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1991 Mercury Cougar CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Mercury REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
A/C & HEATER SERVICE PROCEDURES FOR 1991 Mercury Cougar AUTOMOBILES
A/C & Cooling System Maintenance -> Ford Motor Co. -> 1990-2002 Ford Thunderbird & Mercury Cougar
Vehicle: 1991 Mercury Cougar LS 5.0 V8 GAS
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BRAKE SERVICE PROCEDURES FOR 1991 Mercury Cougar AUTOMOBILES
HYDRAULIC BRAKES, FORD MOTOR CO. -> DUAL MASTER CYLINDER SYSTEMS -> 1991 Escort & Tracer -> Assembly -> BRAKE DISTRIBUTION VALVE & SWITCH -> BRAKE WARNING LIGHT SWITCHES -> Capri -> COMBINATION VALVE -> DIAGONALLY SPLIT SYSTEMS -> Disassemble -> Except Capri, Sable, Taurus, 1991 Escort & Tracer -> Failure Warning Switch -> FRONT & REAR SPLIT SYSTEMS -> Inspection -> MASTER CYLINDER SERVICE -> MASTER CYLINDER, REPLACE -> Metering Valve -> Proportioner Or Pressure Control Valves -> Sable & Taurus -> Testing Warning Light System
Vehicle: 1991 Mercury Cougar LS 5.0 V8 GAS
FRONT & REAR SPLIT SYSTEMS
When the brake pedal is depressed, both the primary (front brake) and the secondary (rear brake) master cylinder pistons are moved simultaneously to exert hydraulic fluid pressure on their respective independent hydraulic systems. The fluid displacement of the two master cylinders is proportioned to fulfill the requirements of each of the two independent hydraulic brake systems,Figs. and .
If a failure of a rear (secondary) brake system should occur, initial brake pedal movement causes the unrestricted secondary piston to bottom in the mas...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1991 Mercury Cougar AUTOMOBILES
Ford Motor Co. Passenger Cars -> Fuel Filter Scheduled Maintenance -> 1980-97 Cougar, XR-7 & Thunderbird -> Normal Service -> Severe Service
Vehicle: 1991 Mercury Cougar LS 5.0 V8 GAS
Normal Service
Se...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1991 Mercury Cougar AUTOMOBILES
DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble
Vehicle: 1991 Mercury Cougar LS 3.8 V6 GAS
Disassemble
Do not clamp driveshaft in jaws of a vice or a similar holding fixture.
- Place driveshaft on a suitable workbench.
- Mark positions of driveshaft components relative to driveshaft tube. This ensures all components are reassembled in same relationship to maintain correct balance.
- Index driveshaft and driveshaft components.
- Clamp U-Joint Tool in a vise.
- Remove snap rings.
- If bearing cup cannot be pressed all way out, remove it with vise grips.
- Remove driveshaft slip-yoke.
- Position driveshaft in U-Joint Tool.
- Press out a bearing cup.
- Rotate driveshaft 180 degrees.
- Press on...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1991 Mercury Cougar AUTOMOBILES
Alternator, Replace
Vehicle: 1991 Mercury Cougar XR-7 5.0 V8 GAS
- Disconnect battery ground cable.
- Disconnect wire harness attachments to alternator assembly.
- Loosen alternator pivot bolts. Remove adjustment arm bolt from alternator.
- Disengage alternator drive belt fr...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1991 Mercury Cougar AUTOMOBILES
Ford Motor Co. Cars -> Anti-Lock Brake Warning Lamp ->
Vehicle: 1991 Mercury Cougar XR-7 5.0 V8 GAS
This lamp should light when the ignition is turned On. It may light for as long as 30 seconds as a bulb and system inspect. If the lamp remains lit or lights while operating the vehicle, a fault condition in the anti-lock brake system is indicated. When the lamp is lit, turn ignition Off, then start...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1991 Mercury Cougar AUTOMOBILES
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 1991 Mercury Cougar LS 3.8 V6 GAS
Inlet
- Drain coolant into a suitable container.
- Loosen hose clamp connecting hose to heater core inlet tube.
- Loosen hose clamp connecting hose to engine.
- Remove hose from vehicle.
- Reverse procedure to...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1991 Mercury Cougar AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 1991 Mercury Cougar XR-7 5.0 V8 GAS
- Rotate or lift the belt tensioner arm, using a suitable tool to relieve tension from dr...
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COMPONENT LOCATION DIAGRAMS FOR 1991 Mercury Cougar AUTOMOBILES
Component location diagrams for most 1991 Mercury Cougar cars and light trucks sold in the U.S. from 1990+.
Body Components Diagram for 1991 Mercury Cougar XR-7 5.0 V8 GAS Components on diagram: |
Engine Compartment Components Diagram for 1991 Mercury Cougar LS 3.8 V6 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 1991 Mercury Cougar AUTOMOBILES
OEM drawn wiring diagrams for most 1991 Mercury Cougar cars and light trucks sold in the U.S.
1991 Mercury Cougar LS 3.8 V6 GAS Wiring Diagram Components on diagram: |
1991 Mercury Cougar XR-7 5.0 V8 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1991 Mercury Cougar AUTOMOBILES
OEM TSB listings for most 1991 Mercury Cougar cars and light trucks sold in the U.S. from 1985+.
Document: MERCON ATF IS BEING REPLACED BY MERCON V AS A SERVICE FLUID FOR SOME MANUAL TRANSMISSIONS Vehicle: 1991 Mercury Cougar XR-7 5.0 V8 GAS Auto Systems: |
Document: MERCON ATF IS BRING REPLACED BY MERCON V ATF AS A SERVICE FLUID Vehicle: 1991 Mercury Cougar XR-7 5.0 V8 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1991 Mercury Cougar AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1991 Mercury Cougar cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 1991 Mercury Cougar cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 1991 Mercury Cougar cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 1991 Mercury Cougar cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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