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Mercury Cougar CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Mercury REPAIR SHOPS DON'T WANT YOU TO KNOW
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Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 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 Mercury Cougar AUTOMOBILES
Air Conditioner and Heater Service Includes module configuration procedures, general service, maintenance, automatic temperature control, compressor services, electric cooling fans, vacuum diagrams, specifications, and manual air conditioning and heater diagnostics and replacement procedures for domestic and imported Mercury Cougar cars and light trucks from 1990+
Component Replacement & Adjustment -> Passenger Cars -> ACCUMULATOR/DRIER, REPLACE -> ASPIRE -> CAPRI -> CONTINENTAL, COUGAR, MARK VIII, MUSTANG, SABLE, TAURUS & THUNDERBIRD -> CONTOUR & MYSTIQUE -> CROWN VICTORIA, GRAND MARQUIS & TOWN CAR -> ESCORT, TEMPO, TOPAZ & TRACER -> PROBE
Vehicle: 1995 Mercury Cougar XR-7 4.6 V8 GAS
ASPIRE
- Discharge and recover system.
- Disconnect battery cables and remove battery.
- Remove radiator coolant recovery reservoir.
- Disconnect A/C pressure cutoff switch electrical connector.
- Disconnect jumper line and liquid line from suction accumulator/drier. Discard O-rings.
- Remove two clamp screws and remove suction accumulator/drier.
- Reverse procedure to install. Use new O-ring lubricated with refrigerant oil. When replacing suction accumulator/drier, add one ounce of refrigerant oil to high pressure port of compressor.
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BRAKE SERVICE PROCEDURES FOR Mercury Cougar AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported Mercury Cougar cars and light trucks from 1990+.
Hydraulic Brake Systems -> Component Service -> Assemble -> Disassemble -> Inspection -> Master Cylinder Overhaul -> Overhaul -> Wheel Cylinders
Vehicle: 2001 Mercury Cougar S 2.5 V6 GAS
Master Cylinder Overhaul
Disassemble
- Clean outside of master cylinder thoroughly. Drain brake fluid from master cylinder.
- Remove stop bolt and pressure control valves, if equipped.
- Pry up on reservoir and remove it from master cylinder body.
- Remove fluid control valve, if equipped.
- Depress primary piston and remove snap ring from retaining groove at open end of bore.
- Remove primary and secondary piston assemblies from master cylinder. If secondary piston does not come out, apply air pressure to secondary outlet port to remove.
Inspection
When disassembled, wash all parts in clean brake...
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FUEL FILTER REPLACEMENT PROCEDURES FOR Mercury Cougar AUTOMOBILES
Fuel filter replacement procedures with corresponding images for most domestic and imported Mercury Cougar cars and light trucks sold in the U.S. for 1980+.
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: 1994 Mercury Cougar XR-7 4.6 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 Mercury Cougar AUTOMOBILES
Includes CV axle, universal joint, and driveline replacement, for domestic and imported Mercury Cougar cars and light trucks from 1990+.
DRIVESHAFT, Replace
Vehicle: 1991 Mercury Cougar XR-7 5.0 V8 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 Mercury Cougar AUTOMOBILES
Includes starter and alternator replacement procedures for domestic and imported Mercury Cougar cars and light trucks from 1990+.
Starter, Replace
Vehicle: 1991 Mercury Cougar LS 3.8 V6 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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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR Mercury Cougar AUTOMOBILES
Cabin air filter locations and replacement procedures with corresponding images for most domestic and imported Mercury Cougar cars and light trucks sold in the U.S. as equipped to the current model year.
Cabin Air Filter Service -> Ford Motor Co. -> 1998-2000 Contour, Mystique & 1999-2002 Cougar
Vehicle: 2001 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 Mercury Cougar AUTOMOBILES
Maintenance lamp reset procedures with corresponding images for most domestic and imported Mercury Cougar cars and light trucks sold in the U.S. from 1990+.
Ford Motor Co. Cars -> Service Interval Reminder -> 1990-93 Cougar & Thunderbird
Vehicle: 1992 Mercury Cougar XR-7 5.0 V8 GAS
At approximately 7500 miles, for models less super charged engine, the engine oil change indicator on the Vehicle Maintenance Monitor will indicate an oil change is needed. On mode...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR Mercury Cougar AUTOMOBILES
Includes radiator, cooling and heater hose replacement procedures for domestic and imported Mercury Cougar cars and light trucks from 1990+
Radiator, Replace
Vehicle: 1992 Mercury Cougar LS 3.8 V6 GAS
- Drain cooling system.
- Disconnect upper, lower and overflow hose from radiator.
- Disconnect automatic transmission fluid cooler inlet and outlet lines from radiator.
- Remove two upper fan shroud to radiator su...
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SERPENTINE BELT SERVICE PROCEDURES FOR Mercury Cougar AUTOMOBILES
Serpentine belt replacement procedures with corresponding images for most domestic and imported Mercury Cougar cars and light trucks sold in the U.S. from 1990+.
Serpentine Drive Belt, Replace
Vehicle: 1992 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 Mercury Cougar AUTOMOBILES
Component location diagrams for most Mercury Cougar cars and light trucks sold in the U.S. from 1990+.
 Engine Compartment Components Diagram for 1991 Mercury Cougar XR-7 5.0 V8 GASComponents on diagram: |
 Under Engine & Transmission Diagram for 1992 Mercury Cougar LS 3.8 V6 GASComponents on diagram: |
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WIRING DIAGRAMS FOR Mercury Cougar AUTOMOBILES
OEM drawn wiring diagrams for most Mercury Cougar cars and light trucks sold in the U.S.
 1995 Mercury Cougar XR-7 3.8 V6 GAS Wiring DiagramComponents on diagram: |
 2002 Mercury Cougar 2.0 L4 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR Mercury Cougar AUTOMOBILES
OEM TSB listings for most Mercury Cougar cars and light trucks sold in the U.S. from 1985+.
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Document: WIRE HARNESS TERMINAL REPAIR KIT AND SPLICE PROCEDURE Vehicle: 1997 Mercury Cougar XR-7 4.6 V8 GAS Auto Systems: |
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Document: WIRING HARNESS - TERMINAL REPAIR KIT - REV6 Vehicle: 1985 Mercury Cougar 5.0 V8 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR Mercury Cougar AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 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 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 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 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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