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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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- 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
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 1991 Mercury Cougar car and truck
repair procedures including Mercury engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
your Mercury Cougar automobile. Try the Automotix DIY solution today!
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
DISC BRAKES, FORD MOTOR CO. -> Front Disc Brakes -> CALIPER OVERHAUL -> ASSEMBLY -> Capri, Tracer & 1991 Escort -> DISASSEMBLY -> Except Capri, Festiva, Tracer, Scorpio, XR4Ti, Probe & 1991 Escort -> Festiva -> INSPECTION -> Probe -> Scorpio & XR4Ti
Vehicle: 1991 Mercury Cougar XR-7 5.0 V8 GAS
DISASSEMBLY
Except Capri, Festiva, Tracer, Scorpio, XR4Ti, Probe & 1991 Escort
- Remove caliper assembly from vehicle as described under "Caliper, Replace."
- Position fiber block and shop towels between caliper piston and caliper housing, then apply compressed air to caliper brake line fitting bore to force piston from caliper.
- Remove dust boot from caliper assembly,Figs. and .
- Remove piston seal from cylinder and discard.
Festiva
- Remove brake pads and caliper as outlined previously.
- Remove bleeder screw, drain remaining fluid from caliper, then reinstall screw.
- Remove dust boot retaining r...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1991 Mercury Cougar AUTOMOBILES
Ford Motor Co. Passenger Cars -> Fuel Pressure Relief -> Except Aspire, Festiva, Focus, Fusion, Milan, 2003-06 Crown Victoria, Grand Marquis, Sable, Taurus & Town Car, 1991-96 Escort, 1988-96 Tracer, 1991-94 Capri, 1989-91 Probe & 2005-06 Mustang
Vehicle: 1991 Mercury Cougar XR-7 5.0 V8 GAS
Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.
Prior to disconnecting fuel lines, the fuel system pressure must be relieved to prevent accidental spray of fuel.
When installing the fuel filter, ensure the flow arrow is facing in the proper direction...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1991 Mercury Cougar AUTOMOBILES
DRIVESHAFT, Replace
Vehicle: 1991 Mercury Cougar LS 3.8 V6 GAS
- Raise and support vehicle.
- Index-mark driveshaft. Place a paint index-mark on pinion flange to driveshaft centering socket yoke.
- Remove driveshaft-to-driveshaft pinion flange bolts.
- Place a paint index-mark on driveshaft slip-yoke to transmissio...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1991 Mercury Cougar AUTOMOBILES
Starter, Replace
Vehicle: 1991 Mercury Cougar LS 5.0 V8 GAS
- Disconnect battery ground cable.
- Raise and support vehicle.
- Disconnect starter cable, then relay connector from starter solenoid.
- Remove starter motor mounting bolts.
- R...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1991 Mercury Cougar AUTOMOBILES
Ford Motor Co. Cars -> Electronic Throttle Control ->
Vehicle: 1991 Mercury Cougar XR-7 5.0 V8 GAS
Electronic throttle displays when the system has malfunctioned and the engine has defaulted to a limp-home operation. On vehicles equipped with ...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1991 Mercury Cougar AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 1991 Mercury Cougar LS 5.0 V8 GAS
Lower
- Drain coolant into a suitable container.
- Loosen hose clamp connecting hose to radiator.
- Loosen hose clamp connecting hose to water inlet.
- Remove hose from vehicle.
- Reverse procedure to i...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1991 Mercury Cougar AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 1991 Mercury Cougar LS 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+.
 Instrument Panel Components Diagram for 1991 Mercury Cougar XR-7 5.0 V8 GASComponents on diagram: |
 Engine Compartment Components Diagram for 1991 Mercury Cougar LS 3.8 V6 GASComponents 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 5.0 V8 GAS Wiring DiagramComponents on diagram: |
 1991 Mercury Cougar XR-7 5.0 V8 GAS Wiring DiagramComponents 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+.
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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: |
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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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