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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 -> Instrument Panel, Replace -> Continental -> Cougar -> Crown Victoria, Grand Marquis & Town Car -> Escort -> Focus -> LS -> Mustang -> Sable & Taurus -> Thunderbird
Vehicle: 2002 Mercury Cougar 2.0 L4 GAS
Continental
- Remove two wheel spoke bolt covers and two air bag module mounting bolts at rear or sides of steering wheel.
- Lift driver's air bag module away from steering wheel, then disconnect air bag module and horn to clockspring electrical connectors.
- Remove driver's air bag module.
- Open glove compartment, push in on door tabs and rotate it down.
- Disconnect passenger's air bag electrical connector.
- Remove four passenger's air bag module mounting bolts.
- Carefully remove passenger's air bag by pushing it inside panel.
- Re...
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BRAKE SERVICE PROCEDURES FOR 2002 Mercury Cougar AUTOMOBILES
Disc Brakes -> Rear Disc & Parking Brakes -> Brake Disc Service
Vehicle: 2002 Mercury Cougar 2.5 V6 GAS
Disc brake service is critical due to the close tolerances required in machining the brake disc to ensure proper brake operation.
Maintaining close control of the shape of the rubbing surfaces is required to prevent brake roughness. In addition, the surface finish must be non-directional and maintained at a micro-inch finish. This is required to avoid pulls and erratic performance and promote long lining life and equal lining wear of both the lefthand and righthand brakes.
Do not attempt to refinish the rubbing surfaces unless precision equipme...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2002 Mercury Cougar AUTOMOBILES
Ford Motor Co. Passenger Cars -> Fuel Filter Replacement -> Except 2002-05 Thunderbird, 2000-06 LS, 1984-87 Escort, Tracer, Tempo & Topaz 2.0L Diesel Engine & 1984-85 Continental & Mark VI 2.4L Diesel Engine
Vehicle: 2002 Mercury Cougar 2.0 L4 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 pro...
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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
Starter, Replace
Vehicle: 2002 Mercury Cougar 2.5 V6 GAS
- Disconnect battery ground cable.
- Drain cooling system into a suitable container.
- Remove lower intake manifold.
- Remove air cleaner, then air cleaner bracket.
- Disconnect starter motor electrical connectors.
- Remove shift cable bracket bolts, then disconnect shift cable.
- Remove starter motor support bracket, then Schrader valve cap.
- Relieve fuel pressure.
- Disconnect fuel return and supply lines, using suitable tool.
- Disconnect cooling system hoses from crossover pipe, then coolant temperature sensor electrical connector.
- Remove accelerator...
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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 2.0 L4 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 -> Check Fuel Cap Lamp ->
Vehicle: 2002 Mercury Cougar 2.5 V6 GAS
The Check Fuel Cap Lamp will illuminate momentarily when the ignition switch is placed in the On position as a bulb check. If the lamp remains...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2002 Mercury Cougar AUTOMOBILES
Radiator, Replace
Vehicle: 2002 Mercury Cougar 2.5 V6 GAS
- Drain engine coolant into a suitable container.
- Remove motor, fan and shroud.
- Remove upper shield and secure condenser.
- Disconnect radiator upper cooling hose.
- On models equipped with automatic tr...
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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+.
 Front Door Diagram for 2002 Mercury Cougar 2.5 V6 GASComponents on diagram: |
 Braking Components 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 2.0 L4 GAS Wiring DiagramComponents on diagram: |
 2002 Mercury Cougar 2.0 L4 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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