OEM 2002 Mercury Villager Intake Manifold

2002 Mercury Villager Intake Manifold Parts Q&A

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

  A: Service and repair operations on the upper intake manifold need to begin with engine cooling system drain procedures. The service includes removing the outlet tube from the air cleaner and disconnecting all electrical connections beginning with the MAP/BARD sensor through the TP switch and ending with the ISC connector. Proceed with disconnecting the coolant hose after releasing its clamp and then move to disconnect the Evaporative Emission (EVAP) vacuum hose and the fuel regulator vacuum hose. Pull aside the spark plug wires after unclipping their retainers then unplugging them. The process requires disconnecting the vacuum reservoir vacuum hose before removing the bolt to reposition the wire harness and bracket together with disconnecting speed control and accelerator cables. First release the clamp to remove the brake booster check valve vacuum hose and secondly unclip the MAP/BARD solenoid vacuum hose. First disconnect MAP/BARD vacuum hoses while removing Positive Crankcase Ventilation (PCV) breather tube bracket screws before disconnecting the PCV breather hose from the breather tube. To access the EVAP purge solenoid electrical connector along with the upper intake manifold requires unscrewing the bolts which allows movement of the manifold towards the underside. First disconnect the coolant and vacuum hoses while unscrewing the clamp before continuing to remove the PCV vacuum hose and upper intake manifold with gaskets. Begin by installing new upper intake manifold gaskets followed by positioning the upper intake manifold properly before connecting the vacuum hose. Before you install the bolts for the upper intake manifold you must position the coolant hose with its clamp. Reestablish the EVAP purge solenoid electrical connection then connect the PCV breather tube to its tube using a clamp. Secure the PCV breather tube bracket bolts before connecting the MAP/BARD vacuum hoses along with positioning the MAP/BARD solenoid vacuum hose into the specified clip area. The brake booster check valve vacuum hose requires a clamp for securing before installing speed control and accelerator cable bracket bolts. The speed control and accelerator cables need installation followed by attachment of the main wire harness bracket and vacuum reservoir vacuum hose connection. Clamping down the spark plug wire retainers while connecting each wire is the first step before attaching the fuel regulator vacuum hose and the EVAP vacuum hose where the clamp should be properly positioned. Attach the coolant hose while placing the clamp. After that, reconnect the electrical connectors for TP sensor, TP switch and ISC. The last step includes the air cleaner outlet tube installation followed by engine cooling system filling.