2002 Mercury Villager BaseFACTORY OEM SERVICE PROCEDURE

Pump Assembly: Disassembly

  1. Remove the oil pump seals.
    Fig 1: Removing Oil Pump Seals
    G03412426Courtesy of FORD MOTOR CO.
  2. Remove the oil pump cover bolts in the indicated sequence.
    Fig 2: Removing Oil Pump Cover Bolts
    G03412427Courtesy of FORD MOTOR CO.
  3. Remove the oil pump cover.
    Fig 3: Removing Oil Pump Cover
    G03412428Courtesy of FORD MOTOR CO.
  4. Remove the oil pump gears.
    • Remove the outer gear.
    • Remove the inner gear.
      Fig 4: Removing Oil Pump Gears
      G03412429Courtesy of FORD MOTOR CO.
  5. Remove the O-ring from the oil pump housing.
    Fig 5: Removing O-Ring From Oil Pump Housing
    G03412430Courtesy of FORD MOTOR CO.
  6. Remove the front oil pump seal.
    Fig 6: Removing Front Oil Pump Seal
    G03412431Courtesy of FORD MOTOR CO.
  7. Inspect the oil pump assembly for wear.
    • Check the oil pump housing.
    • Check the oil pump cover.
    • Check the inner gear.
    • Check the outer gear.
    8. NOTE: The inner gear is installed with the two center teeth facing up.
  8. Install the oil pump gears.
    • Install the outer gear.
    • Install the inner gear.
      Fig 7: Installing Oil Pump Gears
      G03412432Courtesy of FORD MOTOR CO.
  9. Using the special tool, check the oil pump side gear clearance. If the measured clearance is not within 0.030-0.050 mm (0.0012-0.0020 in), install a new oil pump assembly.
    Fig 8: Checking Oil Pump Side Gear Clearance
    G03412433Courtesy of FORD MOTOR CO.
  10. Measure the clearance between the outer gear and the oil pump housing. If the measured clearance is not within 0.111-0.181mm (0.0044-0.0071inch) install a new oil pump assembly.
    Fig 9: Measuring Clearance Between Outer Gear And Oil Pump Housing
    G03412434Courtesy of FORD MOTOR CO.
    11. CAUTION: Do not spread the seals further than necessary or damage to the seal may occur.
  11. Install the oil pump seals.
    • Coat the seals with petroleum jelly.
      Fig 10: Installing Oil Pump Seals
      G03412435Courtesy of FORD MOTOR CO.
  12. Measure the clearance between the oil pump seals and the oil pump housing. The clearance should measure 0.036 mm (0.0014 in) to 0.176 mm (0.0069 in). If the measured clearance is not within specification, install a new oil pump cover assembly.
    Fig 11: Measuring Clearance Between Oil Pump Seals And Oil Pump Housing
    G03412436Courtesy of FORD MOTOR CO.
Factory Service Tools

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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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