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2002 Mercury Villager CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Mercury REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Cabin Air Filter Locations & Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
A/C & HEATER SERVICE PROCEDURES FOR 2002 Mercury Villager AUTOMOBILES
Air Bag System Precautions -> Ford Motor Co. -> Arming -> 1990-91 -> 1990-92 -> 1991-92 -> 1992-93 -> 1992-94 -> 1992-96 -> 1992-98 -> 1993 -> 1993-94 -> 1993-95 -> 1994 -> 1994-95 -> 1994-96 -> 1994-97 -> 1995 -> 1995-2004 -> 1995-96 -> 1995-98 -> 1996-97 -> 1996-99 -> 1997-2000 -> 1997-2001 -> 1997-2004 -> 1997-99 -> 1998 -> 1998-2000 -> 1998-2002 -> 1999-2000 -> 1999-2001 -> 1999-2002 -> 1999-2004 -> 2000 -> 2000-01 -> 2000-04 -> 2001-02 -> 2001-03 -> 2001-04 -> 2002-03 -> 2002-04 -> 2004 -> Aerostar & Bronco -> Aspire -> Aviator -> Blackwood, Expedition & Navigator -> Built After February 2002 -> Built Before March 2002 -> Capri -> Continental -> Contour & Mystique -> Cougar -> Crown Victoria Grand Marquis & Marauder -> Econoline -> Escape -> Escort, Tracer & ZX2 -> Excursion -> Explorer & Mountaineer -> Explorer Sport & Sport Trac -> F Series -> Focus -> Freestar & Monterey -> Light Trucks & Vans -> LS -> Mark VII -> Mark VIII -> Mustang -> Passenger Cars -> Probe -> Ranger -> Sable & Taurus -> Tempo & Topaz -> Thunderbird -> Town Car -> Villager -> Windstar
Vehicle: 2002 Mercury Villager 3.3 V6 GAS
Passenger Cars
Aspire
- Disconnect battery ground cable.
- Wait one minute for back-up power supply to deplete stored energy.
- Remove restraint system diagnostic tool from driver's side air bag module electrical connector.
- Connect driver's side air bag module electrical connector.
- Install driver's side air bag module as outlined under "Component Service."
- Remove restraint system diagnostic tool from passenger's side air bag module electrical connector.
- Install passenger's side air bag module as outlined under "Component Service."
- C...
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BRAKE SERVICE PROCEDURES FOR 2002 Mercury Villager AUTOMOBILES
Hydraulic Brake Systems -> Description -> Bendix Hydro-Boost Brake Booster -> Bendix Hydro-Max Brake Booster -> Combination Valve -> Height Sensing Proportioning Valve -> Hydraulic Control Unit (HCU) -> Hydraulic Control Valves -> Integral Bypass Proportioning Valve -> Master Cylinder
Vehicle: 2002 Mercury Villager 3.3 V6 GAS
Master Cylinder
The master cylinder consists primarily of a hydraulic cylinder, primary and secondary hydraulic pistons and a single or dual chamber fluid reservoir. The front brakes are connected to the primary outlet port(s) and are actuated by the primary piston assembly. The rear brakes are connected to the secondary outlet port and are actuated by the secondary piston assembly.
Hydraulic Control Valves
Combination Valve
This multi-function hydraulic control unit consists primarily of a pressure differential valve, brake lamp warning switch and a proportioning valve. A pressure diff...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2002 Mercury Villager AUTOMOBILES
Ford Motor Co. Light Trucks, SUVs & Vans -> Fuel Pressure Relief -> Villager
Vehicle: 2002 Mercury Villager 3.3 V6 GAS
The fuel system remains under high pressure even when the engine is not running. This residual pressure must be relieved before servicing the fuel system. To avoid injury or fire, release pressure from the fuel system before disconnecting any fuel line.
The fuel system pressure must be relieved prior to disconnecting fuel lines to prevent accidental spray of fuel.
After the battery has been disconnected and re...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2002 Mercury Villager AUTOMOBILES
CV AXLE SHAFT, Replace -> Front -> Rear
Vehicle: 2002 Mercury Villager 3.3 V6 GAS
Front
- Raise and support vehicle and support it with safety stands in proper locations.
- Remove wheel nuts and front wheels.
- Remove brake caliper assembly and rotor using suitable tool. Brake hose does not need to be disconnected from brake caliper. Suspend caliper assembly using mechanics wire. Do not stretch or twist brake hose and depress brake pedal or brake caliper piston will eject out from caliper bore.
- Place alignment mark on brake disc and wheel hub and bearing assembly.
- Remove ABS sensor from steering knuckle. Do not pull in ABS sensor harness.
- Remove cotter pin then wh...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2002 Mercury Villager AUTOMOBILES
Starter, Replace
Vehicle: 2002 Mercury Villager 3.3 V6 GAS
- Disconnect battery ground cable.
- Remove air cleaner assembly.
- Slide solenoid B+ terminal protective boot rearward and remove battery cable to B+ terminal nut.
- Disconnect S-terminal electrical connec...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2002 Mercury Villager AUTOMOBILES
Cabin Air Filter Service -> Ford Motor Co. -> 1997-2002 Villager
Vehicle: 2002 Mercury Villager 3.3 V6 GAS
Under normal operating conditions the cabin air filter should be replaced every 15,000 miles. In dusty areas change the cabin air filter more often.
- Lift the windshield wiper arms away from the windshield.
- While holding the retaining clip at the base of the wiper arm outward, lift the wiper arm from the pivot.
- Remove the six cowl cover retaining screws, Fig. .
- Open the hood.
- Remove the four plastic pin type retainers from the forward edge of the cowl cover, then remove the retainer anchors, Fig. .
- Disconnect the windshield washer nozzle hose.
- Lift the cowl cover upward and position...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2002 Mercury Villager AUTOMOBILES
Ford Motor Co. Trucks -> Check Engine Lamp -> 1998-2002 EEC -> Except Malfunction Indicator Lamp (MIL) -> Malfunction Indicator Light
Vehicle: 2002 Mercury Villager 3.3 V6 GAS
Except Malfunction Indicator Lamp (MIL)
When using NGS tool No. 007-00500, or equivalent, select Diagnostic Test Mode Results, then press CLEAR or disconnect battery ground cable. Codes will be erased from back-up memory after 24 hours.
Malfunc...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2002 Mercury Villager AUTOMOBILES
Radiator, Replace
Vehicle: 2002 Mercury Villager 3.3 V6 GAS
- Drain cooling system into suitable container.
- Remove fasteners holding grill panel to upper center reinforcement and fascia, then remove grill panel.
- Remove righthand and lefthand headlamp and cornering lamp assemblies.
- Disconnect and remove grill panel brackets from lower and upper center radiator supports.
- Remove and position aside hood latch support brace from lower and upper center radiator supports.
- Remove harness cover from upper center radiator support reinforcement.
- Disconnect underhood lamp from upper center radiator support reinforcement.
- Disconnect harness from cooling fan...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2002 Mercury Villager AUTOMOBILES
Serpentine Drive Belt, Replace -> Air Conditioning -> Alternator -> Power Steering
Vehicle: 2002 Mercury Villager 3.3 V6 GAS
Air Conditioning
Mark direction of rotation on drive belt with a marking pen to ensure correct installation if drive belt is to be reused. Failure to do so may result in drive belt noise. To ensure maximum drive belt life and proper component operation, replacement drive belts must be same type and size as original drive belts. When installing a new drive belt, ensure that it is properly seated on pulleys.
- Disconnect battery ground cable from battery.
- Loosen A/C compressor drive belt idler pulley tensioner bolt.
- Loosen A/C compressor drive belt idler pulley adjustment...
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COMPONENT LOCATION DIAGRAMS FOR 2002 Mercury Villager AUTOMOBILES
Component location diagrams for most 2002 Mercury Villager cars and light trucks sold in the U.S. from 1990+.
Dash Panel Diagram for 2002 Mercury Villager 3.3 V6 GAS Components on diagram: |
Liftgate Diagram for 2002 Mercury Villager 3.3 V6 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 2002 Mercury Villager AUTOMOBILES
OEM drawn wiring diagrams for most 2002 Mercury Villager cars and light trucks sold in the U.S.
2002 Mercury Villager 3.3 V6 GAS Wiring Diagram Components on diagram: |
2002 Mercury Villager 3.3 V6 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2002 Mercury Villager AUTOMOBILES
OEM TSB listings for most 2002 Mercury Villager cars and light trucks sold in the U.S. from 1985+.
Document: RECALL - CERTAIN 1992-2003 MODEL YEAR CARS AND TRUCKS - FUSED JUMPER HARNESS REPLACEMENT FOR VEHICLES SERVICED WITH AN INCOMPATIBLE FUSED JUMPER HARNESS Vehicle: 2002 Mercury Villager 3.3 V6 GAS Auto Systems: |
Document: RECALL - 1992-2004 MULTIPLE VEHICLE LINES - SPEED CONTROL SYSTEM MODIFICATION Vehicle: 2002 Mercury Villager 3.3 V6 GAS |
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COMPONENT/PARTS SPECIFICATIONS FOR 2002 Mercury Villager AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2002 Mercury Villager cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 2002 Mercury Villager cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 2002 Mercury Villager cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 2002 Mercury Villager cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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