The punch sensor top top the 1993 with 1998 Mercury Villager 3.0-liter engine is situated under the intake manifold. That checks because that pre-ignition, otherwise recognized as spark knock. If the senses spark knock, it sends a signal to the programmable regulate module (PCM), i beg your pardon is the engine"s computer. The punch sensor functions by sensing the vibrations in the engine, caused by spark knock. The pressure caused by vibrations native spark punch is converted to a voltage signal. This is the signal that the PCM reads. The PCM adjusts the ignition timing and also the fuel timing until it go not sense spark knock.

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Open the relay box, located near the driver"s-side fender well. Check out the underside the the covering to recognize which relay is the fuel pump relay. Pull the fuel pump relay out of the box using the needle-nose pliers. Crank the engine over 3 or 4 times to relax the fuel pressure. The Villager will certainly not start. Disconnect the an unfavorable battery cable utilizing the ideal wrench.


Place the drain pan under the radiator petcock. Loosen the petcock and enable the antifreeze mixture to drainpipe into the drainpipe pan. If the drain pan is clean, you have the right to reuse the antifreeze mixture, unless the mixture is number of years old. If the drain pan is dirty or the antifreeze mixture is numerous years old, use new antifreeze as soon as you refill the radiator.


Disconnect the waiting breather tube, the EGR solenoid vent hose and the bypass waiting inlet water tap from the wait cleaner-to-intake manifold hose, using the proper sockets. Ease the water tap clamps ~ above the wait cleaner-to-intake manifold hose clamps, utilizing the appropriate socket, driver or pliers, depending on the form of clamp.


Disconnect the wait intake resonator tube from the wait cleaner-to-intake manifold hose making use of the ideal socket. Traction the wait cleaner-to-intake manifold hose off the engine. Disconnect the two electric connectors on the throttle body, climate slide the wiring harness from its bracket. Unclamp and remove the coolant hose from the throttle body. Unplug the EGR solenoid wiring harness connector from the EGR solenoid.


Disconnect the evaporative emissions canister vacuum water tap from the input manifold. Disconnect the EVAP canister-to-throttle body hose. Eliminate the vacuum water tap from the fuel push regulator come the upper intake manifold.


Mark the spark plug wires, so you know where castle go as soon as you put the engine ago together. Traction the wires turn off the spark plugs, then remove the 2 spark plug wire bracket bolts and also the brackets from the upper intake manifold using the ideal sockets.


Remove the distributor dust cover using the ideal socket, then loosen the distributor cap screws using a screwdriver. Remove the lid and collection it aside (leave the spark plug wires attached to the cap). Disconnect the rear heater valve vacuum hose from the top intake manifold. Eliminate both wiring harness bracket bolts and the bracket native the top intake manifold. Collection it out of the way. Disconnect the speed control actuator top top the throttle lever, then disconnect the accelerator cable native the accelerator lever. If the Villager has a speed regulate actuator, which would be attached come the bracket, remove it.


Remove the accelerator cable indigenous its parentheses on the optimal of the top intake manifold. Ease the locknut top top the accelerator cable, then pull the cable the end of its bracket on the top of the upper intake manifold. If the Villager has actually a speed manage actuator, loosen the locknut, then remove the actuator indigenous its parentheses on the optimal of the upper intake manifold. Collection it aside.


Disconnect the brake booster hose from the strength brake booster"s inspect valve. Eliminate the back pressure transducer valve tube from the EGR valve, then unbolt and remove the EGR valve-to-manifold pipe from the EGR valve. Unplug the fast idle regulate solenoid electric connector.


Disconnect the engine"s wiring harness clips from the breather pipe bracket, then eliminate the two ground wire bolts indigenous the top intake manifold. Move the ground wires and also the harness aside, so that it is no in your way.


Unbolt and remove the two left breather tube bracket bolts from the upper intake manifold. Disconnect the left breather hose from the left valve cover. Eliminate the bolt from the fuel pipe mounting bracket. Ease the clamp ~ above the coolant hose for the thermostat real estate on the upper intake manifold. Unplug the wiring harness connector native the EGR temperature sensor, the connector for the bypass valve, and also the idle air manage electrical connector. Traction the PCV water tap from the top intake manifold. Eliminate the five Allen bolts indigenous the top intake manifold--these bolts host the upper and lower intake manifold together. Different the two manifolds, then clean the gasket mating surface ar of every gasket material.


Unplug the electric connectors on the six fuel injectors. Pull the appropriate breather hose off the appropriate valve cover. Loosen the clamps ~ above the crossover breather tube and remove the breather tube and the bracket from the upper engine former cover. Unbolt the 4 fuel injection rail bolts. Relocate the fuel injector rail and the insulators out of the way. Unplug the engine coolant temperature sensor"s wiring harness connector. Unplug the coolant temperature sending unit wiring exploit connector.


Loosen the clamps top top the upper radiator hose utilizing the proper socket, driver or pliers. Traction the radiator hose off the input manifold. Eliminate the upper radiator water tap bracket making use of the suitable socket. Ease the clamps on the bypass hose on the input manifold water outlet, then remove the hose. Unbolt and remove the water outlet indigenous the former cover. Remove the heater water tap from the peak heater main point pipe. Making use of the Allen wrench and the proper sequence (see picture in References), eliminate the lower intake manifold bolts. Remove the 4 manifold nuts.


Remove the lower intake manifold washers, climate lift the entry manifold native the engine. Clean the gasket adjustment surfaces of all gasket material.


Work the coolant crossover tube earlier and forth and pull it off the engine. Disconnect the punch sensor"s electric connector. Unbolt and remove the knock sensor utilizing the ideal socket. Install the new sensor and also tighten the bolt firmly. Plug the brand-new sensor"s electrical connector in. Reinstall the coolant crossover tube.


Lay the brand-new lower intake manifold gaskets ~ above the cylinder heads, then position the reduced intake manifold on the engine. Reinstall the reduced intake manifold washers, climate install the bolts and nuts. Making use of the photo in referral 1, tighten the bolts and also nuts in sequence to 30 inch-pounds that torque. On the second go-around, tighten the nuts come 18 foot-pounds that torque, then tighten the bolts to 10 foot-pounds the torque. On the 3rd go-around, tighten the nuts to 18 foot-pounds of torque, then tighten the bolts come 10 foot-pounds of torque, still following the sequence.

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Reinstall the materials on the lower intake manifold in reverse order of removal. Ar the top intake gaskets top top the reduced intake manifold, then collection the upper intake manifold ~ above the gasket. Tighten the five Allen head bolts to 14 foot-pounds of torque. Reinstall the hoses, plug the sensors in and reinstall the cables top top the accelerator body. Adjust the cables together necessary. Tighten the radiator petcock. Refill the cooling system. Plug the fuel pump relay in. Affix the an unfavorable battery cable. Begin the Villager and also check because that leaks.