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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+
A/C & Cooling System Maintenance -> Ford Motor Co. -> 1990-2002 Ford Thunderbird & Mercury Cougar
Vehicle: 2000 Mercury Cougar 2.5 V6 GAS
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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+.
Disc Brakes -> Rear Disc Brakes & Parking Brakes -> Troubleshooting -> BRAKE ROUGHNESS
Vehicle: 1994 Mercury Cougar XR-7 3.8 V6 GAS
BRAKE ROUGHNESS
The most common cause of brake chatter on disc brakes is a variation in thickness of the disc. If roughness or vibration is encountered during highway operation or if pedal pumping is experienced at low speeds, the disc may have excessive thickness variation. To check for this condition, measure the disc at 12 points with a micrometer at a radius approximately one inch from the edge of the disc. If thickness measurements vary by more t...
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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: 2001 Mercury Cougar S 2.5 V6 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 U-JOINT, Replace -> Assemble -> Disassemble
Vehicle: 1993 Mercury Cougar XR-7 3.8 V6 GAS
Disassemble
Do not clamp driveshaft in jaws of a vice or a similar holding fixture.
- Place driveshaft on a suitable workbench.
- Mark positions of driveshaft components relative to driveshaft tube. This ensures all components are reassembled in same relationship to maintain correct balance.
- Index driveshaft and driveshaft components.
- Clamp U-Joint Tool in a vise.
- Remove snap rings.
- If bearing cup cannot be pressed all way out, remove it with vise grips.
- Remove driveshaft slip-yoke.
- Position driveshaft in U-Joint Tool.
- Press out a bearing cup.
- Rotate driveshaft 180 degrees.
- Press on...
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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+.
Alternator, Replace
Vehicle: 1993 Mercury Cougar XR-7 5.0 V8 GAS
- Disconnect battery ground cable.
- Disconnect wire harness attachment to alternator assembly.
- Loosen alternator pivot bolt. Remove adjustment arm bolt from alternator.
- Disengage accessory drive ...
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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 -> Powertrain Malfunction Indicator ->
Vehicle: 1999 Mercury Cougar 2.0 L4 GAS
This lamp should light when the ignition is turned On. After engine starts, the lamp should go off, unless a fault condition is detected in the powertrain system. If the lamp remains On a diagnostic trouble code is stored in the PCM. Following diagnosis and repair, the Powertrain Malfunction Indicator will automatically reset when stored diagnostic trouble codes are cleared from PCM memory. The PCM reset procedure allows the scan tool to command the PCM to clear all diagnostic trouble codes.
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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+
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 1993 Mercury Cougar XR-7 5.0 V8 GAS
Lower
- Drain cooling system into a suitable container.
- Reposition hose clamp from radiator using hose clamp pliers.
- Remove radiator outlet hose from radiator.
- Reposition hose clamp from reservoir hose using hose clamp pliers.
- Remove radiator outlet hose from reservoir hose.
- Reposition hose clamp from water pump using hose clamp pliers.
- Remove radiator outlet hose...
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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: 1994 Mercury Cougar XR-7 3.8 V6 GAS
- Rotate automatic tensioner away from belt.
- Remove old belt from pulleys.
- Install new belt over pulleys.
- Ensure all V-groo...
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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 Component Locations Diagram for 1999 Mercury Cougar 2.5 V6 GASComponents on diagram: |
 Engine Compartment Components 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.
 2001 Mercury Cougar S 2.5 V6 GAS Wiring DiagramComponents on diagram: |
 1994 Mercury Cougar XR-7 4.6 V8 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: SPEC TOOL - NEW - TORQUE CONVERTER LEAK TEST Vehicle: 1995 Mercury Cougar XR-7 4.6 V8 GAS Auto Systems: |
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Document: SPEED CONTROL DIAGNOSTICS - WITHOUT SCP Vehicle: 2001 Mercury Cougar 2.0 L4 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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