Safety First!
* Disconnect the negative battery terminal before starting any work. This prevents accidental sparks near flammable fuel vapors.
* Work in a well-ventilated area. Fuel vapors are extremely dangerous.
* Use proper safety glasses and gloves.
* Have a fire extinguisher readily available.
Steps (General Outline - Consult a Repair Manual for Precise Instructions):
1. Prepare the Vehicle: Park the vehicle on a level surface, engage the parking brake, and chock the wheels.
2. Locate the Fuel Tank: The fuel tank is typically located under the vehicle, towards the rear.
3. Access the Fuel Tank: You'll likely need to lower or remove parts of the vehicle's undercarriage to access the tank. This might involve removing some plastic shields or other components. Your repair manual will show you exactly what needs to be removed.
4. Disconnect Fuel Lines: Carefully disconnect the fuel lines leading to and from the fuel tank. You'll need to relieve pressure in the fuel system first. This often involves running the engine until it stalls or using a fuel pressure release tool. Be extremely careful not to spill any fuel. Use appropriately sized fuel line clamps or plugs to prevent fuel leakage.
5. Disconnect Electrical Connectors: Disconnect the electrical connector(s) to the fuel pump.
6. Lower the Fuel Tank: The fuel tank is usually supported by straps or brackets. You will need to carefully loosen and remove these to lower the tank. Some vehicles may require special tools or a fuel tank lowering strap. Be prepared for the weight of the tank; it will be heavy even when nearly empty. It may be helpful to support the tank with jack stands.
7. Access the Fuel Pump: Once the tank is lowered sufficiently, you will be able to access the fuel pump assembly. This is usually located at the top of the tank. It's commonly held in place by a retaining ring or clamp.
8. Remove the Fuel Pump: Carefully remove the retaining ring or clamp and remove the fuel pump assembly.
9. Install the New Fuel Pump: Install the new fuel pump, making sure to correctly seat the gasket and seal. Reattach any electrical connectors and fuel lines, making sure they are securely fastened.
10. Raise the Fuel Tank: Carefully raise and secure the fuel tank back into its position. Double check all straps/brackets are correctly attached.
11. Reconnect Fuel Lines and Electrical Connectors: Double and triple-check that all fuel lines and electrical connectors are properly reconnected and secured. Avoid kinks in the fuel lines.
12. Check for Leaks: Inspect for any fuel leaks before starting the vehicle.
13. Reconnect the Negative Battery Terminal: Once you're certain there are no leaks, reconnect the negative battery terminal.
14. Start the Vehicle: Start the vehicle and check for any issues.
Again, this is a very general outline. You absolutely need a repair manual specific to your 2000 Mercury Villager to provide detailed instructions, torque specifications, and diagrams. If you are not comfortable performing this repair yourself, take it to a qualified mechanic. Working with fuel is dangerous and improper procedures can lead to serious injury or even death.
