2002 Mercury Villager maintenance

•Resting your foot on the brake pedal while driving may reduce fuel
economy.
•Combine errands and minimize stop-and-go driving.
Maintenance
•Keep tires properly inflated and use only recommended size.
•Operating a vehicle with the wheels out of alignment will reduce fuel
economy.
•Use recommended engine oil. Refer toLubricant specificationsin
this chapter.
•Perform all regularly scheduled maintenance items. Follow the
recommended maintenance schedule and owner maintenance checks
found in your vehicle scheduled maintenance guide.
Conditions
•Heavily loading a vehicle or towing a trailer may reduce fuel economy
at any speed.
•Carrying unnecessary weight may reduce fuel economy (approximately
0.4 km/L [1 mpg] is lost for every 180 kg [400 lb] of weight carried).
•Adding certain accessories to your vehicle (for example bug
deflectors, rollbars/light bars, running boards, ski/luggage racks) may
reduce fuel economy.
•Using fuel blended with alcohol may lower fuel economy.
•Fuel economy may decrease with lower temperatures during the first
12–16 km (8–10 miles) of driving.
•Driving on flat terrain offers improved fuel economy as compared to
driving on hilly terrain.
•Transmissions give their best fuel economy when operated in the top
cruise gear and with steady pressure on the gas pedal.
•Close windows for high speed driving.
EPA window sticker
Every new vehicle should have the EPA window sticker. Contact your
dealer if the window sticker is not supplied with your vehicle. The EPA
window sticker should be your guide for the fuel economy comparisons
with other vehicles.
It is important to note the box in the lower left corner of the window
sticker. These numbers represent the Range of L/100 km (MPG)
expected on the vehicle under optimum conditions. Your fuel economy
may vary depending upon the method of operation and conditions.
Maintenance and Specifications
228

EMISSION CONTROL SYSTEM
Your vehicle is equipped with various emission control components and a
catalytic converter which will enable your vehicle to comply with applicable
exhaust emission standards. To make sure that the catalytic converter and
other emission control components continue to work properly:
•Use only the specified fuel listed.
•Avoid running out of fuel.
•Do not turn off the ignition while your vehicle is moving, especially at
high speeds.
•Have the items listed in your scheduled maintenance guide performed
according to the specified schedule.
The scheduled maintenance items listed in the scheduled maintenance
guide are essential to the life and performance of your vehicle and to its
emissions system.
If other than Ford, Motorcraft or Ford-authorized parts are used for
maintenance replacements or for service of components affecting
emission control, such non-Ford parts should be equivalent to genuine
Ford Motor Company parts in performance and durability.
Do not park, idle, or drive your vehicle in dry grass or other dry
ground cover. The emission system heats up the engine
compartment and exhaust system, which can start a fire.
Illumination of the“Service Engine Soon”light, charging system warning
light or the temperature warning light, fluid leaks, strange odors, smoke
or loss of engine power, could indicate that the emission control system
is not working properly.
Exhaust leaks may result in entry of harmful and potentially
lethal fumes into the passenger compartment.
Do not make any unauthorized changes to your vehicle or engine. By law,
vehicle owners and anyone who manufactures, repairs, services, sells,
leases, trades vehicles, or supervises a fleet of vehicles are not permitted to
intentionally remove an emission control device or prevent it from working.
Information about your vehicle’s emission system is on the Vehicle
Emission Control Information Decal located on or near the engine. This
decal identifies engine displacement and gives some tune up specifications.
Please consult yourWarranty Guidefor complete emission warranty
information.
Maintenance and Specifications
229

Readiness for Inspection/Maintenance (I/M) testing
In some localities, it may be a legal requirement to pass an I/M test of
the on-board diagnostics system. If your“Check Engine/Service Engine
Soon”light is on, refer to the description in theWarning lights and
chimessection of theInstrument Clusterchapter. Your vehicle may not
pass the I/M test with the“Check Engine/Service Engine Soon”light on.
If the vehicle’s powertrain system or its battery has just been serviced,
the on-board diagnostics system is reset to a“not ready for I/M test”
condition. To ready the on-board diagnostics system for I/M testing,
follow the procedure described below:
1. Allow the engine to cool to ambient temperature (the engine coolant
temperature gauge indicator will point to C).
2. Start the engine and let it run until it reaches normal operating
temperature (the engine coolant temperature gauge indicator will be
near the center of the normal area between H and C).
3. Accelerate the vehicle to 88 km/h (55 mph), then quickly release the
accelerator pedal completely for at least six seconds.
4. Quickly depress the accelerator pedal for a moment, then drive the
vehicle at a speed of 86 to 96 km/h (53 to 60 mph) for at least five
minutes.
5. Bring the vehicle to a complete stop.
6. Accelerate the vehicle to 55 km/h (35 mph), and maintain the speed
for 20 seconds.
7. Repeat steps five and six at least three times.
8. Accelerate the vehicle to 88 km/h (55 mph), and maintain the speed
for at least three minutes.
9. Bring the vehicle to a complete stop and turn the engine off.
10. Repeat steps one through nine at least one more time.
If step one through eight are interrupted, repeat the preceding step. Any
safe driving mode is acceptable between steps. Once started, do not turn
off the engine until step seven is completed.
Maintenance and Specifications
230

CHECKING AND ADDING POWER STEERING FLUID
Check the power steering fluid. Refer to the scheduled maintenance
guide for the service interval schedules. If adding fluid is necessary, use
only MERCONAT F.
1. Start the engine and let it run
until it reaches normal operating
temperature (the engine coolant
temperature gauge indicator will be
near the center of the normal area
between H and C).
2. While the engine idles, turn the
steering wheel left and right several
times.
3. Turn the engine off.
4. Check the fluid level in the
reservoir. It should be between the
MIN and MAX lines. Do not add
fluid if the level is in this range.
5. If the fluid is low, add fluid in
small amounts, continuously
checking the level until it reaches
the range between the MIN and
MAX lines. Be sure to put the cap
back on the reservoir.
BRAKE FLUID
Checking and adding brake fluid
Brake fluid should be checked and
refilled as needed. Refer to the
scheduled maintenance guide for
the service interval schedules.
1. Clean the reservoir cap before
removal to prevent dirt or water
from entering the reservoir.
MAX
MIN
Maintenance and Specifications
231

2. Visually inspect the fluid level.
3. If necessary, add brake fluid from
a clean un-opened container until
the level reaches MAX. Do not fill
above this line.
4. Use only a DOT 3 brake fluid
certified to meet Ford specification
ESA-M6C25–A. Refer toLubricant
specificationsin this chapter.
Brake fluid is toxic. If brake fluid contacts the eyes, flush eyes
with running water for 15 minutes. Seek medical attention if
irritation persists. If taken internally, drink water and induce vomiting.
Seek medical attention immediately.
If you use a brake fluid that is not DOT 3, you will cause
permanent damage to your brakes.
Do not let the fluid level in the reservoir for the master cylinder
fall below the MIN mark. If master cylinder runs dry, this may
cause the brakes to fail.
TRANSMISSION FLUID
Checking automatic transmission fluid
Refer to your scheduled maintenance guide for scheduled intervals for
fluid checks and changes. Your transaxle does not consume fluid.
However, the fluid level should be checked if the transaxle is not working
properly, i.e., if the transaxle slips or shifts slowly or if you notice some
sign of fluid leakage.
Automatic transmission fluid expands when warmed. To obtain an
accurate fluid check, drive the vehicle until it is warmed up
(approximately 30 km [20 miles]). If your vehicle has been
operated for an extended period at high speeds, in city traffic
during hot weather or pulling a trailer, the vehicle should be
turned off for about 30 minutes to allow fluid to cool before
checking.
MAX
MIN
Maintenance and Specifications
232

1. Drive the vehicle 30 km (20 miles) or until it reaches normal operating
temperature.
2. Park the vehicle on a level surface and engage the parking brake.
3. With the parking brake engaged and your foot on the brake pedal,
start the engine and move the gearshift lever through all of the gear
ranges. Allow sufficient time for each gear to engage.
4. Latch the gearshift lever in P (Park) and leave the engine running.
5. Remove the dipstick, wiping it clean with a clean, dry lint free rag. If
necessary, refer toIdentifying components in the engine compartment
in this chapter for the location of the dipstick.
6. Install the dipstick making sure it is fully seated in the filler tube.
7. Remove the dipstick and inspect the fluid level. The fluid should be in
the designated areas for normal operating temperature.
Low fluid level
Do not drive the vehicle if the fluid
level is at the bottom of the dipstick
and the outside temperatures are
above 10°C (50°F).
Correct fluid level
The transmission fluid should be checked at normal operating
temperatures 66°C-77°C (150°F-170°F) on a level surface. The normal
operating temperature can be reached after approximately 30 km (20
miles) of driving.
The transmission fluid should be in
this range if at normal operating
temperature (66°C-77°C
[150°F-170°F]).
High fluid level
Fluid levels above the safe range
may result in transaxle failure. An
overfill condition of transmission
fluid may cause shift and/or
engagement concerns and/or
possible damage.
High fluid levels can be caused by an overheating condition.
HOT
HOT
HOT
Maintenance and Specifications
233

Adjusting automatic transmission fluid levels
Before adding any fluid, make sure the correct type is used. The type of
fluid used is normally indicated on the dipstick and also in the
Lubricant specificationssection in this chapter.
Use of a non-approved automatic transmission fluid may cause
internal transaxle component damage.
If necessary, add fluid in 250 mL (1/2 pint) increments through the filler
tube until the level is correct.
If an overfill occurs, excess fluid
should be removed by a qualified
technician.
An overfill condition of
transmission fluid may cause
shift and/or engagement concerns and/or possible damage.
Do not use supplemental transmission fluid additives, treatments or
cleaning agents. The use of these materials may affect transmission
operation and result in damage to internal transmission components.
AIR FILTER MAINTENANCE
Refer to the scheduled maintenance guide for the appropriate intervals
for changing the air filter element.
When changing the air filter element, use only the Motorcraft air filter
element listed. Refer toMotorcraft Part Numbers.
Note:Do not start your engine with the air cleaner removed and do not
remove it while the engine is running.
Changing the air filter element
1. Release the four clamps that
secure the air filter housing cover.
2. Carefully separate the two halves
of the air filter housing.
3. Remove the air filter element
from the air filter housing.
HOT
Maintenance and Specifications
234

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