1994 Mercury Villager Water Pump REMOVAL AND INSTALLATION

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Filed Under (Mercury) by admin on 03-04-2011

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Water Pump Removal 1. Drain the cooling system. Refer to Section 03-03. 2. Disconnect the battery ground cable (14301) . 3. Remove the generator drive belt, water pump and power steering pump drive belt, and the A/C compressor drive belt (if equipped). Refer to Section 03-05. 4. Raise and support the vehicle. 5. Use Strap Wrench D85L-6000-A or equivalent to hold the water pump pulley (8509) while removing the four water pump pulley bolts. 6. Remove the water pump pulley from the water pump (8501) . 7. Remove the crankshaft pulley (6312) . Refer to the procedure in this section 8. Remove the five lower engine front cover bolts and the lower engine front cover (6019) . NOTE: Make a note of the location of the one water pump bolt with the threads in the bolt head for ease of installation. 9. Remove the six water pump bolts. 10. Remove the water pump . Installation NOTE: Ensure the mating surfaces between the water pump and the cylinder block (6010) are cleaned of any sealant material. 1. Install a continuous 2.0-3.0mm (0.079-0.118 inch) wide bead of Gasket Maker E2AZ-19562-B or equivalent meeting Ford specification WSK-M2G348-A5, on the water pump and position the water pump on the cylinder block . NOTE: Refer to the note made during removal for the location of the bolt with the threads in the bolt head. 2. Install the six water pump bolts. Tighten the water pump bolts to 16-21 Nm (12-15 lb-ft). 3. Install the crankshaft pulley . Refer to the procedure in this section. 4. Position the water pump pulley on the water pump and install the four water pump pulley bolts. 5. Use Strap Wrench D85L-6000-A or equivalent to hold the water pump pulley , and tighten the four water pump pulley bolts to 16-21 Nm (12-15 lb-ft). 6. Install the lower engine front cover and the five lower engine front cover bolts. Tighten the five lower engine front cover bolts to 3-5 Nm (27-44 lb-in). 7. Lower the vehicle. 8. Install and adjust the generator drive belt, water pump and power steering pump drive belt, and the A/C compressor drive belt (if equipped). Refer to Section 03-05. 9. Connect the battery ground cable . 10. Fill the cooling system. Refer to Section 03-03. 11. Start the engine (6007) and check for leaks.

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1999 Mercury Cougar Idle Air Control (IAC) Valve REMOVAL AND INSTALLATION

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Filed Under (Mercury) by admin on 28-03-2011

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Idle Air Control (IAC) Valve Removal 1. Disconnect the vacuum line from the exhaust gas recirculation valve. 2. Disconnect the idle air control (IAC) valve electrical connector. 3. Detach the wiring harness from the IAC valve stud. 4. Disconnect the vacuum supply lines from the upper intake manifold. 5. Remove the IAC valve. 6. Remove and discard the IAC valve gasket. Installation 1. NOTE: Install a new IAC valve gasket. To install, reverse the removal procedure.

1997 Mercury Villager Cooling System, Draining, Filling and Bleeding

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Filed Under (Mercury) by admin on 08-03-2011

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WARNING: THE ELECTRIC COOLING FAN MAY COME ON AT ANY TIME WHEN THE IGNITION SWITCH IS IN THE ON POSITION. If the coolant has not been changed in the last 36 months, or 48,000 km (30,000 miles), or if the inspection reveals hoses, gaskets, or other components requiring service or replacement, the coolant must be drained and discharged, or saved for reuse, depending on its condition. For a vehicle with a rear heater, set the rear blower switch to 4 and the rear temperature control knob to the full WARM position. 1. For vehicles equipped with manual A/C-heater, turn the ignition switch to the ON position and set the front temperature control panel selectors in the following positions: The front blower switch to 4. The front temperature control knob to the full WARM position. The rear control switch to the 4 position. The mode selector switches to any mode except OFF. 2. For vehicles equipped with electronic automatic temperature control (EATC), turn the ignition switch to the ON position and perform the following procedures: Turn the blower motor control to HI. Press the TEMP button to the maximum temperature setting. Turn the rear control switch to the 4 position. Turn the mode selector switches to any mode except OFF. 3. Turn the ignition switch (11572) OFF. 4. Remove the RH engine and transmission splash shield (6776). 5. NOTE: Do not use a galvanized drain pan if the coolant is going to be reused. Position a drain pan under the radiator (8005). 6. Open the radiator draincock (8115) at the bottom of the radiator inlet tank (8079). 7. CAUTION: Do not allow coolant to contact the drive belts (8620) or they will be damaged. Remove the radiator cap (8100) from the filler neck. If the system is hot and pressurized, carefully release the pressure before fully opening the radiator cap. 8. Use an Allen wrench to loosen the radiator air relief plug three turns. Do not remove the radiator air relief plug.

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1998 Mercury Villager Transmission Range (TR) Switch REMOVAL AND INSTALLATION

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Filed Under (Mercury) by admin on 06-03-2011

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Transmission Range (TR) Switch Removal 1. Disconnect the 2-pin and 8-pin transmission range (TR) switch connectors. 2. Raise and support the vehicle. 3. Remove the six engine and transmission splash shield bolts, engine and transmission splash shield screw and the engine and transmission splash shield (6776) . 4. Remove the shift cable and bracket nut, and the shift cable and bracket (7E395) from the manual shift linkage rod. 5. Remove the three TR switch bolts from the TR switch. 6. Remove the TR switch from the transaxle. Installation To install, reverse the removal procedure. Adjust the TR switch. Refer to the procedure in this section. Tighten the TR switch bolts to 3 Nm (27 lb-in).

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1999 Mercury Cougar Rear Strut and Spring Assembly REMOVAL AND INSTALLATION

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Filed Under (Mercury) by admin on 04-03-2011

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Removal All vehicles 1. Remove the wheel and tire. For additional information, refer to Section 204-04. Vehicles with rear drum brakes 2. Disconnect the brake tube. 1. Clamp the flexible brake hose. 2. Disconnect the brake tube union. 3. Remove the retaining clip. 4. Detach the flexible brake hose. Vehicles with rear disc brakes 3. Detach the flexible brake hose and the brake pad wear sensor wiring loom (if equipped) from the strut and spring assembly. 4. Disconnect the brake pad wear sensor electrical connector (if equipped). 5. Detach the anti-lock brake system (ABS) sensor and wiring loom. All Vehicles 6. Detach the stabilizer bar connecting link and bushing from the front arm. 7. Detach the rear arm from the wheel spindle. 8. Detach the tie-bar from the wheel spindle. 9. Detach the front arm from the wheel spindle. 10. Remove the wheel spindle to strut and spring assembly pinch bolt. 11. CAUTION: Secure the wheel spindle to prevent damage to the parking brake cable and brake hose (disc brake vehicles only). Detach the wheel spindle from the strut and spring assembly. 12. Detach the strut and spring assembly from the crossmember. 1. Raise the strut and spring assembly on a jack. 2. Detach the strut and spring assembly from the crossmember. 13. Remove the strut and spring assembly.