2002 Mercury Villager BaseFACTORY OEM SERVICE PROCEDURE

Diagnostic Test Mode

  1. 1) Perform Diagnostic Test Mode

    Ensure engine is warmed to normal operating temperature. If engine does not start, continue with testing. Turn ignition on. Ensure test equipment is properly attached. Using New Generation Star (NGS) tester, select and enter the following data:
    • Select VEHICLE & ENGINE SELECTION menu.
    • Select year, engine, model and any additional information requested by scan tool.
    • Select DIAGNOSTIC DATA LINK.
    • Select PCM-POWERTRAIN CTRL MODULE.
    • Select DIAGNOSTIC TEST MODE RESULTS.

    If any DTCs are retrieved, go to next step. If no DTCs are retrieved, proceed as follows:

    • If a communication error exists between scan tool and PCM, go to TEST QA, step  1).
    • If scan tool displays DTC P0000 NO FAILURES and engine starts, go to SWITCH MONITOR TEST .
    • If no DTCs are displayed and engine does not start, go to TEST A, step  1).

    2. NOTE: Erasing and retesting will indicate if DTCs received in step 1)  are hard or intermittent faults. Hard faults will be repeated immediately and DTCs will be displayed during retest. If DTCs are not repeated, it may be necessary to perform TEST Z  , step  1) in order to induce a failure. Perform TEST Z and repeat step 1)  after each repair.

  2. 2) Erase DTCs & Retest
    Repeat step  1) to determine if DTCs will reappear indicating a hard (non-intermittent) fault. Clear DTCs. See CLEARING CODES . Repeat step 1)  to check for DTCs. If DTC is present, malfunction is considered to be a hard fault. Perform appropriate system test for DTC retrieved. See DIAGNOSTIC TROUBLE CODE DEFINITIONS . If DTC is not present, fault may be intermittent. Go to TEST Z  , step  1), or go to INTERMITTENTS in TROUBLE SHOOTING - NO CODES - VILLAGER article.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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