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1994 Mercury Cougar CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Mercury REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
A/C & HEATER SERVICE PROCEDURES FOR 1994 Mercury Cougar AUTOMOBILES
Manual Air Conditioning & Heater System Diagnosis & Testing -> COMPONENT TESTING & DIAGNOSIS -> 1.8L/4-112 Engine -> 1.9L/4-116 Engine -> 1995 -> A/C BLOWER MOTOR CURRENT DRAW TEST -> A/C CONDENSER COOLING FAN -> A/C RELAY -> AEROSTAR -> Aerostar & Villager -> Aerostar, Explorer & Ranger -> Aspire, Escort, Probe & Tracer -> Aspire, Probe & Villager -> AUXILIARY HEATER CORE PRESSURE TEST -> BLOWER MOTOR -> BLOWER MOTOR CIRCUIT TEST -> BLOWER MOTOR RELAY -> BLOWER MOTOR SWITCH -> Bronco, E-Series & F-Series -> COUGAR, CROWN VICTORIA, GRAND MARQUIS, SABLE, TAURUS, TEMPO, THUNDERBIRD AND TOPAZ -> ESCORT & TRACER -> FUNCTION SELECTOR SWITCH -> HEATER BLOWER MOTOR -> HEATER BLOWER RESISTOR -> HEATER CORE PRESSURE TEST -> PROBE -> REAR CONTROL SWITCH AT FRONT CLIMATE CONTROL ASSEMBLY -> REAR CONTROL SWITCH AT REAR CLIMATE CONTROL ASSEMBLY -> Villager -> Villager & Windstar -> Windstar
Vehicle: 1994 Mercury Cougar XR-7 3.8 V6 GAS
A/C BLOWER MOTOR CURRENT DRAW TEST
COUGAR, CROWN VICTORIA, GRAND MARQUIS, SABLE, TAURUS, TEMPO, THUNDERBIRD AND TOPAZ
On electrical circuits, continuity must exist from the source of power battery positive voltage (+) to the unit where the power is used and back-up to the source of power battery ground (-) terminal. A check at each connection in a circuit, starting at the battery will locate an open circuit or will show the circuit is complete.
A suitable multimeter or self-powered test lamp connected at any two points of a circuit, with the p...
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BRAKE SERVICE PROCEDURES FOR 1994 Mercury Cougar AUTOMOBILES
Anti-lock Brakes -> 1993-94 Cougar, Mark VIII & Thunderbird -> System Service -> ABS MODULE -> Brake System Bleed -> Component Replacement -> FRONT BRAKE SENSOR INDICATOR -> Front Sensor -> HYDRAULIC CONTROL UNIT -> Installation -> PEDAL TRAVEL SWITCH -> REAR BRAKE SENSOR INDICATOR -> Rear Sensor -> Removal -> WHEEL SENSOR
Vehicle: 1994 Mercury Cougar XR-7 4.6 V8 GAS
MASTER CYLINDER RESERVOIR
Brake fluid level in the master cylinder reservoir should be between 0.16 inch below the MAX line and the MAX line on the reservoir. If brake fluid is low, the red "Brake" lamp will illuminate. Fill reservoir with brake fluid C6AZ-19542-AA (ESA-M6C25-A) or DOT-3 equivalent.
Brake System Bleed
The master cylinder and hydraulic control unit must be bled using ABS test adapter tool No. T90P-50-ALA, or equivalent. If this procedure is not followed, air will be trapped in the hydraulic control unit which will eventually lead to a spongy brake pedal.
To bleed the ma...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1994 Mercury Cougar AUTOMOBILES
Ford Motor Co. Passenger Cars -> Component Locations -> 1993-98 Mark VIII, 1987-97 Thunderbird & Cougar
Vehicle: 1994 Mercury Cougar XR-7 4.6 V8 GAS
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1994 Mercury Cougar AUTOMOBILES
DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble
Vehicle: 1994 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 1994 Mercury Cougar AUTOMOBILES
Alternator, Replace
Vehicle: 1994 Mercury Cougar XR-7 3.8 V6 GAS
- Disconnect battery ground cable.
- Disconnect wire harness attachment to alternator.
- Disengage drive belt from alternator pulley.
- Remove alternator mounting bolts.
- Remove alte...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1994 Mercury Cougar AUTOMOBILES
Ford Motor Co. Cars -> Check Fuel Cap Lamp ->
Vehicle: 1994 Mercury Cougar XR-7 3.8 V6 GAS
The Check Fuel Cap Lamp will illuminate momentarily when the ignition switch is placed in the On position as a bulb check. If the lamp remains...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1994 Mercury Cougar AUTOMOBILES
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 1994 Mercury Cougar XR-7 3.8 V6 GAS
Inlet
- Drain cooling system into a suitable container.
- Reposition heater hose inlet clamp at intake manifold fitting using hose clamp pliers.
- Remove heater inlet hose from intake manifold fitting.
- Reposition heater core inlet hose clamp at heater core using hose clamp pliers.
- Remove hose from vehicle.
- Reverse procedure to...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1994 Mercury Cougar AUTOMOBILES
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 1994 Mercury Cougar AUTOMOBILES
Component location diagrams for most 1994 Mercury Cougar cars and light trucks sold in the U.S. from 1990+.
Engine Components Diagram for 1994 Mercury Cougar XR-7 3.8 V6 GAS Components on diagram: |
Power Seats Diagram for 1994 Mercury Cougar XR-7 4.6 V8 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 1994 Mercury Cougar AUTOMOBILES
OEM drawn wiring diagrams for most 1994 Mercury Cougar cars and light trucks sold in the U.S.
1994 Mercury Cougar XR-7 3.8 V6 GAS Wiring Diagram Components on diagram: |
1994 Mercury Cougar XR-7 3.8 V6 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1994 Mercury Cougar AUTOMOBILES
OEM TSB listings for most 1994 Mercury Cougar cars and light trucks sold in the U.S. from 1985+.
Document: RECALL - CERTAIN 1992-2003 MODEL YEAR CARS AND TRUCKS - FUSED JUMPER HARNESS REPLACEMENT FOR VEHICLES SERVICED WITH AN INCOMPATIBLE FUSED JUMPER HARNESS Vehicle: 1994 Mercury Cougar XR-7 4.6 V8 GAS Auto Systems: |
Document: RECALL - 1992-2004 MULTIPLE VEHICLE LINES - SPEED CONTROL SYSTEM MODIFICATION Vehicle: 1994 Mercury Cougar XR-7 4.6 V8 GAS |
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COMPONENT/PARTS SPECIFICATIONS FOR 1994 Mercury Cougar AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1994 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 1994 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 1994 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 1994 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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