If your 1997 through 2000 Mercury Villager has been driven more than 100,000 miles, it is time to perform scheduled maintenance. One form of that maintenance is to replace the valve cover gasket. With an investment of about two to three hours of your time, a little patience and a few parts purchased from your local automotive supply store, you can complete this maintenance.
Allow the engine to cool. Disconnect the negative battery cable. Locate and remove the upper intake manifold. Locate and disconnect the breather hose from the valve cover, the bolt from the upper intake manifold stabilizer bracket and remove the bracket.
Unclasp the wiring harness from the valve cover and move it out of the way. Locate and disconnect the vacuum hoses from the valve cover. Remove the nine valve cover screws.
Use a flathead screwdriver to gently nudge the valve cover gasket to remove it. Try not to scratch the gasket seating area when you do this. Using automotive engine cleaner and a clean cloth rag, clean the gasket seating area.
Place the new gasket into the gasket seating area. Place the valve cover back into place and using a torque wrench, tighten the bolts. Reconnect the vacuum hoses. Reinstall the wiring harness, upper intake manifold bracket, breather hose and upper intake manifold.
Make sure that the negative battery cable is disconnected. Located and disconnect the heated oxygen sensor electrical connector. Unclasp the connector from the valve cover.
Locate and disconnect the breather hose from the valve cover. Remove the nine valve cover screws. Remove the valve cover. Using a flathead screwdriver, gently nudge the valve cover gasket to remove it. Using automotive engine cleaner and a clean cloth rag, clean the gasket seating area.
Place the new gasket into the gasket seating area. Place the valve cover back into place and using a torque wrench, tighten the bolts. Reinstall the breather hose and heated oxygen sensor connector. Reconnect the negative battery cable.
Check the oil level. If necessary add 1 to 2 quarts of oil. Start the car and allow the engine to run idle for 10 to 15 minutes. This will allow the oil to move to the top of the engine, lubricating the engine parts as it does.
