fuel cap Mercury Villager 2002 Owner's Manuals

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
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system or translation in whole or part is not permitted without written
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notice and without incurring obligation.
Copyright © 2002 Ford Motor Company
Table of Contents
3

Vehicle Symbol Glossary
Power Window Lockout
Child Safety Door
Lock/Unlock
Interior Luggage
Compartment Release
Symbol
Panic Alarm
Engine OilEngine Coolant
Engine Coolant
TemperatureDo Not Open When Hot
BatteryAvoid Smoking, Flames,
or Sparks
Battery AcidExplosive Gas
Fan WarningPower Steering Fluid
Maintain Correct Fluid
LevelMAX
MIN
Emission System
Engine Air FilterPassenger Compartment
Air Filter
JackCheck fuel cap
Low tire warning
Introduction
9

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
P!
BRAKE
Instrument Cluster
11

Optional electronic instrument cluster gauges
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 toEngine coolantin theMaintenance
and specificationschapter.
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.
•Standard analog instrument
cluster
ABSAIR
BAGSERVICE
ENGINE
SOONABSO/D
OFF
OUTSIDE TEMP
INST ECONOMY
AVG. ECONOMY
TO EMPTY
PRND21FUEL DOOR UNLEADED FUEL ONLY CRUISE
MPH
km/h
km
F
EH
C
1/2N
O
R
M
A
L
012345
6
78
P!BRAKE
X 1000
RPMTRIP 1
TRIP 2 ˚F ˚C
MILES/BAL
L/100 km
H
C
Instrument Cluster
16

•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
H
CN
O
R
M
A
L
F
E
F
E
1/2
Instrument Cluster
17

When parking, do not use the gearshift in place of the parking
brake. Always set the parking brake fully and make sure that the
gearshift is securely latched in Park (P). Turn off the ignition
whenever you leave your vehicle. Never leave your vehicle unattended
while it is running. If you do not take these precautions, your vehicle
may move unexpectedly and injure someone.
Driving with an automatic overdrive transaxle
Your automatic transaxle electronically controls the shift feel by using an
adaptive learning strategy. This feature is designed to optimize shift
smoothness.
Note:It is normal for your transaxle to shift firmly during the first few
hundred kilometers (miles) of operation until the adaptive strategy has
been learned. The adaptive learning strategy is maintained by power
from the battery. When the battery is disconnected or a new battery is
installed, the transaxle must relearn its adaptive strategy. Optimal
shifting will resume within a few hundred kilometers (miles) of
operation.
Your automatic overdrive transaxle
provides fully automatic operation in
either D (Overdrive) or with the
O/D OFF switch depressed. Driving
with the gearshift lever in D
(Overdrive) gives the best fuel economy for normal driving conditions.
For manual control, start in 1 (First) and then shift manually.
To put your vehicle in gear, start the
engine, depress the brake pedal,
then move gearshift lever out of P
(Park).
DRIVING THROUGH WATER
Do not drive quickly through standing water, especially if the depth is
unknown. Traction or brake capability may be limited and if the ignition
system gets wet, your engine may stall. Water may also enter your
engine’s air intake and severely damage your engine.
If driving through deep or standing water is unavoidable, proceed very
slowly. Never drive through water that is higher than the bottom of the
hubs.
OVERDRIVE
OFF/ON
P R N D 2 1
Driving
166

If you drive in extremely hot climates:
•It is still necessary to maintain the coolant concentration
above 40%.
•NEVER decrease the coolant concentration below 40%.
•Decreased engine coolant concentrations below 40% will
decrease the corrosion protection characteristics of the engine
coolant and may cause engine damage.
•Decreased engine coolant concentrations below 40% will
decrease the freeze protection characteristics of the engine
coolant and may cause engine damage.
•Refer to the chart on the coolant container to ensure the
coolant concentration in your vehicle will provide adequate
protection at the temperatures in which you drive.
Vehicles driven year-round in non-extreme climates should use a 50/50
mixture of engine coolant and distilled water for optimum cooling system
and engine protection.
WHAT YOU SHOULD KNOW ABOUT AUTOMOTIVE FUELS
Important safety precautions
Do not overfill the fuel tank. The pressure in an overfilled tank
may cause leakage and lead to fuel spray and fire.
The fuel system may be under pressure. If the fuel filler cap is
venting vapor or if you hear a hissing sound, wait until it stops
before completely removing the fuel filler cap. Otherwise, fuel may
spray out and injure you or others.
If you do not use the proper fuel filler cap, excessive pressure or
vacuum in the fuel tank may damage the fuel system or cause
the fuel cap to disengage in a collision, which may result in possible
personal injury.
Automotive fuels can cause serious injury or death if misused or
mishandled.
Gasoline may contain benzene, which is a cancer-causing agent.
Maintenance and Specifications
221

Use the following guidelines to avoid static build-up when filling an
ungrounded fuel container:
•Place approved fuel container on the ground.
•DO NOT fill a fuel container while it is in the vehicle (including the
cargo area).
•Keep the fuel pump nozzle in contact with the fuel container while
filling.
•DO NOT use a device that would hold the fuel pump handle in the fill
position.
Fuel Filler Cap
Your fuel tank filler cap has an indexed design with a 1/4 turn on/off
feature.
When the fuel filler door is open, the left hand sliding door will
not open.
When fueling your vehicle:
1. Turn the engine off.
2. Carefully turn the filler cap counterclockwise 1/4 of a turn until it
stops.
3. Pull to remove the cap from the fuel filler pipe.
4. To install the cap, align the tabs on the cap with the notches on the
filler pipe.
5. Turn the filler cap clockwise 1/4 of a turn until it stops.
If the“Service Engine Soon”indicator comes on and stays on when you
start the engine, the fuel filler cap may not be properly installed. Turn
off the engine, remove the cap, align the cap properly and reinstall it.
If you must replace the fuel filler cap, replace it with a fuel filler
cap that is designed for your vehicle. The customer warranty may
be void for any damage to the fuel tank or fuel system if the
correct genuine Ford or Motorcraft fuel filler cap is not used.
The fuel system may be under pressure. If the fuel filler cap is
venting vapor or if you hear a hissing sound, wait until it stops
before completely removing the fuel filler cap. Otherwise, fuel may
spray out and injure you or others.
Maintenance and Specifications
223

If you do not use the proper fuel filler cap, excessive pressure or
vacuum in the fuel tank may damage the fuel system or cause
the fuel cap to disengage in a collision, which may result in possible
personal injury.
Choosing the right fuel
Use only UNLEADED FUEL. The use of leaded fuel is prohibited by law
and could damage your vehicle.
Do not use fuel containing methanol. It can damage critical fuel system
components.
Your vehicle was not designed to use fuel or fuel additives with metallic
compounds, including manganese-based compounds containing MMT.
Repairs to correct the effects of using a fuel for which your vehicle was
not designed may not be covered by your warranty.
Octane recommendations
Your vehicle is designed to use
“Regular”unleaded gasoline with
pump (R+M)/2 octane rating of 87.
We do not recommend the use of
gasolines labeled as“Regular”that
are sold with octane ratings of 86 or lower in high altitude areas.
Do not be concerned if your engine sometimes knocks lightly. However, if
it knocks heavily under most driving conditions while you are using fuel
with the recommended octane rating, see your dealer or a qualified
service technician to prevent any engine damage.
Fuel quality
If you are experiencing starting, rough idle or hesitation driveability
problems during a cold start, try a different brand of“Regular”unleaded
gasoline.“Premium”unleaded gasoline is not recommended (particularly
in the United States) because it may cause these problems to become
more pronounced. If the problems persist, see your dealer or a qualified
service technician.
It should not be necessary to add any aftermarket products to your fuel
tank if you continue to use high quality fuel of the recommended octane
rating. Aftermarket products could cause damage to the fuel system.
Repairs to correct the effects of using an aftermarket product in your
fuel may not be covered by your warranty.
87(R+M)/2 METHOD
Maintenance and Specifications
224

possible. Fuel expense, frequency of fill-ups or fuel gauge readings are
NOT accurate as a measure of fuel economy. We do not recommend
taking fuel economy measurements during the first 1 600 km (1 000
miles) of driving (engine break-in period). You will get a more accurate
measurement after 3 000 km–5 000 km (2 000 miles-3 000 miles).
Filling the tank
The advertised fuel capacity of the fuel tank on your vehicle is equal to
the rated refill capacity of the fuel tank as listed in theRefill capacities
section of this chapter.
The advertised capacity is the amount of the indicated capacity and the
empty reserve combined. Indicated capacity is the difference in the
amount of fuel in a full tank and a tank when the fuel gauge indicates
empty. Empty reserve is the small amount of fuel remaining in the fuel
tank after the fuel gauge indicates empty.
The amount of usable fuel in the empty reserve varies and should
not be relied upon to increase driving range. When refueling your
vehicle after the fuel gauge indicates empty, you might not be
able to refuel the full amount of the advertised capacity of the
fuel tank due to the empty reserve still present in the tank.
For consistent results when filling the fuel tank:
•Turn the engine/ignition switch to the off position prior to refueling,
an error in the reading will result if the engine is left running.
•Use the same filling rate setting (low—medium—high) each time
the tank is filled.
•Allow no more than 2 automatic click-offs when filling.
•Always use fuel with the recommended octane rating.
•Use a known quality gasoline, preferably a national brand.
•Use the same side of the same pump and have the vehicle facing the
same direction each time you fill up.
•Have the vehicle loading and distribution the same every time.
Your results will be most accurate if your filling method is consistent.
Calculating fuel economy
1. Fill the fuel tank completely and record the initial odometer reading
(in kilometers or miles).
2. Each time you fill the tank, record the amount of fuel added (in liters
or gallons).
Maintenance and Specifications
226