How to Replace a Relay in a Mercury Villager

The 2002 Mercury Villager has relays--used to help regulate high current devices such as your air conditioning or fuel system--scattered throughout three separate compartments: the passenger side compartment, the engine compartment fuse/relay box (also called the power distribution box) to the left of the battery and the engine compartment relay box in front of the battery.

Difficulty: Moderately Easy

Instructions

Things You'll Need:

• Owner's manual
• Replacement relay
• Magnifying glass
• Soldering tools

1. Confirm the type of relay you need to replace in your Mercury Villager and the location of the relay within one of the three compartments by referring to your owner's manual diagrams (pages 175 through 182) and associated relay keys.

2. Disconnect the battery. Keep in mind that if you don't disconnect the battery you run the risk of an accidental electrical surge that could hurt you or cause costly damage to your vehicle.

3. Access the appropriate fuse/relay and/or standalone relay box in your Mercury Villager and remove the box cover.

4. Unplug your relay and check the box area for dirt, corrosion or damage. Clean, fix or repair any area, as needed.

5. Check your relay's circuit board solder for microscopic cracks with a magnifying glass before replacing it with your new relay. Soldered joints can crack causing resistance in the relay and a voltage drop. Consider resoldering the joints to restore the non-working relay to working condition.

6. Plug the relay back into the socket (if repaired with soldering) or plug in your new replacement relay. Confirm that the relay fits securely within its socket as current running through a loose relay can cause the relay to overheat or the outer casing to melt.

7. Replace the box cover and reconnect your battery. Start the Mercury Villager and ensure the repair worked.

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