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2004 Mercury Monterey 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
- Tire Pressure Monitoring System
- 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 2004 Mercury Monterey 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 Monterey automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 2004 Mercury Monterey AUTOMOBILES
Component Replacement & Adjustment -> Freestar & Monterey -> Radiator, Replace
Vehicle: 2004 Mercury Monterey 4.2 V6 GAS
- Raise and support vehicle with transmission in NEUTRAL position.
- Drain coolant into suitable container.
- Remove transmission oil cooler.
- Remove retainers and upper radiator sight shield, Fig. .
- Disconnect electrical connectors and harness retainers.
- Remove clamp and upper radiator hose.
- Tie radiator and condenser to upper support using suitable mechanics wire. Allow two inches slack.
- Remove radiator alignment pins.
- Remove clamp and degas bottle return hose.
- Remove clamp and lower radiator hose...
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BRAKE SERVICE PROCEDURES FOR 2004 Mercury Monterey AUTOMOBILES
Hydraulic Brake Systems -> Component Replacement -> Aviator -> E-Series -> Escape & Mariner -> Excursion & F-Super Duty -> Expedition, Explorer, Explorer Sport & Sport/Trac, F-150, Mark LT, Mountaineer & Navigator -> Freestar & Monterey -> Less Hydro Max -> Master Cylinder -> Ranger -> With Hydro-Max
Vehicle: 2004 Mercury Monterey 4.2 V6 GAS
Master Cylinder
Aviator
Remove components in sequence illustrated, Fig. .
E-Series
- Drain brake master cylinder with suitable suction device.
- Remove coolant reservoir.
- On models equipped with Hydro Boost, remove three power distribution box bracket bolts and position box aside.
- On all models, remove speed control deactivator switch.
- Disconnect fluid level sensor connector.
- Remove and discard master cylinder mounting nuts.
- Disconnect master cylinder brake tubes.
- Remove master cylinder cylinder.
- Reverse procedure to install, noting the following:
- Torque master cylinder mounting nuts to 18...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2004 Mercury Monterey AUTOMOBILES
Ford Motor Co. Light Trucks, SUVs & Vans -> Fuel Filter Replacement -> Except Diesel Engines & Villager
Vehicle: 2004 Mercury Monterey 4.2 V6 GAS
The fuel system remains under high pressure even when the engine is not running. This residual pressure must be relieved before servicing the fuel system. To avoid injury or fire, release pressure from the fuel system before disconnecting any fuel line.
The fuel system pressure must be relieved prior to disconnecting fuel lines to prevent accidental spray of fuel.
After the battery has been disconnected and reconnected, some abnormal driveability symptoms may occur. The vehicle may need to be driven 10 miles or more while it relearns its adaptive strategy.
On model...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2004 Mercury Monterey AUTOMOBILES
CV AXLE SHAFT, Replace -> Front
Vehicle: 2004 Mercury Monterey Premier 4.2 V6 GAS
Front
- With vehicle in NEUTRAL, position on a hoist.
- Remove front wheel and tire assembly.
- Remove bolts and position disc brake caliper aside.
- Remove front axle wheel hub retainer nut and washer.
- Remove lower control arm bal...
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TIRE PRESSURE MONITORING SYSTEM PROCEDURES FOR 2004 Mercury Monterey AUTOMOBILES
Diagnosis & Testing -> Intermittent & Poor Connections -> Intermittents -> Poor Connections -> Symptom Test
Vehicle: 2004 Mercury Monterey 4.2 V6 GAS
Symptom Test
Refer to Fig. for Symptom Test Chart.
Intermittent & Poor Connections
Intermittents
Most intermittents are caused by faulty electrical connections or wiring. Inspect for the following:
- Wiring broken inside insulation.
- Poor connection between male and female terminal at connector.
- Poor terminal to wire connection. Some conditions which fall under this are:
- Poor crimps.
- Poor solder joints.
- Crimping over wire insulation rather than wire.
- Corrosion in wire to terminal contact.
- Wire insulation which is rubbed through. This causes an intermittent short as bare area touches other...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2004 Mercury Monterey AUTOMOBILES
Alternator, Replace
Vehicle: 2004 Mercury Monterey 4.2 V6 GAS
- Disconnect battery ground cable.
- Rotate accessory drive belt tensioner counterclockwise, then position drive belt aside.
- Position alternator B+ terminal protective boot aside, remove nut, then disconnect B+ terminal connector.
- Remove air conditioning line bracket mounting...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2004 Mercury Monterey AUTOMOBILES
Cabin Air Filter Service -> Ford Motor Co. -> 1999-2003 Windstar & 2004-07 Freestar & Monterey
Vehicle: 2004 Mercury Monterey 4.2 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.
- Open the hood.
- Release the cabin air filter cover retaining snaps, then remove the cover. The cabin air filter cover is located on the ...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2004 Mercury Monterey AUTOMOBILES
Ford Motor Co. Trucks -> Check Gauge Warning Lamp ->
Vehicle: 2004 Mercury Monterey Premier 4.2 V6 GAS
This indicator should light if any of the following conditions appear:
- Engine oil pressure drops below approxi...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2004 Mercury Monterey AUTOMOBILES
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 2004 Mercury Monterey Premier 4.2 V6 GAS
Inlet
- Drain cooling system into a suitable container.
- Reposition heater core inlet hose clamp at heater tube assembly.
- Remove hose from heater tube assembly.
- Reposition heater hose inlet clamp at heater core.
- Remove heater inlet hose from heater core.
- Remove hose from vehicle.
- Reverse procedure to in...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2004 Mercury Monterey AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2004 Mercury Monterey 4.2 V6 GAS
- Disconnect battery ground cable from battery.
- Rotate accessory drive belt tensioner counterclockwise to relieve t...
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COMPONENT LOCATION DIAGRAMS FOR 2004 Mercury Monterey AUTOMOBILES
Component location diagrams for most 2004 Mercury Monterey cars and light trucks sold in the U.S. from 1990+.
 Wiring Harnesses Diagram for 2004 Mercury Monterey Premier 4.2 V6 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 2004 Mercury Monterey AUTOMOBILES
OEM drawn wiring diagrams for most 2004 Mercury Monterey cars and light trucks sold in the U.S.
 2004 Mercury Monterey Premier 4.2 V6 GAS Wiring DiagramComponents on diagram: |
 2004 Mercury Monterey Premier 4.2 V6 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2004 Mercury Monterey AUTOMOBILES
OEM TSB listings for most 2004 Mercury Monterey cars and light trucks sold in the U.S. from 1985+.
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Document: RECALL - 1992-2004 MULTIPLE VEHICLE LINES - SPEED CONTROL SYSTEM MODIFICATION Vehicle: 2004 Mercury Monterey 4.2 V6 GAS |
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Document: SPARK KNOCK UNDER LIGHT LOAD AND ACCELERATION - SPLIT PORT INTAKE MANIFOLD RUNNER CONTROL (IMRC) Vehicle: 2004 Mercury Monterey 4.2 V6 GAS Symptoms: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2004 Mercury Monterey AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2004 Mercury Monterey 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 2004 Mercury Monterey 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 2004 Mercury Monterey 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 2004 Mercury Monterey 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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