engine Mercury Villager 2002 s Repair Manual

4. Install a new air filter element. Be
careful not to crimp the filter
element edges between the air filter
housing and cover. This could cause
filter damage and allow unmetered
air to enter the engine if not
properly seated.
5. Replace the air filter housing
cover and secure the four clamps.
INFORMATION ABOUT UNIFORM TIRE QUALITY GRADING
New vehicles are fitted with tires
that have a rating on them called
Tire Quality Grades. The Quality
grades can be found where
applicable on the tire sidewall
between tread shoulder and
maximum section width. For
example:
•Treadwear 200 Traction AA Temperature A
These Tire Quality Grades are determined by standards that the United
States Department of Transportation has set.
Tire Quality Grades apply to new pneumatic tires for use on passenger
cars. They do not apply to deep tread, winter-type snow tires,
space-saver or temporary use spare tires, tires with nominal rim
diameters of 10 to 12 inches or limited production tires as defined in
Title 49 Code of Federal Regulations Part 575.104(c)(2).
U.S. Department of Transportation-Tire quality grades:The U.S.
Department of Transportation requires Ford to give you the following
information about tire grades exactly as the government has written it.
Treadwear
The treadwear grade is a comparative rating based on the wear rate of
the tire when tested under controlled conditions on a specified
government test course. For example, a tire graded 150 would wear one
and one-half (1 1/2) times as well on the government course as a tire
graded 100. The relative performance of tires depends upon the actual
conditions of their use, however, and may depart significantly from the
norm due to variations in driving habits, service practices, and
differences in road characteristics and climate.
Maintenance and Specifications
235

MOTORCRAFT PART NUMBERS
Component 3.3L V6 engine
Engine air filter element FA-1121
Cabin air filter FP-27
Fuel filter FG-993
Battery BXT-24-F
Oil filter FL-2007
PCV Valve EV-217
Spark plugs
1AGSP-32FP
1Refer to Vehicle Emissions Control Information (VECI) decal for spark
plug gap information.
REFILL CAPACITIES
Fluid Ford Part Name Capacity
Engine oil (includes
filter change)Motorcraft SAE 5W-30
Super Premium Motor
Oil4.0L (4.2 quarts)
Brake fluid Motorcraft High
Performance DOT 3
Motor Vehicle Brake
FluidFill to line on reservoir
Power steering fluid Motorcraft MERCON
AT FFill to line on reservoir
Automatic transaxle
fluidMotorcraft MERCON
AT F8.3L (8.8 quarts)
Engine coolant
1Motorcraft Premium
Engine Coolant10.6L (11.2 quarts)
Fuel tank N/A 75.7L (20.0 gallons)
Windshield washer
fluidUltra-Clear Windshield
Washer ConcentrateFill to line on reservoir
1Use Motorcraft Premium Engine Coolant (green in color). DO NOT USE
Ford Extended Life Engine Coolant (orange in color). Refer toAdding
engine coolant, in the Maintenance and Specificationschapter.
Maintenance and Specifications
239

LUBRICANT SPECIFICATIONS
Item Ford part
nameFord part
numberFord
specification
Brake fluid Motorcraft High
Performance
DOT 3 Motor
Vehicle Brake
FluidPM-1 ESA-M6C25-A
and DOT 3
Door
weatherstripsSilicone
LubricantF7AZ-19G208-BA
and
F5AZ-19553-AAESR-M13P4-A
Engine coolant
1Motorcraft
Premium
Engine Coolant
(green colored)VC-4–A (in
Canada,
Motorcraft
CXC-8-B)ESE-M97B44-A
Engine oil Motorcraft SAE
5W-30 Super
Premium Motor
OilXO-5W30-QSP WSS-M2C205–A
with API
Certification
Mark
Door latch,
hood
latch,auxiliary
hood latch, door
and liftgate
hinges, striker
plates, seat
tracks, fuel filler
door hinge.Multi-Purpose
GreaseXG-4or
F5AZ-19G209-AAESR-M1C159-A
Lock cylinders Penetrating and
Lock LubricantMotorcraft XL-1 none
Power steering
fluidMotorcraft
MERCONAT FXT-2-QDX MERCON
Automatic
transaxle
2Motorcraft
MERCONAT FXT-2-QDX MERCON
Maintenance and Specifications
240

Item Ford part
nameFord part
numberFord
specification
Disc brake
caliper railsMotorcraft
Silicone Brake
Caliper Grease
and Dielectric
CompoundXG-3 ESE-M1C171-A
Constant
velocity jointsMotorcraft CV
Joint Grease
(High Temp.)XG-2 ESP-M1C207-A
Windshield
washer fluidUltra-clear
Windshield
Washer
ConcentrateC9AZ-19550-AC ESR-M17P5-A
1DO NOT USE Motorcraft Extended Life Engine Coolant VC-2 (CXC-209
in Canada) meeting Ford specification WSS-M97B44–D (orange in color).
Refer toAdding engine coolantin this chapter.
2Ensure the correct automatic transmission fluid is used. Transmission
fluid requirements are indicated on the dipstick or on the dipstick
handle. MERCONand MERCONV are not interchangeable. DO NOT
mix MERCONand MERCONV. Refer to your scheduled maintenance
guide to determine the correct service interval.
ENGINE DATA
Engine 3.3L V6 engine
Cubic inches 200
Required fuel 87 octane
Firing order 1-2-3-4-5-6
Spark plug gap 1.0-1.1 mm (0.039-0.043 inch)
Ignition system
1Distributor ignition system
Compression ratio 8.9:1
1This ignition system meets all Canadian Interference-Causing Equipment
standard requirements regulating the impulse electrical field strength of
radio noise.
Maintenance and Specifications
241

Vehicle identification number
The vehicle identification number is
attached to a metal tag and is
located on the driver side
instrument panel and under the
liftgate scuff plate at the bottom of
the liftgate opening. (Please note
that in the graphic XXXX is
representative of your vehicle
identification number.)
1. World manufacturer identifier
2. Brake type and gross vehicle
weight rating (GVWR)
3. Vehicle line, series, body type
4. Engine type
5. Check digit
6. Model year
7. Assembly plant
8. Production sequence number
Engine and transmission serial number
The engine serial number is stamped on the engine block, and the
transmission serial number is on the transmission case.
XXXXXXXXXXXXXXXXX
Maintenance and Specifications
244

FORD ACCESSORIES FOR YOUR VEHICLE
A wide selection of genuine Ford accessories are available for your
vehicle through your local authorized Ford, Lincoln, Mercury or Ford of
Canada dealer. These quality accessories have been specifically
engineered to fulfill your automotive needs; they are custom designed to
complement the style and aerodynamic appearance of your vehicle. In
addition, each accessory is made from high quality materials and meets
or exceeds Ford’s rigorous engineering and safety specifications. Ford
Motor Company will repair or replace any properly dealer-installed Ford
accessory found to be defective in factory-supplied materials or
workmanship during the warranty period, as well as any component
damaged by the defective accessory. The accessory will be warranted for
whichever provides you the greatest benefit:
•12 months or 20 000 km (12 000 miles) (whichever occurs first), or
•the remainder of your new vehicle limited warranty.
This means that genuine Ford accessories purchased along with your
new vehicle and installed by the dealer are covered for the full length of
your New Vehicle’s Limited Warranty—3 years or 60 000 km (36 000
miles) (whichever occurs first). Contact your dealer for details and a
copy of the warranty.
Not all accessories are available for all models.
Vehicle Security
Non—decorative wheel locks
Vehicle security systems
Comfort and convenience
Cargo nets
Cargo organizer
Cargo tray
Electrochromic inside mirror with compass display
Electrochromic inside mirror with compass and temperature display
Engine block heater
Remote start system
Seatback organizer
Tire step
Accessories
245

For maximum vehicle performance, keep the following information in
mind when adding accessories or equipment to your vehicle:
•When adding accessories, equipment, passengers and luggage to your
vehicle, do not exceed the total weight capacity of the vehicle or of
the front or rear axle (GVWR or GAWR as indicated on the Safety
compliance certification label). Consult your dealer for specific weight
information.
•The Federal Communications Commission (FCC) and Canadian Radio
Telecommunications Commission (CRTC) regulate the use of mobile
communications systems - such as two-way radios, telephones and
theft alarms - that are equipped with radio transmitters. Any such
equipment installed in your vehicle should comply with FCC or CRTC
regulations and should be installed only by a qualified service
technician.
•Mobile communications systems may harm the operation of your
vehicle, particularly if they are not properly designed for automotive
use or are not properly installed. When operated, such systems may
cause the engine to stumble or stall or cause the transmission to be
damaged or operate improperly. In addition, such systems may be
damaged or their performance may be affected by operating your
vehicle. (Citizens band [CB] transceivers, garage door openers and
other transmitters with outputs of five watts or less will not ordinarily
affect your vehicle’s operation.)
•Ford cannot assume responsibility for any adverse effects or damage
that may result from the use of such equipment.
Accessories
247

A
ABS (see Brakes) .....................159
Accessory delay ..........................88
Air bag supplemental restraint
system ................................136–137
and child safety seats ............138
description ..............................137
disposal ....................................140
driver air bag ..........................139
indicator light ...................12, 140
operation .................................139
passenger air bag ...................139
Air cleaner filter ...............234, 239
Air conditioning
automatic temperature
control system ..........................63
manual heating and air
conditioning system .................58
rear seat controls ...............61, 69
Air filter, cabin ............................73
Antifreeze (see Engine
coolant) .....................................217
Anti-lock brake system
(see Brakes) ......................159–160
Anti-theft system ......................112
arming the system ..................113
disarming a triggered
system .....................................114
disarming an untriggered
system .....................................114
Audio system (see Radio) .........20
Automatic transaxle
driving with .............................163
fluid, adding ............................232
fluid, checking ........................232
fluid, refill capacities ..............239
fluid, specification ..................241
Auxiliary power point .................86Axle
lubricant specifications ..........240
B
Battery .......................................215
acid, treating emergencies .....215
charging system warning
light ............................................13
jumping a disabled battery ....188
maintenance-free ....................215
replacement, specifications ...239
servicing ..................................215
Brakes ........................................158
anti-lock ...........................159–160
anti-lock brake system
(ABS) warning light .........12, 160
brake warning light ..................11
fluid, checking and adding ....231
fluid, refill capacities ..............239
fluid, specifications .........240–241
lubricant specifications ..240–241
parking ....................................160
shift interlock ..........................162
Break-in period .............................6
Bulbs ............................................77
C
Capacities for refilling fluids ....239
Cargo cover ...............................106
Cargo net ...........................105–106
CD changer .................................53
Certification Label ....................243
Changing a tire .........................182
Child safety restraints ..............141
child safety belts ....................141
Child safety seats ......................144
attaching with tether straps ..149
Index
248

in front seat ............................146
in rear seat ......................146, 148
tether anchorage hardware ...150
Cleaning your vehicle
engine compartment ..............204
exterior ....................................207
instrument panel ....................206
interior .....................................207
plastic parts ............................205
washing ....................................203
waxing .....................................203
wheels ......................................204
wiper blades ............................206
woodtone trim ........................205
Climate control (see Air
conditioning or Heating) ......58, 63
Clock ................................24, 33, 44
Console ......................................103
overhead ....................................86
Controls
power seat ...............................117
steering column ........................94
Coolant
checking and adding ..............217
refill capacities ................220, 239
specifications ..................240–241
Cruise control (see Speed
control) ........................................90
Customer Assistance ................173
Ford accessories for your
vehicle .....................................208
Ford Extended Service
Plan ..........................................196
Getting assistance outside the
U.S. and Canada .....................200
Getting roadside assistance ...173
Getting the service you
need .........................................194
Ordering additional owner’s
literature .................................201The Dispute Settlement
Board .......................................197
Utilizing the
Mediation/Arbitration
Program ...................................200
D
Defrost
rear window ..............................72
Dipstick
automatic transmission
fluid ..........................................232
engine oil .................................212
Doors
door ajar warning .....................14
lubricant specifications ..........240
Driving under special
conditions
through water .........................166
E
Emergencies, roadside
jump-starting ..........................188
Emission control system ..........229
Engine ................................241–242
check engine/service engine
soon light ..................................10
cleaning ...................................204
coolant .....................................217
idle speed control ...................215
lubrication
specifications ..................240–241
refill capacities ........................239
service points ..........................211
starting after a collision .........174
Engine oil ..................................212
checking and adding ..............212
dipstick ....................................212
Index
249

filter, specifications ........214, 239
recommendations ...................214
refill capacities ........................239
specifications ..................240–241
Exhaust fumes ..........................158
F
Floor mats .................................103
Fluid capacities .........................239
Foglamps .....................................74
Fuel ............................................221
calculating fuel economy .......225
cap ...........................................223
capacity ...................................239
choosing the right fuel ...........224
comparisons with EPA fuel
economy estimates .................228
detergent in fuel .....................225
filling your vehicle with
fuel ...........................221, 223, 226
filter, specifications ........225, 239
fuel pump shut-off switch .....174
gauge .........................................17
improving fuel economy ........225
low fuel warning light ..............13
octane rating ...........224, 241–242
quality ......................................224
running out of fuel .................225
safety information relating to
automotive fuels .....................221
Fuses ..................................175–176
G
Garage door opener ....................95
Gas cap (see Fuel cap) ............223
Gas mileage (see Fuel
economy) ...................................225
Gauges ...................................15–16engine coolant temperature
gauge .........................................16
fuel gauge ..................................17
odometer ...................................18
speedometer .............................18
trip odometer ............................19
GAWR (Gross Axle Weight
Rating) .......................................167
calculating ...............................168
definition .................................167
driving with a heavy load ......167
location ....................................167
GVWR (Gross Vehicle Weight
Rating) .......................................167
calculating .......................167–168
definition .................................167
driving with a heavy load ......167
location ....................................167
H
Hazard flashers .........................174
Head restraints .........................115
Headlamps ...................................74
aiming ........................................75
autolamp system .......................74
bulb specifications ....................77
flash to pass ..............................75
high beam ...........................15, 75
replacing bulbs .........................79
turning on and off ....................74
warning chime ..........................15
Heating
heating and air conditioning
system .................................58, 63
rear seat controls ...............61, 69
HomeLink universal
transceiver (see Garage door
opener) ...................... 95–96, 98–99
Hood ..........................................210
Index
250