1991 Mercury Cougar Service & Repair Manual Software
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🏷️ Basic Information Identification Make: Mercury Model: Cougar Year: 1991 Generation Cougar Generation: Sixth Generation (1989-1997) Codes Vehicle Platform: MN12 👋 Introduction Market Position Market Position: Mid-size personal luxury coupe, competing with Chevrolet Camaro, Pontiac Firebird, and American Honda Prelude. Competitive Analysis Competitive Analysis: The 1991 Cougar, based on the MN12 platform, offered a more refined and performance-oriented option compared to its predecessor, emphasizing European handling characteristics and improved aerodynamics. Key Features Key Features: Rear-wheel drive, optional 5.0L V8 engine, independent rear suspension (IRS), aerodynamic styling, comfortable interior. 📋 Manual Details Coverage Areas Manual Coverage Areas: Comprehensive Service and Repair Page Count Manual Page Count: Digital Access (No specific page count provided, but implies extensive content) Manual Type Manual Type: Software/Online Service and Repair Manual Language Manual Language: English Format Manual Format: Web-based access via browser, compatible with PC, laptop, smartphone, tablet 📖 Manual Coverage Systems Covered Systems Covered Engine: Engine mechanical, lubrication, cooling, fuel, ignition, emissions control, starting, charging Systems Covered Transmission: Automatic transmission service and repair (likely AOD/AODE variations for 1991) Systems Covered Drivetrain: Driveshaft, axles, rear axle assembly Systems Covered Brakes: Brake system hydraulics, components, anti-lock brake system (if equipped) Systems Covered Suspension: Front and rear suspension, steering system Systems Covered Electrical: Wiring diagrams, lighting, instrumentation, power distribution, body electrical components Systems Covered HVAC: Heating, ventilation, and air conditioning (HVAC) system Systems Covered Body: Body panels, interior trim, doors, windows, glass, seats Systems Covered Exhaust: Exhaust system components and diagnosis. Systems Covered Fuel: Fuel tank, fuel pump, fuel lines, fuel filter, fuel injection system. Systems Covered Ignition: Distributor, ignition coil, spark plugs, spark plug wires, ignition module. Procedures Included Procedures Included Maintenance: Routine maintenance, fluid changes, filter replacements, tune-ups Procedures Included Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs) if applicable, symptom-based diagnostics Procedures Included Repair: Component removal and installation, system repairs, adjustments Procedures Included Specifications: Torque specifications, clearances, alignments, electrical values Procedures Included Body Repair: Front and rear bumper replacement, fender repairs, door panel removal and installation, hood and trunk lid adjustments. Procedures Included Steering Repair: Steering column overhaul, power steering pump and rack replacement. Procedures Included Engine Rebuild: Engine teardown, inspection, assembly, piston and ring replacement, bearing replacement, cylinder head overhaul. Technical Depth Technical Depth: Factory-derived, comprehensive, suitable for DIY and professional technicians Technical Depth Wiring: Detailed wiring diagrams for all electrical systems, including component location and pin-out data. Technical Depth Diagnostics: Comprehensive diagnostic procedures for all major systems, including flowcharts and symptom-to-cause mappings. Technical Depth Specifications: Precise torque values, diagnostic tool usage, measurement specifications for all mechanical and electrical components. 📊 Manual Specifications File Format Digital File Format: Web-based access, not a downloadable file Print Quality Print Quality: N/A (Digital Access) Binding Type Binding Type: N/A (Digital Access) Paper Type Paper Type: N/A (Digital Access) ⚙️ Engine Specifications Primary Engine Engine Options 1991: 2.3L Turbocharged Inline-4 (Brazil), 5.0L V8 (North America) Engine 2.3L Turbo Specs: 2.3L Turbocharged Inline-4 (likely similar to Mustang GT Turbo), estimated horsepower and torque figures vary but would be lower than V8. Performance Engine 5.0L V8 Horsepower: Approximately 200 hp (149 kW) Engine 5.0L V8 Torque: Approximately 275 lb-ft (373 Nm) Fuel System Engine Fuel System 5.0L: Electronic Fuel Injection (EFI) 🔧 Transmission Standard Transmission Standard: Automatic (Likely AOD - Automatic Overdrive) Optional Transmission Optional: Manual transmission may have been available on certain configurations, but automatic was more common, especially with the V8. Features Transmission Features: Overdrive gear for improved fuel economy at highway speeds. 📐 Dimensions Exterior Exterior Length: Approximately 197.5 inches (4991 mm) Exterior Width: Approximately 70.5 inches (1791 mm) Exterior Height: Approximately 53.5 inches (1359 mm) Weights Curb Weight Approx: 3400 - 3600 lbs (1542 - 1633 kg) depending on engine and options Interior Interior Wheelbase: Approximately 104.2 inches (2647 mm) 🛡️ Safety Features Ratings Safety Ratings: NHTSA ratings not readily available for specific year/model in a consistent format, but MN12 platform aimed for improved safety over previous generations. Active Features Active Safety Features: Optional Anti-lock Braking System (ABS) Passive Features Passive Safety Features: Seat belts, reinforced passenger compartment. 💡 Technology Features Infotainment Infotainment Features: AM/FM stereo with cassette player, optional CD player, graphic equalizer. Driver Assistance Driver Assistance Features: Cruise control. Connectivity Connectivity Features: N/A (No modern connectivity features like Bluetooth or USB) 🔧 Maintenance Service Intervals Maintenance Oil Change Interval: Every 3,000-5,000 miles or 6 months (typical for this era, consult manual for specific recommendations) Maintenance Tune Up Interval: Typically every 30,000 miles, including spark plug replacement and inspection of ignition components. Fluid Specifications Fluid Engine Oil Spec: SAE 5W-30 or 5W-30 Synthetic (check manual for exact specification and viscosity index) Fluid Transmission Oil Spec: Mercon ATF (Automatic Transmission Fluid) Fluid Coolant Spec: Ford Premium Engine Coolant (Green) or equivalent ethylene glycol based coolant Fluid Brake Fluid Spec: DOT 3 Brake Fluid Fluid Power Steering Spec:...
Mid-size personal luxury coupe, competing with Chevrolet Camaro, Pontiac Firebird, and American Honda Prelude.
Competitive Analysis
Competitive Analysis:
The 1991 Cougar, based on the MN12 platform, offered a more refined and performance-oriented option compared to its predecessor, emphasizing European handling characteristics and improved aerodynamics.
Front and rear bumper replacement, fender repairs, door panel removal and installation, hood and trunk lid adjustments.
Procedures Included Steering Repair:
Steering column overhaul, power steering pump and rack replacement.
Procedures Included Engine Rebuild:
Engine teardown, inspection, assembly, piston and ring replacement, bearing replacement, cylinder head overhaul.
Technical Depth
Technical Depth:
Factory-derived, comprehensive, suitable for DIY and professional technicians
Technical Depth Wiring:
Detailed wiring diagrams for all electrical systems, including component location and pin-out data.
Technical Depth Diagnostics:
Comprehensive diagnostic procedures for all major systems, including flowcharts and symptom-to-cause mappings.
Technical Depth Specifications:
Precise torque values, diagnostic tool usage, measurement specifications for all mechanical and electrical components.
📊 Manual Specifications
File Format
Digital File Format:
Web-based access, not a downloadable file
Print Quality
Print Quality:
N/A (Digital Access)
Binding Type
Binding Type:
N/A (Digital Access)
Paper Type
Paper Type:
N/A (Digital Access)
⚙️ Engine Specifications
Primary Engine
Engine Options 1991:
2.3L Turbocharged Inline-4 (Brazil), 5.0L V8 (North America)
Engine 2.3L Turbo Specs:
2.3L Turbocharged Inline-4 (likely similar to Mustang GT Turbo), estimated horsepower and torque figures vary but would be lower than V8.
Performance
Engine 5.0L V8 Horsepower:
Approximately 200 hp (149 kW)
Engine 5.0L V8 Torque:
Approximately 275 lb-ft (373 Nm)
Fuel System
Engine Fuel System 5.0L:
Electronic Fuel Injection (EFI)
🔧 Transmission
Standard
Transmission Standard:
Automatic (Likely AOD - Automatic Overdrive)
Optional
Transmission Optional:
Manual transmission may have been available on certain configurations, but automatic was more common, especially with the V8.
Features
Transmission Features:
Overdrive gear for improved fuel economy at highway speeds.
📐 Dimensions
Exterior
Exterior Length:
Approximately 197.5 inches (4991 mm)
Exterior Width:
Approximately 70.5 inches (1791 mm)
Exterior Height:
Approximately 53.5 inches (1359 mm)
Weights
Curb Weight Approx:
3400 - 3600 lbs (1542 - 1633 kg) depending on engine and options
Interior
Interior Wheelbase:
Approximately 104.2 inches (2647 mm)
🛡️ Safety Features
Ratings
Safety Ratings:
NHTSA ratings not readily available for specific year/model in a consistent format, but MN12 platform aimed for improved safety over previous generations.
Active Features
Active Safety Features:
Optional Anti-lock Braking System (ABS)
Passive Features
Passive Safety Features:
Seat belts, reinforced passenger compartment.
💡 Technology Features
Infotainment
Infotainment Features:
AM/FM stereo with cassette player, optional CD player, graphic equalizer.
Driver Assistance
Driver Assistance Features:
Cruise control.
Connectivity
Connectivity Features:
N/A (No modern connectivity features like Bluetooth or USB)
🔧 Maintenance
Service Intervals
Maintenance Oil Change Interval:
Every 3,000-5,000 miles or 6 months (typical for this era, consult manual for specific recommendations)
Maintenance Tune Up Interval:
Typically every 30,000 miles, including spark plug replacement and inspection of ignition components.
Fluid Specifications
Fluid Engine Oil Spec:
SAE 5W-30 or 5W-30 Synthetic (check manual for exact specification and viscosity index)
Fluid Transmission Oil Spec:
Mercon ATF (Automatic Transmission Fluid)
Fluid Coolant Spec:
Ford Premium Engine Coolant (Green) or equivalent ethylene glycol based coolant
Fluid Brake Fluid Spec:
DOT 3 Brake Fluid
Fluid Power Steering Spec:
Mercon ATF or equivalent power steering fluid.
Known Issues
Known Issues Electrical:
Flickering dashboard lights, power window/lock issues, ABS sensor failures.
Known Issues Suspension:
Wear in ball joints, tie rod ends, and bushings due to the independent rear suspension design. Potential for IRS vibration issues if not maintained.
Known Issues Engine:
Spark plug blow-out on 5.0L HO engines (requiring thread inserts), potential for oil leaks, fuel injector issues.
Known Issues HVAC:
Leaking heater cores, AC compressor failures, blend door actuator issues.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Mercury, a division of Ford Motor Company, was positioned as a premium brand, offering a balance of style, comfort, and performance.
Model Evolution
Model Evolution:
The 1991 Cougar marked the second year of the sixth generation, which was a significant departure from earlier models, adopting the MN12 platform for improved handling and a more European sports coupe aesthetic.
Model Evolution Mn12 Platform:
The MN12 platform was a significant engineering effort by Ford, featuring a much stiffer chassis and sophisticated suspension compared to previous front-wheel drive personal luxury coupes.