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2002 Mercury Cougar CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Mercury REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Section
- 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
- Cabin Air Filter Locations & 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 2002 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 2002 Mercury Cougar AUTOMOBILES
Component Replacement & Adjustment -> Passenger Cars -> Evaporator Core, Replace -> Continental -> Cougar -> Crown Victoria & Grand Marquis -> Escort -> Focus -> LS & Thunderbird -> Mustang -> Sable & Taurus -> Town Car
Vehicle: 2002 Mercury Cougar 2.5 V6 GAS
Continental
The evaporator core is not serviced separately and can only be replaced with the evaporator housing assembly.
- Remove seats and rear seat airflow duct.
- Remove instrument panel as outlined under "Instrument Panel."
- Drain coolant into suitable container to level below heater core.
- Recover refrigerant as outlined under .
- Disconnect Powertrain Control Module (PCM) electrical connector.
- Disconnect heater core hoses.
- Disconnect vacuum supply hose.
- Disconnect condenser to evaporator tube and evaporato...
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BRAKE SERVICE PROCEDURES FOR 2002 Mercury Cougar AUTOMOBILES
Disc Brakes -> Front Disc Brakes -> Description -> Dual Piston Calipers -> Single Piston Calipers
Vehicle: 2002 Mercury Cougar 2.5 V6 GAS
Single Piston Calipers
The caliper assembly consists of a pin sliding caliper housing, inner and outer shoe and lining assemblies and a single piston, Figs. and . The caliper slides on two pins which also act as attaching bolts between caliper and the combination anchor plate and spindle. The outer brake shoe and lining assembly is longer than the inner brake shoe and lining assembly. Inner and outer shoe and lining assemblies are attached to the caliper by spring clips riveted to the shoe surfaces. The inner shoe is attached to the caliper by installing the spring clip to the insid...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2002 Mercury Cougar AUTOMOBILES
Ford Motor Co. Passenger Cars -> Component Locations -> 1995-00 Contour & Mystique & 1999-02 Cougar
Vehicle: 2002 Mercury Cougar 2.5 V6 GAS
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2002 Mercury Cougar AUTOMOBILES
CV AXLE SHAFT, Replace -> Intermediate -> Left -> Right
Vehicle: 2002 Mercury Cougar 2.0 L4 GAS
Left
- Use an Allen key to stop piston rod from turning.
- Loosen suspension strut nut five turns.
- Loosen wheel hub retaining nut and wheel nuts.
- Raise and support vehicle.
- Remove wheel.
- Remove wheel hub retaining nut.
- On models with automatic transaxle, drain automatic transmission fluid.
- On all models, remove splash shields.
- Do not damage CV joint boot and wheel speed sensor ring.
- Detach suspension.
- Disconnect stabilizer link end from suspension strut.
- Disconnect tie-rod end.
- Disconnect lower suspension arm from wheel knuckle.
- Disconnect wiring harness bracket from suspension strut.
- To av...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2002 Mercury Cougar AUTOMOBILES
Alternator, Replace
Vehicle: 2002 Mercury Cougar 2.0 L4 GAS
- Disconnect battery ground cable.
- Disconnect air cleaner outlet pipe.
- Remove bolts and nuts, then resonator.
- Detach coolant hose from retaining clip.
- Disconnect vacuum pipe underneath.
- Remove radiator splash shield.
- Disconnect cable and wiring from alternator.
- Disconnect ground cable on eye hook, then raise and support vehicle.
- Remove radiator splash shield.
- Remove righthand front wheel, then sp...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2002 Mercury Cougar AUTOMOBILES
Cabin Air Filter Service -> Ford Motor Co. -> 1998-2000 Contour, Mystique & 1999-2002 Cougar
Vehicle: 2002 Mercury Cougar 2.5 V6 GAS
Under normal operating conditions the cabin air filter should be replaced every 15,000 miles. In dusty areas change the cabin air filter more often.
- Position windshield wipers in the Park position.
- Disconnect and isolate the battery ground cable.
- Lift up the plastic wiper arm retaining nut covers.
- Remove the wiper arm retaining nuts.
- Lift up the wiper arms.
- Remove the wiper arms by moving them from side to side.
- Open the hood.
- Remove the plastic screw covers from the cowl grille retaining screws.
- Remove the cowl grille re...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2002 Mercury Cougar AUTOMOBILES
Ford Motor Co. Cars -> Service Interval Reminder -> 2000-02 Cougar
Vehicle: 2002 Mercury Cougar 2.5 V6 GAS
The maintenance interval warning indicator is controlled by the HEC. The HEC illuminates the indicator advising a scheduled maintenance (which is dependant on time of d...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2002 Mercury Cougar AUTOMOBILES
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 2002 Mercury Cougar 2.5 V6 GAS
Inlet
- Drain cooling system into a suitable container.
- Reposition heater hose inlet clamp at heater core.
- Remove heater inlet hose from heater core.
- Reposition heater core inlet hose clamp at engine.
- Remove hose from engine.
- Remove hose from vehicle.
- Reverse procedure to in...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2002 Mercury Cougar AUTOMOBILES
Serpentine Drive Belt, Replace -> Accessory Drive -> Water Pump
Vehicle: 2002 Mercury Cougar 2.5 V6 GAS
Water Pump
- Remove engine cover, then rotate drive belt tensioner clockwise by hand.
- Lift drive belt over pulley flanges and remove.
- Reverse procedure to install.
Accessory Drive
- R...
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COMPONENT LOCATION DIAGRAMS FOR 2002 Mercury Cougar AUTOMOBILES
Component location diagrams for most 2002 Mercury Cougar cars and light trucks sold in the U.S. from 1990+.
 Braking Components Diagram for 2002 Mercury Cougar 2.5 V6 GASComponents on diagram: |
 Clutch Controls Diagram for 2002 Mercury Cougar 2.0 L4 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 2002 Mercury Cougar AUTOMOBILES
OEM drawn wiring diagrams for most 2002 Mercury Cougar cars and light trucks sold in the U.S.
 2002 Mercury Cougar 2.5 V6 GAS Wiring DiagramComponents on diagram: |
 2002 Mercury Cougar 2.5 V6 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2002 Mercury Cougar AUTOMOBILES
OEM TSB listings for most 2002 Mercury Cougar cars and light trucks sold in the U.S. from 1985+.
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Document: RECALL - CERTAIN 1992-2003 MODEL YEAR CARS AND TRUCKS - FUSED JUMPER HARNESS REPLACEMENT FOR VEHICLES SERVICED WITH AN INCOMPATIBLE FUSED JUMPER HARNESS Vehicle: 2002 Mercury Cougar 2.0 L4 GAS Auto Systems: |
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Document: RECALL - 1992-2004 MULTIPLE VEHICLE LINES - SPEED CONTROL SYSTEM MODIFICATION Vehicle: 2002 Mercury Cougar 2.0 L4 GAS |
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COMPONENT/PARTS SPECIFICATIONS FOR 2002 Mercury Cougar AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2002 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 2002 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 2002 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 2002 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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