OEM 2002 Mercury Villager Intake Manifold

2002 Mercury Villager Intake Manifold Parts Questions & Experts Answers

• Q: How to service and repair the lower intake manifold on 2002 Mercury Villager?

  A: Before servicing or repairing the lower intake manifold it is necessary to reduce fuel system pressure. You must detach all i.e. disconnect electrical connectors from upper intake manifold and the Fuel Injector connectors and the Engine Coolant Temperature (ECT) sensor connector. Sanitize the H02S electrical connection by both removing ground wire bolts and unclipping socket retention on the bracket while removing the Heated Oxygen Sensor (H02S) electrical connector. Position the Positive Crankcase Ventilation (PCV) breather tube and wire harness to the side through disconnecting the PCV hose using the hose clamp followed by removing the wire straps. After disconnecting the water temperature sender electrical connection you should take out the bolt securing the spark plug wire bracket. It is necessary to exercise care near fuel components especially since these areas contain highly flammable mixtures and personnel must reduce fuel system pressure by unbolting connectors and releasing clamps and disconnecting fuel lines. The removal process includes taking out the fuel injection supply manifold bolts after both the manifold and insulators are detached from each other. The upper radiator hose requires release from its clamp and bolt so you can position it aside before removing the upper timing belt cover bolt. Proceed with disconnecting the coolant bypass hose from the water hose connection after releasing its clamp and perform the same operation with heater hose pipe and heater hose. The two-step method helps to separate lower intake manifold bolts and nuts in their specified sequence before removing the lower intake manifold while discarding the gaskets. The installation process requires fitting new lower intake manifold gaskets and lower intake manifold to the vehicle before installing nuts and bolts according to their specified sequence and performing a 3-step tightening process which starts at 4 Nm (35 inch lbs.) followed by 9 Nm (80 inch lbs.) twice. Begin with securing the heater hose pipe to the heater hose after you place the clamp onto it. Move to connect the coolant bypass hose to the water hose connection then secure its clamp. Before mounting the upper timing belt cover bolt install the upper radiator hose while also ensuring the fuel injection supply manifold insulators are in position before bolt installation. The fuel lines require positioning for installation of bolts before a fuel hose connection with clamping. The next steps include fastening the spark plug wire bracket bolt and hooking up the water temperature indicator sender electrical connector before positioning the PCV breather tube with its wire harness. Users then connect the PCV breather hose with new wire straps installed. The installation process requires connecting the H02S electrical connector then clipping the wire harness onto the bracket before bolt installation of the ground wire. When finishing the installation connect both electrical connectors which serve the fuel injectors and ECT sensor before adding the upper intake manifold.