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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 -> Water Pump, Replace -> 2.0L DOHC Engine -> 2.0L Engine -> 2.0L SOHC Engine -> 2.5L Engine -> 3.0L DOHC Engine -> 3.0L Engine -> 3.8L Engine -> 3.9L Engine -> 4.6L Engine -> Continental, Crown Victoria, Grand Marquis & Town Car -> Cougar -> Escort -> Focus -> LS & Thunderbird -> Mustang -> Sable & Taurus
Vehicle: 2001 Mercury Cougar 2.0 L4 GAS
Cougar
2.0L Engine
- Drain engine coolant into suitable container.
- Raise and support vehicle.
- Remove righthand front wheel and lower splash shield.
- Lower vehicle.
- Disconnect coolant expansion tank hoses.
- Loosen water pump pulley mounting bolts and remove accessory drive belt.
- Remove mounting bolts and water pump pulley.
- Remove mounting bolts and water pump bolts by turning it 180º
- Reverse procedure to install.
2.5L Engine
- Remove battery and air cleaner.
- Remove thermostat housing and ...
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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 -> Caliper Service -> Assemble -> CALIPER OVERHAUL -> CALIPER, REPLACE -> CAPRI -> Cleaning & Inspection -> CONTINENTAL, COUGAR, MARK VIII & THUNDERBIRD -> CROWN VICTORIA, GRAND MARQUIS & TOWN CAR -> Disassemble -> ESCORT & TRACER -> Inspection -> Installation -> MARK VII -> MUSTANG -> PROBE -> Removal -> SABLE & TAURUS
Vehicle: 1992 Mercury Cougar LS 3.8 V6 GAS
CALIPER, REPLACE
MARK VII
Removal
- Raise and support vehicle, then remove tire and wheel assemblies.
- Disconnect fitting on rear brake tube from hose end fitting at frame mounted bracket. Plug end of brake tube to prevent fluid loss and entry of dirt.
- Remove horse shoe retaining clip from hose fitting and disengage hose from bracket.
- Disconnect parking cable from lever, Fig. , using care to avoid kinking or cutting cable or return spring, then remove screw from caliper key, Fig. , then remove caliper locating pins.
- Slide caliper key and support spring from anchor plate, Fig. , noting the...
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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: 1993 Mercury Cougar XR-7 3.8 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, Replace
Vehicle: 1996 Mercury Cougar XR-7 3.8 V6 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+.
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: 2000 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 -> Low Oil Level Warning Indicator ->
Vehicle: 1991 Mercury Cougar LS 3.8 V6 GAS
This system is used to indicate when the engine oil level is 11/2 quarts or more below the specified level. The lamp should light during engine starting. If the oil level is sufficient, the lamp will go off when the engine is operating. If the ...
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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+
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 2002 Mercury Cougar 2.5 V6 GAS
Inlet
- Drain cooling system into a suitable container.
- Reposition heater hose inlet clamp at heater core.
- Remove heater inlet hose from heater core.
- Reposition heater core inlet hose clamp at engine.
- Remove hose from engine.
- Remove hose from vehicle.
- Reverse procedure to in...
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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: 2001 Mercury Cougar 2.0 L4 GAS
- Raise and support vehicle.
- Loosen drive belt tensioner pulley mounting bolt, using a 13mm wrench, then rotate drive belt tensioner away from accessory drive be...
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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 1992 Mercury Cougar XR-7 5.0 V8 GASComponents on diagram: |
 Engine Components Diagram for 1996 Mercury Cougar XR-7 4.6 V8 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.
 1997 Mercury Cougar XR-7 3.8 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 - HUB-MOUNT BRAKE ROTOR MACHINING EQUIP Vehicle: 1994 Mercury Cougar XR-7 3.8 V6 GAS Auto Systems: |
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Document: LABOR TIME STANDARDS - NEWLY RELEASED SBDS LABOR OPS Vehicle: 1988 Mercury Cougar LS 3.8 V6 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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