How to Replace the Alternator in a Mercury Villager

The Mercury Villager uses an alternator to run electrical devices in your vehicle while the engine is running. A voltage regulator maintains a constant voltage level and is frequently integrated into the alternator assembly. If your battery continually runs down or your headlights become dimmer while the engine is running, you may need to replace the alternator.

Step 1 - Determine which alternator your Mercury Villager will need. You'll want to be sure the new alternator is compatible with your Villager's engine. Models made from 1993 to 1998 have a 3.0 L VG30E engine and models made after 1998 have a 3.3 L VG33E engine.

Step 2 - Disconnect the negative battery cable with a socket wrench. Loosen the idler adjusting bolt so you can remove the air conditioner drive belt. Remove the engine under cover.

Step 3 - Unplug the electrical connectors to the alternator and remove the alternator bracket with a socket wrench. Remove the mounting bolts on the alternator with a socket wrench and take off the alternator drive belt so you can remove the alternator.

Step 4 - Install the new alternator assembly and replace the alternator drive belt. Tighten the mounting bolts with a torque wrench to between 16 and 22 foot pounds. Replace the alternator drive belt and torque the bolt on the alternator mounting bracket to between 12 and 15 foot pounds.

Connect the electrical connector to the alternator and replace the engine undercover. Put the air conditioner drive belt back on and tighten the idler adjusting bolt with a socket wrench. Reconnect the negative battery cable with a socket wrench.

THINGS YOU'LL NEED: New alternator, Socket wrench set, Torque wrench

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