1991 Mercury Capri Service & Repair Manual Software
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🏷️ Basic Information Identification Make: Mercury Model: Capri Year: 1991 Region Of Origin: United States (as a Mercury model, though the Capri was originally a Ford product primarily sold in Europe and Australia) Codes Platform Code: Fox platform (shared with Ford Mustang) 👋 Introduction Market Position Positioning: A performance-oriented personal luxury coupe, positioned as a more stylish and sporty alternative within the Mercury lineup. Competitive Analysis Competitors: Ford Mustang, Chevrolet Camaro, Pontiac Firebird, Toyota Celica, Nissan 300ZX. Key Features Unique Selling Points: Sporty styling, European-influenced design (based on the Ford Australia Capri), rear-wheel drive platform, powerful engine options. Manual Advantage Digital Vs Print: Offers instant access, searchability, and up-to-date information compared to older printed manuals. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service and repair for the 1991 Mercury Capri. Secondary Coverage: Maintenance, diagnostics, troubleshooting, and component-level repairs. Page Count Estimated Page Count: Varies by digital version, but indicative of full factory workshop manual content. Likely several hundred pages equivalent. Manual Type Type: Service and Repair Manual Software Language Language: English Format Format: Digital Software (Online Access) Access Duration Access: 1 Year (with discounts for renewal) 📖 Manual Coverage Systems Covered Engine: Engine mechanical, lubrication, cooling, fuel, ignition, emissions, and engine control systems. Drivetrain: Clutch, manual transmission, automatic transmission, drive axles, and differentials. Suspension: Front and rear suspension systems, steering components, wheel alignment. Brakes: Hydraulic brake system, power assist, anti-lock braking system (if equipped), brake components. Electrical: Battery, starting system, charging system, lighting, instruments, gauges, power accessories, wiring diagrams. HVAC: Heating, ventilation, and air conditioning (HVAC) system components and service. Body: Body panels, doors, windows, locks, interior trim, exterior trim, bumpers. Procedures Included Maintenance: Routine maintenance, fluid changes, filter replacements, tune-ups, lubrication. Troubleshooting: Diagnostic procedures, symptom-based troubleshooting, common fault diagnosis. Repair: Step-by-step repair procedures for all major vehicle systems and components. Diagnostics: On-board diagnostics (OBD-I) for the era, fault code interpretation, sensor testing. Component Replacement: Detailed instructions for replacing wear items and major components. Technical Depth Depth: Factory-level diagnostic and repair information, suitable for professional technicians and advanced DIY enthusiasts. 📊 Manual Specifications File Format Digital Format: Proprietary web-based software (RepairSurge) accessible via browser. Print Quality Digital Quality: High-resolution, clear text and diagrams. Printable pages are supported. Binding Type Binding: N/A (Digital) Paper Type Paper: N/A (Digital) Software Compatibility Compatibility: PC, laptop, smartphone, tablet with internet connection and web browser. ⚙️ Engine Specifications Primary Engine Engine Code And Type: 2.3L Turbocharged Inline-4 (OHC 'CFI-E' or 'Turbo' variants). Engine Displacement: 2302 cc (140 cubic inches) Horsepower: Approx. 160-180 hp (depending on specific turbo and tuning). Torque: Approx. 200-220 lb-ft (depending on specific turbo and tuning). Performance 0-60 Mph: Approximately 7-8 seconds for the turbocharged models. Fuel System Injection Type: Electronic Fuel Injection (EFI) with turbocharger and intercooler. Engine Management System: EEC-IV engine control module (ECM). 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission (e.g., T-5). Optional Transmission Type: 4-speed Automatic Transmission. Features Clutch: Hydraulically actuated clutch system. Fluid Specifications Manual Transmission Fluid: API GL-4 or GL-5 rated manual transmission fluid (e.g., Mercon ATF for some Ford applications, check specific manual recommendations for T-5). Automatic Transmission Fluid: Mercon Automatic Transmission Fluid (ATF). 📐 Dimensions Exterior Wheelbase: Approx. 100.4 inches (2550 mm) Length: Approx. 179.7 inches (4564 mm) Width: Approx. 69.1 inches (1755 mm) Height: Approx. 52.2 inches (1326 mm) Weights Curb Weight: Approx. 3,000 - 3,200 lbs (1360 - 1450 kg), depending on engine and options. Gross Vehicle Weight Rating: Typically around 3,900 lbs. Cargo Trunk Volume: Approx. 11.5 cubic feet (0.32 cubic meters). 🛡️ Safety Features Ratings NHTSA Ratings: No specific NHTSA ratings are readily available for the 1991 Mercury Capri. Generally, vehicles of this era had less rigorous testing. Active Features ABS: Optional Anti-lock Braking System (ABS) available on some models. Passive Features Airbags: Driver-side airbag standard for 1991 model year. Seatbelts: Three-point retractable front seat belts, lap belts in rear. Rollover Protection: Reinforced A-pillars and windshield frame. 💡 Technology Features Infotainment Audio System: Factory AM/FM cassette player, optional premium sound system with amplifier. Gauges And Displays: Analog gauges for speedometer, tachometer, fuel, coolant temperature, oil pressure. Some models featured a boost gauge. Driver Assistance Cruise Control: Optional cruise control system. Connectivity OBD Interface: OBD-I diagnostic connector, typically located under the dashboard. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 miles or 3-6 months, depending on driving conditions and oil type used. Consult manual for specific recommendation. Spark Plug Replacement: Typically every 30,000 miles for standard plugs, or longer for platinum/iridium plugs (check specific plug type). Timing Belt Replacement: For the 2.3L OHV or OHC engines, the timing belt typically required replacement every 60,000 - 90,000 miles or 5-7 years. The 2.3L Turbo utilized a timing belt. Fluid Specifications Engine Oil Type: SAE 5W-30 or 5W-40 API SG or higher specification synthetic blend or conventional oil. Check manual...
Diagnostic procedures, symptom-based troubleshooting, common fault diagnosis.
Repair:
Step-by-step repair procedures for all major vehicle systems and components.
Diagnostics:
On-board diagnostics (OBD-I) for the era, fault code interpretation, sensor testing.
Component Replacement:
Detailed instructions for replacing wear items and major components.
Technical Depth
Depth:
Factory-level diagnostic and repair information, suitable for professional technicians and advanced DIY enthusiasts.
📊 Manual Specifications
File Format
Digital Format:
Proprietary web-based software (RepairSurge) accessible via browser.
Print Quality
Digital Quality:
High-resolution, clear text and diagrams. Printable pages are supported.
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper:
N/A (Digital)
Software Compatibility
Compatibility:
PC, laptop, smartphone, tablet with internet connection and web browser.
⚙️ Engine Specifications
Primary Engine
Engine Code And Type:
2.3L Turbocharged Inline-4 (OHC 'CFI-E' or 'Turbo' variants).
Engine Displacement:
2302 cc (140 cubic inches)
Horsepower:
Approx. 160-180 hp (depending on specific turbo and tuning).
Torque:
Approx. 200-220 lb-ft (depending on specific turbo and tuning).
Performance
0-60 Mph:
Approximately 7-8 seconds for the turbocharged models.
Fuel System
Injection Type:
Electronic Fuel Injection (EFI) with turbocharger and intercooler.
Engine Management
System:
EEC-IV engine control module (ECM).
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transmission (e.g., T-5).
Optional
Transmission Type:
4-speed Automatic Transmission.
Features
Clutch:
Hydraulically actuated clutch system.
Fluid Specifications
Manual Transmission Fluid:
API GL-4 or GL-5 rated manual transmission fluid (e.g., Mercon ATF for some Ford applications, check specific manual recommendations for T-5).
Automatic Transmission Fluid:
Mercon Automatic Transmission Fluid (ATF).
📐 Dimensions
Exterior
Wheelbase:
Approx. 100.4 inches (2550 mm)
Length:
Approx. 179.7 inches (4564 mm)
Width:
Approx. 69.1 inches (1755 mm)
Height:
Approx. 52.2 inches (1326 mm)
Weights
Curb Weight:
Approx. 3,000 - 3,200 lbs (1360 - 1450 kg), depending on engine and options.
Gross Vehicle Weight Rating:
Typically around 3,900 lbs.
Cargo
Trunk Volume:
Approx. 11.5 cubic feet (0.32 cubic meters).
🛡️ Safety Features
Ratings
NHTSA Ratings:
No specific NHTSA ratings are readily available for the 1991 Mercury Capri. Generally, vehicles of this era had less rigorous testing.
Active Features
ABS:
Optional Anti-lock Braking System (ABS) available on some models.
Passive Features
Airbags:
Driver-side airbag standard for 1991 model year.
Seatbelts:
Three-point retractable front seat belts, lap belts in rear.
Rollover Protection:
Reinforced A-pillars and windshield frame.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM cassette player, optional premium sound system with amplifier.
Gauges And Displays:
Analog gauges for speedometer, tachometer, fuel, coolant temperature, oil pressure. Some models featured a boost gauge.
Driver Assistance
Cruise Control:
Optional cruise control system.
Connectivity
OBD Interface:
OBD-I diagnostic connector, typically located under the dashboard.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles or 3-6 months, depending on driving conditions and oil type used. Consult manual for specific recommendation.
Spark Plug Replacement:
Typically every 30,000 miles for standard plugs, or longer for platinum/iridium plugs (check specific plug type).
Timing Belt Replacement:
For the 2.3L OHV or OHC engines, the timing belt typically required replacement every 60,000 - 90,000 miles or 5-7 years. The 2.3L Turbo utilized a timing belt.
Fluid Specifications
Engine Oil Type:
SAE 5W-30 or 5W-40 API SG or higher specification synthetic blend or conventional oil. Check manual for exact viscosity and API rating.
Coolant Type:
Ethylene glycol-based antifreeze mixed 50/50 with distilled water. Typically a green conventional coolant for this era.
Brake Fluid Type:
DOT 3 brake fluid.
Known Issues
Turbo Specific:
Potential for turbocharger wear, intercooler leaks, and boost control issues. Oil sludge buildup if maintenance is neglected.
Electrical:
Aging wiring harnesses, faulty sensors, and intermittent electrical connections are common for vehicles of this age.
Suspension Steering:
Worn bushings, ball joints, and tie rod ends can lead to steering looseness and alignment issues.
Exhaust System:
Rust and corrosion of the exhaust system components are common.
📚 Vehicle History
Brand Heritage
Mercury Legacy:
Mercury was positioned by Ford as a premium brand, often offering more stylish and upscale versions of Ford models.
Model Evolution
Capri Lineage:
The Mercury Capri was reintroduced in North America for the 1979 model year, based on the Ford Fox platform, and was a sporty coupe/hatchback. The 1991 model year represents the later iteration of this generation, often featuring turbocharged performance.
Production
Production Location:
Assembled in the United States (e.g., Dearborn, Michigan).
Production Years North America:
1979-1986, and then re-introduced as a rebadged Ford Australia Capri from 1990-1994.
🏆 Awards & Recognition
Recognitions
Contemporary Awards:
The 1991 Mercury Capri, in its performance variants, was generally well-regarded for its styling and handling in contemporary automotive reviews, though it didn't receive specific major 'car of the year' awards in the way some mainstream models did.