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2002 Mercury Villager CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Mercury REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Section
- 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
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 2002 Mercury Villager car and truck
repair procedures including Mercury engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
your Mercury Villager automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 2002 Mercury Villager AUTOMOBILES
Electrical Symbol & Wire Color Code Identification -> Wire Color Code Identification -> Domestic Vehicles
Vehicle: 2002 Mercury Villager 3.3 V6 GAS
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BRAKE SERVICE PROCEDURES FOR 2002 Mercury Villager AUTOMOBILES
Power Brake Units -> Bendix Vacuum Brake Booster -> Brake Booster Replacement -> Aviator -> E-Series, Expedition, Explorer, Explorer Sport & Sport/Trac, F-150 & F-250LD, Mountaineer, Navigator & Villager -> Escape -> Excursion & F-Super Duty -> Ranger -> Windstar
Vehicle: 2002 Mercury Villager 3.3 V6 GAS
Aviator
Refer to. Fig. , and remove components in sequence illustrated. Use new nuts when installing brake booster.
Excursion & F-Super Duty
- Remove air cleaner housing, if required.
- Remove brake master cylinder attaching nuts.
- Position brake master cylinder aside.
- Disconnect booster vacuum hose.
- Disconnect power distribution box auxiliary relay and set aside.
- Remove fuse panel cover.
- Remove brake pedal position switch self-locking pin.
- Remove brake pedal position switch and brake booster pushrod from brake pedal pin.
- Remove power brake booster nuts.
- Remove power brake booster.
- Reve...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2002 Mercury Villager AUTOMOBILES
Ford Motor Co. Light Trucks, SUVs & Vans -> Component Locations -> 1993-02 Villager
Vehicle: 2002 Mercury Villager 3.3 V6 GAS
Refer to Fi...
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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
Alternator, Replace
Vehicle: 2002 Mercury Villager 3.3 V6 GAS
- Disconnect battery ground cable.
- Raise and support vehicle.
- Remove engine splash shield.
- Remove alternator adjuster bolt, then drive belt.
- Remove alternator to bracket attaching bolts and support alternator.
- Disconne...
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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 -> Emission Maintenance Reminder Indicator ->
Vehicle: 2002 Mercury Villager 3.3 V6 GAS
This lamp should light after approximately 60,000 miles of operation, Fig. . The amber lens lamp is located on the instrument panel and has the word Emissions, Emiss or EGR printed on it. After performing the required emission control maintenance, the module must be replaced or reset, depending on type of module used. On module equipped with reset feature, reset the module as follows:
- Turn ignition Off.
- On Aerostar models, the module is located under the instrument panel near the bulkhead connector.
- On Bronco, Explorer and F-Series, the module is attached to the instrument cluster to the left of ...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2002 Mercury Villager AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 2002 Mercury Villager 3.3 V6 GAS
Lower
- Drain cooling system into a suitable container.
- Reposition hose clamp from radiator.
- Remove radiator outlet hose from radiator.
- Reposition hose clamp from water pump.
- Remove radiator outlet hose from water pump and from vehicle.
- Reverse procedure to inst...
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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+.
 Brake Booster Components Diagram for 2002 Mercury Villager 3.3 V6 GASComponents on diagram: |
 HVAC Components Diagram for 2002 Mercury Villager 3.3 V6 GASComponents 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 DiagramComponents on diagram: |
 2002 Mercury Villager 3.3 V6 GAS Wiring DiagramComponents 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+.
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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: |
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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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