXX is representative of your
vehicle identification number
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Scheduled Maintenance
MAINTENANCE SCHEDULE — NORMAL SCHEDULE
General Maintenance Information
The Normal Schedule applies to operation of the vehicle under typical, everyday driving
conditions. The maintenance frequency in this schedule typifies what the vast majority of
vehicles will require. The listed services should be carried out at specified mileage or
time, whichever occurs first.
Special Operating Condition Requirements
If the vehicle is operated in one or more of the following special operating conditions,
those additional services will be required in addition to the Normal Schedule. The special
operating conditions are:
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Heavy commercial use such as delivery, taxi, patrol car or livery.
Unpaved roads or off-road use.
See Exceptions to Normal Schedule for details.
Checks and Services
Certain basic maintenance checks and inspections should be carried out at specified
intervals. Any recognized adverse condition should be corrected as soon as possible.
Multi-Point Inspection
The following inspections are recommended at every service interval.
 Top up fluid levels for brakes, coolant, power steering, and windshield washers.
 Inspect tires for wear and correct air pressure.
 Check 12 V battery performance.
 Check operation of horn, exterior lamps, turn signals and hazard warning lights.
 Check radiator, heater, power steering and A/C hoses.
 Inspect windshield wiper spray and wiper operation.
 Check windshield for cracks, chips and pitting.
 Inspect for oil and fluid leaks.
 Inspect drive shaft dust boots.
 Check shocks, struts and other suspension components for leaks and damage.
 Inspect steering and linkage.
 Inspect LV and HV wiring for chafing or damage.
 Check braided ground-strap connections on HV components.
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Scheduled Maintenance
Periodic Checks - Monthly
Check each of the following items every month:
 All interior and exterior lights for correct operation.
 Tires for wear and correct air pressure.
 Windshield washer fluid level.
Periodic Checks - Six Months
Check each of the following items every six months:
 Lap/shoulder belts and seat latches for wear and function.
 Power steering fluid level.
 Washer spray, wiper operation and clean all wiper blades (install new wiper
blades as necessary).
 Parking brake for correct operation.
 Lubricate all hinges, latches, door check straps and outside locks.
 Lubricate upper and lower sliding door tracks.
 Lubricate door rubber weatherstrips.
 Clean body and door drain holes.
 Safety warning lamps (brake, ABS, air bag, safety belt) for correct operation.
 Coolant system fluid level and correct strength.
 12 V battery connections. Clean if necessary.
Periodic Checks - Retighten Lug Nuts
 Retighten the wheel nuts to the specified torque at 500 mi (800 km) after any
wheel disturbance (tire rotation, changing a flat tire, or wheel removal).
Normal Maintenance Schedule
The Normal Maintenance Schedule consists of two sets of alternating items: a short and
long list at 10,000 mi (15,000 km) intervals. At 100,000 mi (160,000 km) the long list
includes additional items.
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Maintenance and Specifications
Normal Maintenance Schedule
10,000 Mi
16,000
Km
Intervals
20,000 Mi
32,000
Km
Intervals
100,000 Mi
160,000
Km
Intervals
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•
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Perform multi-point inspection.
Rotate tires, inspect tires for wear, measure tread depth
and inspect wheel ends for end play and noise.
Inspect control arms, steering linkage, steering ball
joints and sway bar end-links.
Inspect half shaft boots.
Inspect brake pads, rotors, brake linings, drums, brake lines, hoses
and parking brake systems.
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Inspect cooling system and hoses
Check rear spring U-bolt nuts for correct torque.
Change coolant.
Change gearbox oil.
MAINTENANCE SCHEDULES — EXCEPTIONS
The Special Operating Condition Maintenance Requirements are to be followed at the
listed intervals in addition to the Normal Schedule.
Normal Maintenance Schedule Exceptions
Perform multi-point inspection.
Rotate tires, inspect tires for wear, measure tread depth and
inspect wheel ends for end play and noise.
Inspect control arms, steering linkage, steering ball joints and sway
bar end-links.
Inspect Brake pads, rotors, brake linings, drums, brake lines,
hoses and parking brake systems.
Change gearbox oil.
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5,000 Mi
8,000 Km
Heavy
Commercial
50,000 Mi
80,000 Km
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Off-Road
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High Voltage Battery Charging
CHARGING THE HIGH VOLTAGE
BATTERY
1.
Power-down the vehicle.
2.
Unlock the charge port door with the key.
3.
Release the catch to allow the charge port cap to
open.
4.
Plug the charger into the charge port and ensure
that the latch on the top of the charger has
engaged.
5.
Verify that the Green LED is flashing. This indicates a normal charge cycle (solid
green indicates charging is complete).
6.
Follow the charging station instructions to begin
the charging process.
7.
Allow 8-12 hours to charge the high voltage
battery using a Level 2 charging station (208240 V).
8.
Turn off the charging station, release the charger
latch and remove the charger from the charge
port.
NOTE: If the Red LED is flashing, a
charging fault is indicated. If no lights are
illuminated a fault may be present with the
10. Lock the charge port door with the key.
12 V battery if the vehicle will not power
up. Disconnect the charger and seek
service assistance from an authorized AZD
repair facility.
9.
Close the charge port cap.
NOTE: Unless equipped with a Cold Weather Charger (–40°F or –40C.),
high voltage charging is only possible at temperatures above –13°F or –25°C.
See Range Gauge and State of Charge Gauge for additional information.
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