NHTSA owner reports · September 18, 2026 snapshot.
Engine And Engine Cooling complaints
142 reportsClear category filterMileage unknown · Dec 20, 2001
Engine And Engine Cooling
FOUR BOLTS ON ENGINE MANIFOLD HAVE PREMATURELY BROKEN OFF, THIS WOULD EVENTUALLY CAUSE EXHAUST SYSTEM TO SEPARATE FROM VEHICLES FRAME. *AK CONSUMER STATED THAT ALL 8 BOLTS ON EXHAUST MANIFOLD WERE REPLACED AT DEALER, MECHANICS AND SERVICE PERSONNEL TOLD HIM THAT ITS COMMON, PARTICULAR TO 93 VILLAGERS. CONSUMER SAID THE PROBLEM…
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FOUR BOLTS ON ENGINE MANIFOLD HAVE PREMATURELY BROKEN OFF, THIS WOULD EVENTUALLY CAUSE EXHAUST SYSTEM TO SEPARATE FROM VEHICLES FRAME. *AK CONSUMER STATED THAT ALL 8 BOLTS ON EXHAUST MANIFOLD WERE REPLACED AT DEALER, MECHANICS AND SERVICE PERSONNEL TOLD HIM THAT ITS COMMON, PARTICULAR TO 93 VILLAGERS. CONSUMER SAID THE PROBLEM IS LAPPING AGAIN AT 95000 MILES, SINCE THIS IS A DEFECT CONSUMER IS ASKING FOR COMPENSATION. *YD
NHTSA ODI #8000976
Mileage unknown · Sep 1, 2001
Engine And Engine Cooling
BROKEN STUDS ON THE EXHAUST MANIFOLD LED TO FAILURE OF THE OXYGEN SENSOR AND REQUIRED HIRING A SUBCONTRACTOR TO DRILL OUT BROKEN STUDS FROM THE ENGINE BLOCK. TOTAL COST FOR REPAIR WAS $1731. I CALLED FORD CUSTOMER SERVICE AND WAS TOLD THAT THIS WAS A FAILURE THAT SHOULD BE EXPECTED FOR ANY CAR AFTER 76,000 MILES. HOWEVER, SEA…
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BROKEN STUDS ON THE EXHAUST MANIFOLD LED TO FAILURE OF THE OXYGEN SENSOR AND REQUIRED HIRING A SUBCONTRACTOR TO DRILL OUT BROKEN STUDS FROM THE ENGINE BLOCK. TOTAL COST FOR REPAIR WAS $1731. I CALLED FORD CUSTOMER SERVICE AND WAS TOLD THAT THIS WAS A FAILURE THAT SHOULD BE EXPECTED FOR ANY CAR AFTER 76,000 MILES. HOWEVER, SEARCHING INTERNET RESOURCES INDICATES THAT THIS IS A SPECIFIC DEFECT OF MERCURY VILLAGER AND NISSAN QUEST. OVER 100 COMPLAINTS HAVE BEEN FILED WITH NHTSA FOR 1993 AND 1994 VILLAGERS. THE SAME SEARCH OF 1993 DODGE CARAVAN, AS A SIMILAR VEHICLE WITH HIGHER SALES, YIELDED NO COMPLAINTS FOR EXHAUST MANIFOLD FAILURE. ACCORDING TO INTERNET RESOURCES, FORD LOST A LEGAL SUIT IN CANADA ABOUT THIS PROBLEM AND IS PAYING FOR REPAIRS OF VILLAGERS IN CANADA. FORD HOWEVER, REFUSED TO CONSIDER THIS IN MY CASE. NISSAN HAS APPARENTLY CHANGED STUD SPECIFICATIONS 4 TIMES TO ACHIEVE A SUITABLE STUD THAT DOES NOT BREAK. THE CRITERIA LISTED FOR A SUFFICIENT NUMBER OF COMPLAINTS TO INITIATE A RECALL IS VAGUE, BUT THIS SEEMS TO BE AN OBVIOUS MANUFACTURING DEFECT THAT MERITS A RECALL.
NHTSA ODI #751510
Mileage unknown · Aug 31, 2001
Engine And Engine Cooling
BOLTS BROKE OFF CAUSING THE MANIFOLD TO LEAK EXHAUST FUMES AND ENGINE BECAME NOISY.
NHTSA ODI #9004257
Mileage unknown · Jul 29, 2001
Engine And Engine Cooling
THIS IS A KNOWN PROBLEM WITH ALL MERCURY VILLAGER VANS ALLOWING EXHAUST GAS LEAKAGE INTO THE ENGINE BAY IN FRONT OF THE FIREWALL, THEREFORE POSSIBLY ENTERING THE PASSENGER COMPARTMENT. ALSO EXHAUST GASES ARE ALLOWED INTO THE ATMOSPHERE UNTREATED BY THE CATALYTIC CONVERTER. WE FINALLY PICKED UP ON THIS WHEN MY WIFE KEEP GETTIN…
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THIS IS A KNOWN PROBLEM WITH ALL MERCURY VILLAGER VANS ALLOWING EXHAUST GAS LEAKAGE INTO THE ENGINE BAY IN FRONT OF THE FIREWALL, THEREFORE POSSIBLY ENTERING THE PASSENGER COMPARTMENT. ALSO EXHAUST GASES ARE ALLOWED INTO THE ATMOSPHERE UNTREATED BY THE CATALYTIC CONVERTER. WE FINALLY PICKED UP ON THIS WHEN MY WIFE KEEP GETTING SLEEPY DRIVING HOME, AND FOUND THIS INFORMATION ON THE "EDMUNDS" WEBSITE, (EDMUNDS.COM). WE HAVE RETURNED THE VAN RECENTLY TO REPAIR THE FILLER VENT HOSE, PROBABLY A $2.00 REPAIR, WHY HAS THIS PROBLEM NOT BEEN ADDRESSED? IT IS FAR MORE DANGEROUS, MORE EXPENSIVE ($1200), AND DIFFICULT TO DETECT BECAUSE IT ONLY SOUNDS LIKE A "STUCK" VALVE LIFTER. WE HAD THE VAN FOR MANY YEARS WITH THE NOISE PRESENT, (FROM THE LEAKING EXHAUST MANIFOLD), BUT THE ONLY SOURCE OF ANY INFORMATION ON THIS DESIGN PROBLEM WAS THE "TOWNHALL TALK" FORUM ON THE EDMUND'S WEBSITE. HOW MANY PEOPLE ARE GOING TO HAVE TO BE KILLED AFTER FALLING ASLEEP AT THE WHEEL BEFORE SOME TYPE OF NOTIFICATION GOES INTO EFFECT? I HAVE A DEGREE IN MECHANICAL ENGINEERING AND THIS IS OBVIOUSLY AN IMPROPER SHEAR STRENGTH MANIFOLD STUD WHICH I IMAGINE WAS USED TO SAVE SOME MONEY ALONG THE WAY FOR NISSAN/MERCURY. SOME KIND OF RESPONSE HERE WOULD BE APPRECIATED. THANKS, JOHN. *AK
NHTSA ODI #749393
Mileage unknown · Jul 2, 2001
Engine And Engine CoolingFuel System, Gasoline
BOLT BROKE ON EXHAUST MANIFOLD. CAN HEAR A TICKING NOISE. ALSO, FUEL IS LEAKING OUT THOUGH CRACKS. DEALERSHIP IS AWARE OF PROBLEM. *AK
NHTSA ODI #891832
Mileage unknown · Jun 14, 2001
Engine And Engine Cooling
THE MANIFOLD BOLTS BROKE AT AROUND 46,000 MILES. THEY WERE REPLACED BY THE DEALER AND HAVE SINCE BROKEN AGAIN AROUND 50, 000 MILES LATER (95,000). THE VECHILE MAKES A LOUD NOISE AND THERE IS AN ODOR IN THE PASSENGER COMPONENT. THE FIRST TIME THE BOLTS WERE REPLACED NO ENGINE REPLACMENT WAS REQUIRED. BOTH MY REGULAR MECHANIC A…
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THE MANIFOLD BOLTS BROKE AT AROUND 46,000 MILES. THEY WERE REPLACED BY THE DEALER AND HAVE SINCE BROKEN AGAIN AROUND 50, 000 MILES LATER (95,000). THE VECHILE MAKES A LOUD NOISE AND THERE IS AN ODOR IN THE PASSENGER COMPONENT. THE FIRST TIME THE BOLTS WERE REPLACED NO ENGINE REPLACMENT WAS REQUIRED. BOTH MY REGULAR MECHANIC AND MIDAS MUFFLER SAID THESE BOLTS SHOULD HAVE NEVER BROKEN THE FIRST TIME LET ALONE THE SECOND. I HAVE SENT A WRITTEN LETTER TO MERCURY AND AFTER WAITING 4 WEEKS CALLED AND THEY SAID THEY DIDN'T BELEIVE THIS TO BE A PROBLEM AND WOULD NOT FIX THE BOLTS THE SECOND TIME. I BELIEVE THERE IS A DESIGN DEFECT AND THAT THE BREAKING OF THESE BOLTS COULD CAUSE SERIOUS HARM TO PASSENGERS AND REQUEST A FULL INVESTIGATION OF THE BOLT FAILURE RATES AND THE DESIGN OF THE MANIFOLDS BEING INSTALLED IN THE ENGINE BLOCK WITH THESE BOLTS
NHTSA ODI #746868
Mileage unknown · Jun 1, 2001
Engine And Engine CoolingPower Train
ENGINE MANIFOLD STUDS AND BOLTS HAD SNAPPED. WAS DRIVING & AND MANIFOLD WAS MAKING NOISE, EXHAUST SOUND LIKE IT WAS LEAKING. LEAK WAS COMING FROM MANIFOLD WHICH IS ATTACHED TO ENGINE. MANIFOLD HAD SEPARATED AND WAS CAUSING PROBLEMS. HAD TAKEN TO DEALERSHIP IN 1999, AND HAD THE STUDS REPLACED. CURRENTLY, BACK AT THE DEALERSH…
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ENGINE MANIFOLD STUDS AND BOLTS HAD SNAPPED. WAS DRIVING & AND MANIFOLD WAS MAKING NOISE, EXHAUST SOUND LIKE IT WAS LEAKING. LEAK WAS COMING FROM MANIFOLD WHICH IS ATTACHED TO ENGINE. MANIFOLD HAD SEPARATED AND WAS CAUSING PROBLEMS. HAD TAKEN TO DEALERSHIP IN 1999, AND HAD THE STUDS REPLACED. CURRENTLY, BACK AT THE DEALERSHIP FOR THE SAME TYPE OF PROBLEM. *AK LEFT FRONT AXLE BOOTS HAVE VIBRATION DUE TO CV BOOTS FAILURE. EXHAUST MANIFOLD STUDS ARE BROKEN AGAIN AND REPLACED. *YH
NHTSA ODI #889578
Mileage unknown · May 22, 2001
Electrical SystemEngine And Engine Cooling
A LIGHT CAME ON, ON THE DASH BOARD. THEN I SHUT OFF THE ENGINE AND OPENED THE HOOD. THE COOLING FAN WAS SMOKING BADLY AND ALL MAJOR WIRING IN THE MAIN ELECTRICAL WERE MELTED TO BARE WIRING. IF THE CIRCUIT FUSE HAD NOT BLOWN AND THE LIGHT COME ON, THE VEHICLE COULD HAVE CAUGHT ON FIRE.
NHTSA ODI #9002632
Mileage unknown · Mar 27, 2001
Engine And Engine Cooling
MANIFOLD BOLTS SHEARING OFF. *AK
NHTSA ODI #743138
Mileage unknown · Mar 21, 2001
Engine And Engine Cooling
THIS IS A BIG SAFETY ISSUE FOR VILLAGERS. DON;T UNDERSTAND WHY A RECALL HAS NOT HAPPENED YET. NO SAFETY DEFECT LISTED. *AK
NHTSA ODI #742836
Official recalls
5Jan 2, 2001
VEHICLE DESCRIPTION: MINIVANS. THE FUEL TANK VENT HOSE ALLOWS AIR TO VENT FROM THE FUEL TANK DURING REFUELING. CRACKS HAVE DEVELOPED IN THE VENT HOSE. IF (1) THE FUEL TANK IS OVERFILLED, NOT ALLOWING EXCESS FUEL IN THE VENT HOSE TO FLOW BACK INTO THE TANK, (2) THE VEHICLE IS DRIVEN ONLY A SHORT DISTANCE AFTER REFUELING AND, (3) THERE IS SUBSEQUENTLY SIGNIFICANT HEATING OF THE FUEL TANK, THE FUEL IN THE TANK CAN EXPAND INTO THE VENT HOSE AND LEAK FUEL.
Consequence & remedy
Consequence: FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE CAN RESULT IN A FIRE.
Remedy: DEALERS WILL REPLACE THE VENT HOSE.
Nov 21, 1995
LEAVES AND OTHER FOREIGN MATERIAL CAN ENTER THROUGH THE COWL PANEL AIR INTAKE DURING OPERATION OF THE FRONT HEATER AND/OR AIR CONDITIONING SYSTEM RESULTING IN A BUILD-UP OF MATERIAL IN THE PLENUM. THIS CAN LEAD TO NOISE, ODORS, OR IN SOME CASES, IGNITION OF THESE MATERIALS.
Consequence & remedy
Consequence: A VEHICLE FIRE COULD OCCUR.
Remedy: DEALERS WILL INSTALL AN ADDITIONAL HEATER/AIR CONDITIONING SYSTEM INTAKE SCREEN.
Dec 2, 1992
FUEL FILLER HOSES MAY HAVE BEEN CUT PRIOR TO INSTALLATION BY A UTILITY KNIFE USED TO OPEN THE SHIPPING BOX.
Consequence & remedy
Consequence: FUEL LEAKAGE CAN RESULT IF THE CUT EXTENDED THROUGH THETHICKNESS OF THE HOSE WALL. LEAKING FUEL CAN RESULT IN A FIRE IF EXPOSEDTO A SOURCE OF IGNITION.
Remedy: REPLACE THE FUEL FILLER HOSE.
Sep 21, 1992
THE SERVICE BRAKE MASTER CYLINDER WAS NOT PROPERLY ASSEMBLED OR COULD HAVE BEEN DAMAGED BY THE EVACUATION AND FILLING OF THE BRAKE SYSTEM AT THE ASSEMBLY PLANT.
Consequence & remedy
Consequence: THIS CAN RESULT IN A PARTIAL BRAKE SYSTEM FAILURE DUE TOINTERNAL MASTER CYLINDER LEAKAGE WHICH CAN CAUSE LOSS OF BRAKING ON TWO OF THEFOUR WHEELS. IF THIS OCCURS, THERE WOULD BE INCREASED BRAKE PEDAL TRAVEL, HIGHERPEDAL EFFORTS AND INCREASED STOPPING DISTANCES.
Remedy: A NEW BRAKE MASTER CYLINDER WILL BE INSTALLED.
Sep 21, 1992
ONE OR BOTH OF THE BOLTS SECURING THE AUTOMATIC SEAT BELT RESTRAINT SYSTEM TRACKS TO THE B-PILLARS WERE NOT ADEQUATELY TIGHTENED.
Consequence & remedy
Consequence: THIS CONDITION CAN RESULT IN THE AUTOMATIC SEAT BELTSYSTEM TRACK JOINTS HAVING LESS THAN DESIGN STRENGTH, AND INCREASE THE RISK OFINJURY TO THE SEAT OCCUPANT IN THE EVENT OF A COLLISION OR SUDDEN STOP.
Remedy: DEALERS WILL TIGHTEN THE PASSIVE RESTRAINT SYSTEM TRACK MOUNTING BOLTS.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
8EA00014 · Fuel Tank Vent Hose Leakage
Opened May 22, 2000 · Closed Jan 4, 2001
Status: closed (inferred from source dates) · Vehicle Speed Control:linkages
PERIODIC EXPOSURE TO LIQUID GASOLINE MAY RESULT IN EXTRACTION OF ANTIDEGRADANTS FROM THE SUBJECT FUEL TANK VENT HOSE.HOSES WHICH HAVE SUFFERED LOSS OF ANTIDEGRADANTS CAN DEVELOP CRACKS IN AREAS OF HIGH STRAIN.FUEL MAY SPRAY OR DRIP FROM CRACKED VENT HOSES FOLLOWING TANK FILL.STARTING AT JOB#1 1998 MY (CALIFORNIA EMISSIONS VEHICLES) AND JOB#1 1999 MY (FEDERAL EMISSIONS VEHICLES), THE SUBJECT VENT HOSE COMPOSITION CHANGED FROM NITRILE RUBBER HOSES WITH CHLOROPRENE RUBBER COVERS (NBR/CR) TO FLUOROCARBON RUBBER HOSES WITH AN OUTER LAYER BLEND OF NBR/PVC.THE CHANGES WERE MADE TO IMPROVE HYDRACARBON RESISTANCE FOR COMPLAINCE WITH NEW EVAPORATIVE EMISSIONS REGULATIONS.THE MODIFIED HOSES ARE ALSO SIGNIFICANTLY MORE RESISTANT TO DEGRADATION AND CRACKING.IN A LETTER DATED JANUARY 2, 2001, FORD NOTIFIED NHTSA THAT IT WILL CONDUCT A SAFETY RECALL CAMPAIGN TO REPLACE THE SUBJECT VENT HOSE IN AFFACTED VEHICLES.FORD WILL BEGIN NOTIFYING CUSTOMERS OF THE AFFECTED VEHICLES ON OR ABOUT THE WEEK OF FEBRUARY 12, 2001 TO RETURN THEIR VEHICLES TO DEALERS FOR REPLACEMENT OF THE FUEL TANK VENT HOSE WITH THE LATEST DESIGN LEVER PART.
EA99015 · Fuel Rail Hose Fitting Leakage
Opened Jun 29, 1999 · Closed Apr 18, 2001
Status: closed (inferred from source dates) · Vehicle Speed Control:linkages
THE ENGINEERING ANALYSIS CLOSING REPORT COVERS 1993-1998 MERCURY VILLAGER AND NISSAN QUEST MINIVANS.THESE TWO MINIVANS SHARE A COMMON BODY PLATFORM AND POWER TRAIN.BASED ON THE LOW NUMBER OF REPORTED INCIDENTS AND THE ABSENCE OF A DEMONSTRABLE FAILURE TREND, A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES IS NOT WARRANTED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES. SEE ENGINEERING CLOSING REPORT EA99-015 FOR DETAILS.
EA96005 · Battery Explosions
Opened May 30, 1996 · Closed May 29, 1997
Status: closed (inferred from source dates) · Electrical System
A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.AN ENGINEERING ANALYSIS CLOSING REPORT IS INCLUDED IN THE PUBLIC FILE.
PE96009 · Battery Explosion
Opened Jan 25, 1996 · Closed May 30, 1996
Status: closed (inferred from source dates) · Electrical System
1993 MERCURY VILLAGERBATTERY EXPLOSION
EA95027 · Blower Area Fires
Opened Sep 22, 1995 · Closed Nov 17, 1995
Status: closed (inferred from source dates) · Equipment
There is no summary currently available
PE95037 · Front Blower Assembly Fire
Opened Jun 19, 1995 · Closed Sep 22, 1995
Status: closed (inferred from source dates) · Visibility:defroster/defogger/hvac System
There is no summary currently available
PE93047 · Power Door Lock Failure
Opened May 7, 1993 · Closed Aug 11, 1993
Status: closed (inferred from source dates) · Structure
There is no summary currently available
PE93020 · Backlite Shattering
Opened Apr 1, 1993 · Closed Jul 28, 1993
Status: closed (inferred from source dates) · Exterior Lighting
There is no summary currently available
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