Mercury REPAIR MANUAL -- HOW TO FIX YOUR CAR OR TRUCK

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Mercury 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!

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Get Full Access Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about Mercury 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 automobile. Try the Automotix DIY solution today!
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Using the Automotix DIY repair procedures will save you hundreds and even thousands of dollars! In addition, it will save you hours of touring the city searching for Mercury mechanics you can trust. The Automotix DIY solution is particularly affordable. A full access to the entire DIY repair procedures and diagrams for your Mercury vehicle will cost less than a single gallon of gas. Here are some of the DIY repair tips and procedures you will find here:

A/C & HEATER SERVICE PROCEDURES FOR Mercury 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 cars and light trucks from 1990+

Air Bag System Precautions -> Ford Motor Co. -> Arming -> 1990-91 -> 1990-92 -> 1991-92 -> 1992-93 -> 1992-94 -> 1992-96 -> 1992-98 -> 1993 -> 1993-94 -> 1993-95 -> 1994 -> 1994-95 -> 1994-96 -> 1994-97 -> 1995 -> 1995-2004 -> 1995-96 -> 1995-98 -> 1996-97 -> 1996-99 -> 1997-2000 -> 1997-2001 -> 1997-2004 -> 1997-99 -> 1998 -> 1998-2000 -> 1998-2002 -> 1999-2000 -> 1999-2001 -> 1999-2002 -> 1999-2004 -> 2000 -> 2000-01 -> 2000-04 -> 2001-02 -> 2001-03 -> 2001-04 -> 2002-03 -> 2002-04 -> 2004 -> Aerostar & Bronco -> Aspire -> Aviator -> Blackwood, Expedition & Navigator -> Built After February 2002 -> Built Before March 2002 -> Capri -> Continental -> Contour & Mystique -> Cougar -> Crown Victoria Grand Marquis & Marauder -> Econoline -> Escape -> Escort, Tracer & ZX2 -> Excursion -> Explorer & Mountaineer -> Explorer Sport & Sport Trac -> F Series -> Focus -> Freestar & Monterey -> Light Trucks & Vans -> LS -> Mark VII -> Mark VIII -> Mustang -> Passenger Cars -> Probe -> Ranger -> Sable & Taurus -> Tempo & Topaz -> Thunderbird -> Town Car -> Villager -> Windstar
Vehicle: 2000 Mercury Mountaineer 5.0 V8 GAS

Passenger Cars

Aspire
  • Disconnect battery ground cable.
  • Wait one minute for back-up power supply to deplete stored energy.
  • Remove restraint system diagnostic tool from driver's side air bag module electrical connector.
  • Connect driver's side air bag module electrical connector.
  • Install driver's side air bag module as outlined under "Component Service."
  • Remove restraint system diagnostic tool from passenger's side air bag module electrical connector.
  • Install passenger's side air bag module as outlined under "Component Service."
  • C...

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BRAKE SERVICE PROCEDURES FOR Mercury AUTOMOBILES

Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported Mercury cars and light trucks from 1990+.

Disc Brakes -> Front Disc Brakes -> Brake System Bleed -> System Priming -> Wheel Bleeding Sequence
Vehicle: 1998 Mercury Tracer LS 2.0 L4 GAS

Pressure bleeding is recommended for all hydraulic disc brake systems.

Do not reuse brake fluid drained from the hydraulic system when bleeding the brakes. Ensure disc brake pistons are returned to their normal positions and the shoe and lining assemblies are properly seated.

Do not shake the pressure bleeder tank while air is being added or after it has been pressurized. This will prevent air from the tank getting into the lines. Do not move the tank during the bleeding operation. The tank should be kept at least one third full.

On models equipped with power brakes, exhaust the...

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FUEL FILTER REPLACEMENT PROCEDURES FOR Mercury AUTOMOBILES

Fuel filter replacement procedures with corresponding images for most domestic and imported Mercury cars and light trucks sold in the U.S. for 1980+.

Ford Motor Co. Light Trucks, SUVs & Vans -> Component Locations -> Aviator, 1991-06 Explorer & Mountaineer, 1986-06 Ford Ranger & 1986-90 Bronco II w/Fuel Injected Engine
Vehicle: 2002 Mercury Mountaineer 4.6 V8 GAS

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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR Mercury AUTOMOBILES

Includes CV axle, universal joint, and driveline replacement, for domestic and imported Mercury cars and light trucks from 1990+.

DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble -> Single Cardan, Flange Yoke -> Single Cardan, Slip Yoke
Vehicle: 2002 Mercury Mountaineer 4.0 V6 GAS

Single Cardan, Slip Yoke

Disassemble

Do not, under any circumstance, clamp the shaft in the jaws of a vise or similar holding fixture. Denting or localizing fracture can result, causing shaft failure during vehicle operation. Place the shaft on a suitable workbench. Do not damage the tube. If components are not marked and installed incorrectly, driveline imbalance can occur.

  • Index-mark the shaft components.
  • Remove and discard all four snap rings.
  • Clamp bearing cup removal tool No. 205-086 or equivalent in a vise.
  • If necessary, use a pair of pliers to remove a bearing cup t...

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TIRE PRESSURE MONITORING SYSTEM PROCEDURES FOR Mercury AUTOMOBILES

Description, component locations, reset procedures, relearn procedures, diagnosis and testing, wiring diagrams, component replacement, and identification of vehicles equipped and not equipped with tire pressure monitoring system for most domestic and imported Mercury cars and light trucks sold in the U.S. from mid 1990's+.

Diagnosis & Testing -> Accessing Diagnostic Trouble Codes -> Clearing Diagnostic Trouble Codes -> Diagnostic Trouble Code Identification -> Intermittent & Poor Connections -> Intermittents -> Poor Connections -> Symptom Test
Vehicle: 2009 Mercury Sable 3.5 V6 GAS

Accessing Diagnostic Trouble Codes

Connect a suitably programmed scan tool to DLC (Data Link Connector) and follow manufacturer's instructions.

Diagnostic Trouble Code Identification

Refer to Fig. , for diagnostic trouble code identification.

Clearing Diagnostic Trouble Codes

Connect a suitably programmed scan tool to DLC (Data Link Connector), and follow manufacturer's instructions.

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:

  • Wirin...

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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR Mercury AUTOMOBILES

Includes starter and alternator replacement procedures for domestic and imported Mercury cars and light trucks from 1990+.

Starter, Replace
Vehicle: 1997 Mercury Cougar XR-7 4.6 V8 GAS

  • Disconnect battery ground cable.
  • Raise and support vehicle.
  • Remove starter shield, if required.
  • Disconnect starter cable and push on connector. When disconnecting hardshell connector at S-terminal, grasp plastic shell and pull off. Do not pull on wire. Be careful to pull straight off to prevent damage to connector and S-terminal. If any part ...

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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR Mercury AUTOMOBILES

Cabin air filter locations and replacement procedures with corresponding images for most domestic and imported Mercury cars and light trucks sold in the U.S. as equipped to the current model year.

Cabin Air Filter Service -> Ford Motor Co. -> 1997-2002 Villager
Vehicle: 2000 Mercury Villager 3.3 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.

  • Lift the windshield wiper arms away from the windshield.
  • While holding the retaining clip at the base of the wiper arm outward, lift the wiper arm from the pivot.
  • Remove the six cowl cover retaining screws, Fig. .
  • Open the hood.
  • Remove the four plastic pin type retainers from the forward edge of the cowl cover, then remove the retainer anchors, Fig. .
  • Disconnect the windshield washer nozzle hose.
  • Lift the cowl cover upward and position...

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MAINTENANCE LAMP RESET PROCEDURES FOR Mercury AUTOMOBILES

Maintenance lamp reset procedures with corresponding images for most domestic and imported Mercury cars and light trucks sold in the U.S. from 1990+.

Ford Motor Co. Trucks -> Low Fuel Level Warning Lamp ->
Vehicle: 1994 Mercury Villager 3.0 V6 GAS

When fuel level drops below a predetermined level, the CHECK GAUGE indicator should light. The CHECK GAUGE indicator shoul...

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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR Mercury AUTOMOBILES

Includes radiator, cooling and heater hose replacement procedures for domestic and imported Mercury cars and light trucks from 1990+

Radiator, Replace
Vehicle: 2004 Mercury Mountaineer 4.0 V6 FLEX

  • Raise and support vehicle.
  • Drain cooling system into suitable...

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SERPENTINE BELT SERVICE PROCEDURES FOR Mercury AUTOMOBILES

Serpentine belt replacement procedures with corresponding images for most domestic and imported Mercury cars and light trucks sold in the U.S. from 1990+.

Serpentine Drive Belt, Replace
Vehicle: 1995 Mercury Mystique LS 2.0 L4 GAS

Minor cracks in the V-grooved portion of the drive belt are considered normal and acceptable. If the drive belt has chunks missing from the ribs, the drive belt should be replaced.

Conditions requiring drive belt replacement are rib chunk out, severe glazing, frayed cords, etc. Replace any drive belt exhibiting one of these conditions.

  • Raise and support vehicle.
  • Loosen drive belt tensioner with 13 mm...

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COMPONENT LOCATION DIAGRAMS FOR Mercury AUTOMOBILES

Component location diagrams for most Mercury cars and light trucks sold in the U.S. from 1990+.

Engine Compartment Diagram for 2004 Mercury Mountaineer Premier 4.6 V8 GASEngine Compartment Diagram for 2004 Mercury Mountaineer Premier 4.6 V8 GAS

Components on diagram:
  • Washer Fluid Level Switch
  • Horn
  • Windshield Washer Pump Motor
  • Park Lamp
  • Turn Lamp
  • Instrument Panel Diagram for 2005 Mercury Mariner  2.3 L4 GASInstrument Panel Diagram for 2005 Mercury Mariner 2.3 L4 GAS

    Components on diagram:
  • Data Link Connector
  • Radio
  • Cigar Lighter
  • Lighting Control Module
  • Function Selector Switch Assembly
  • CLICK HERE TO GET FULL ACCESS TO Mercury PARTS/COMPONENTS LOCATION DIAGRAMS!

    WIRING DIAGRAMS FOR Mercury AUTOMOBILES

    OEM drawn wiring diagrams for most Mercury cars and light trucks sold in the U.S.

    1991 Mercury Colony Park  5.0 V8 GAS Wiring Diagram1991 Mercury Colony Park 5.0 V8 GAS Wiring Diagram

    Components on diagram:
  • Battery
  • Starter Relay
  • Ignition Switch
  • Alternator Indicator
  • Integral Alternator Regulator (IAR)
  • 1999 Mercury Mystique  2.0 L4 GAS Wiring Diagram1999 Mercury Mystique 2.0 L4 GAS Wiring Diagram

    Components on diagram:
  • Low Coolant Level Switch
  • O/D Off
  • Instrument Interface Module
  • Low Coolant Level
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    TECHNICAL SERVICE BULLETINS FOR Mercury AUTOMOBILES

    OEM TSB listings for most Mercury cars and light trucks sold in the U.S. from 1985+.

    Document: REAR WINDOW DEFROSTER GRID / INTEGRAL ANTENNA DIAGNOSIS AND REPAIR - TERMINAL TAB REPAIR - REVISED
    Vehicle: 2004 Mercury Mountaineer 4.0 V6 FLEX

    Auto Systems:
  • Heating, A/C, Ventilation, Defogger
  • Entertainment: Stereo, Radio, Cassettes
  • Document: FUEL FILLER CAP BINDING, FUEL CAP LIGHT / WARNING MESSAGE AND/OR DTC P0457 - REVISED
    Vehicle: 2007 Mercury Montego Luxury 3.0 V6 GAS

    Auto Systems:
  • Fuel Sys, Driveability, Filters (Air & Fuel)
  • CLICK HERE TO GET FULL ACCESS TO Mercury TECHNICAL SERVICE BULLETINS!

    COMPONENT/PARTS SPECIFICATIONS FOR Mercury AUTOMOBILES

    BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most Mercury 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 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 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 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

    CLICK HERE TO GET FULL ACCESS TO Mercury SPECIFICATIONS DATA!

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