I just got my 97 Villager and I love it already :) Next trip, Calgary to Tofino for some surfing :)
It sounds like motor and transmission mounts have to be replaced. I had the same hard starts unless I apply the gas very gently at start. Check for cracks in the rubber of the mounts. There are 3 motor mounts and 1 transmission mount. The last one you can replace from the top. You just have to pull the battery and the battery pan to have easier access to it. I hope that helps!
I had the same problem with my 1997 Villager. I changed the distributor, and it runs fine now. I hope that helps.
Here's hoping 29 January 2007 is still monitoring; Please tell me more about MIG welding the nuts to your broken-off studs. I have a TIG welder, though it looks mighty tight to get it in there. I'll probably pull the head first. Did you use a way oversize nut, and just weld the middle in solid, starting with the end of the stud?
Just repaired that on mine. It's a part that connects directly to the transmission... We got our part at a pick a part place for 10 bucks, and it was easy to put in...
Have a well maintained 96 Villager with 178K on it, with no other problems except that the shifter indicator on the dash panel no longer lights up, and I have to constantly turn the map light on to know what gear I'm in.
Does anyone know if and how the bulb is replaceable? I checked the user manual, and it does not mention the instrument panel cluster lights.
To note: My model is the LS with the electronic digital dashboard.
Also to note: Among the things that keep my Villager running so well is keeping up with routine maintenance; oil changes, transmission fluid changes, regular cooling system service (1 or 2 times per year depending), power steering/brakes service (once a year).
I would try your replacing all your spark plugs; that is what I had to do when I through my timing belt!! Good luck.
I'm owner of a Mercury of the same year, and I have the same problem with the bad idle. Same as you, I replace the TPS sensor many times without success. I took the van to the Mercury dealer to get a diagnosis of this, and they came up with the same TPS, knock sensor, oxygen sensor, and another sensor that I don't remember.
My question is, did you find any solution for this problem? It really make me think that the problem must be something else...
Thank you in advance.
The rear blower problem is nothing more than a burned trace on that circuit board. Re-solder and it will be as good as new.
My recommendation would be to find a new mechanic that is easy to communicate with, who will take the time to explain to what is going on, and is reasonably priced and does not charge Doctor's rates for labor.
I'm on my second MV, and the first was a 96 that I got 220K out of. Would have kept it longer, but the rocker panels and pinch weld seals were rotted out, as the result of careless mechanics improperly placing the lifts on it when they worked on it.