Cougar 1999 (08.1998-01.2001): Mechanical Repairs
General
Body & interior
Choose Sections to see everything in a chapter, or a chapter title to start at its first page.
1 General Information › 100 Service Information11 pages
100-00 General Information › Description and Operation4 pages
- 100-01 Identification Codes › Description and Operation › Identification Codes
100-04 Noise, Vibration and Harshness › Description and Operation4 pages
- Noise, Vibration and Harshness (NVH)
Diagnosis and Testing3 pages
2 Chassis125 pages
204 Suspension32 pages
204-00 Suspension System - General Information5 pages
- Specifications
Diagnosis and Testing4 pages
- Suspension System
General Procedures3 pages
204-01 Front Suspension10 pages
- Specifications
Description and Operation9 pages
Diagnosis and Testing8 pages
- Front Suspension
204-02 Rear Suspension12 pages
Description and Operation11 pages
- Rear Suspension
Diagnosis and Testing10 pages
- Specifications
204-04 Wheels and Tires5 pages
- Specifications
Description and Operation4 pages
- Safety Precautions
- Wheels and Tires
Diagnosis and Testing2 pages
205 Driveline › 205-04 Front Drive Halfshafts7 pages
- Specifications
Description and Operation6 pages
Diagnosis and Testing5 pages
- Front Drive Halfshafts
Removal and Installation4 pages
- Front Drive Halfshafts
206 Brake System53 pages
206-00 Brake System - General Information6 pages
- Specifications
Description and Operation5 pages
- Brake System
Diagnosis and Testing4 pages
- Brake System
General Procedures3 pages
206-03 Front Disc Brake6 pages
- Specifications
Description and Operation5 pages
- Front Disc Brake
Diagnosis and Testing4 pages
- Front Disc Brake
Removal and Installation3 pages
206-04 Rear Disc Brake6 pages
- Specifications
Description and Operation5 pages
Diagnosis and Testing4 pages
- Rear Disc Brake
Removal and Installation3 pages
- Rear Disc Brake
206-05 Parking Brake and Actuation5 pages
- Specifications
Description and Operation4 pages
- Parking Brake
Diagnosis and Testing3 pages
- Parking Brake
Removal and Installation2 pages
206-06 Hydraulic Brake Actuation11 pages
Description and Operation10 pages
- Hydraulic Brake Actuation
Diagnosis and Testing9 pages
- Hydraulic Brake Actuation
Removal and Installation8 pages
- Brake Pedal and Bracket - LHD, Vehicles With: Manual Transaxle
- Brake Pedal and Bracket - RHD, Vehicles With: Manual Transaxle
- Brake Pedal and Bracket - LHD, Vehicles With: Automatic Transaxle
- Brake Master Cylinder
- Brake Pedal and Bracket - RHD, Vehicles With: Automatic Transaxle
- Brake Fluid Reservoir
- Brake Pedal Cross-Shaft Bearing - RHD
- Brake Pedal Cross-Shaft - RHD
- Specifications
206-07 Power Brake Actuation5 pages
- Specifications
Description and Operation4 pages
- Brake Booster
Diagnosis and Testing3 pages
- Power Brake System
Removal and Installation2 pages
206-09A Anti-Lock Control9 pages
- Specifications
Description and Operation8 pages
- Anti-Lock Control
Diagnosis and Testing7 pages
206-09B Anti-Lock Control - Traction Control › Description and Operation5 pages
- Anti-Lock Control - Traction Control
Diagnosis and Testing4 pages
- Anti-Lock Control - Traction Control
Removal and Installation3 pages
211 Steering System33 pages
211-00 Steering System - General Information7 pages
- Specifications
Description and Operation6 pages
- Steering System
Diagnosis and Testing5 pages
211-02 Power Steering9 pages
- Specifications
Description and Operation8 pages
- Power Steering
Diagnosis and Testing7 pages
- Power Steering
General Procedures6 pages
211-03 Steering Linkage5 pages
- Specifications
Description and Operation4 pages
Diagnosis and Testing3 pages
- Steering Linkage
Removal and Installation2 pages
- Steering Linkage
211-04 Steering Column8 pages
- Specifications
Description and Operation7 pages
Diagnosis and Testing6 pages
- Steering Column
211-05 Steering Column Switches › Description and Operation4 pages
- Steering Column Switches
Diagnosis and Testing3 pages
- Steering Column Switches
Removal and Installation2 pages
3 Powertrain291 pages
303 Engine152 pages
303-00 Engine System - General Information29 pages
Description and Operation28 pages
- Engine
Diagnosis and Testing27 pages
- Engine
General Procedures26 pages
- Camshaft Bearing Journal Diameter
- Camshaft End Play
- Camshaft Bearing Journal Clearance
- Camshaft Surface Inspection
- Crankshaft Main Bearing Journal Clearance
- Camshaft Lobe Lift
- Crankshaft End Play
- Cylinder Bore Out-of-Round
- Piston Pin to Bore Diameter
- Piston Inspection
- Piston Diameter
- Piston Ring End Gap
- Piston to Cylinder Bore Clearance
- Piston Pin Diameter
- Piston Ring-to-Groove Clearance
- Connecting Rod Cleaning
- Connecting Rod Large End Bore
- Valve Stem Diameter
- Valve Spring Free Length
- Valve Clearance - 2.5L
- Flywheel Inspection
- Valve Seat Inspection
- Flywheel Clutch Surface Inspection
- Cylinder Head Distortion
- Exhaust Manifold Cleaning and Inspection
- Bearing Inspection
- Specifications
303-01A Engine - 2.0L22 pages
303-01B Engine - 2.5L33 pages
- Specifications
Description and Operation32 pages
Diagnosis and Testing31 pages
- Engine
In-vehicle Repair30 pages
- Upper Intake Manifold
- Lower Intake Manifold
- Valve Cover LH
- Valve Cover RH
- Crankshaft Pulley
- Crankshaft Front Seal
- Engine Front Cover
- Valve Springs
- Camshafts LH
- Valve Seals
- Camshafts RH
- Camshaft Seal
- Timing Chain
- Camshaft Followers
- Exhaust Manifold LH
- Exhaust Manifold RH
- Cylinder Head LH
- Cylinder Head RH
- Oil Cooler
- Crankshaft Rear Seal
- Oil Pan
- Engine Front Mount
Removal8 pages
- Engine - Vehicles With: Manual Transaxle
- Engine - Vehicles With: Automatic Transaxle
Disassembly6 pages
- Engine
Disassembly and Assembly of Subassemblies5 pages
- Cylinder Head
- Piston
Assembly3 pages
- Engine
303-03 Engine Cooling16 pages
- Specifications
Description and Operation15 pages
- Engine Cooling
Diagnosis and Testing14 pages
303-04A Fuel Charging and Controls - 2.0L7 pages
- Specifications
Description and Operation6 pages
Diagnosis and Testing5 pages
- Fuel Charging and Controls
303-04B Fuel Charging and Controls - 2.5L5 pages
Description and Operation4 pages
- Fuel Charging and Controls
Diagnosis and Testing3 pages
- Fuel Charging and Controls
Removal and Installation2 pages
- Specifications
303-05 Accessory Drive5 pages
- Specifications
Description and Operation4 pages
- Accessory Drive
Diagnosis and Testing3 pages
- Accessory Drive
Removal and Installation2 pages
303-06 Starting System8 pages
Description and Operation7 pages
- Starting System
Diagnosis and Testing6 pages
- Starting System - Vehicles Built Up To: 05-1999
- Starting System - Vehicles Built From: 05-1999
Removal and Installation4 pages
- Starter Motor - 2.0L
- Starter Motor - 2.5L
Disassembly and Assembly2 pages
- Specifications
303-07A Engine Ignition - 2.0L3 pages
- Specifications
Description and Operation2 pages
303-07B Engine Ignition - 2.5L3 pages
- Specifications
Description and Operation2 pages
303-08 Engine Emission Control5 pages
Description and Operation4 pages
- Engine Emission Control
Diagnosis and Testing3 pages
- Engine Emission Control
Removal and Installation2 pages
- Specifications
303-13 Evaporative Emissions5 pages
- Specifications
Description and Operation4 pages
Diagnosis and Testing3 pages
- Evaporative Emissions
Removal and Installation2 pages
- Evaporative Emissions
303-14A Electronic Engine Controls - 2.0L5 pages
Description and Operation4 pages
- Electronic Engine Controls
Diagnosis and Testing3 pages
- Electronic Engine Controls
Removal and Installation2 pages
- Specifications
303-14B Electronic Engine Controls - 2.5L6 pages
- Specifications
Description and Operation5 pages
- Electronic Engine Controls
Diagnosis and Testing4 pages
- Electronic Engine Controls
Removal and Installation3 pages
307 Automatic Transmission-Transaxle47 pages
307-01 Automatic Transmission-Transaxle35 pages
- Specifications
Description and Operation34 pages
- Transaxle Description
Diagnosis and Testing33 pages
- Diagnostic Strategy
- Preliminary Inspection
- Diagnostics
- Diagnosis By Symptom
General Procedures29 pages
- Transmission Fluid Cooler and Tubes - Backflushing and Cleaning
In-vehicle Repair28 pages
- Transmission Fluid Drain and Refill
- Transmission Fluid Pan, Gasket and Filter
- Turbine Shaft Speed (TSS) Sensor
- Halfshaft Seal LH
- Halfshaft Seal RH
- Main Controls
- Vehicle Speed Sensor (VSS)
- Transmission Range (TR) Sensor
- Output Shaft Speed (OSS) Sensor
Removal19 pages
- Transaxle
Disassembly18 pages
- Transaxle
Disassembly and Assembly of Subassemblies17 pages
- Torque Converter Insert Check
- Low-Reverse Piston
- Chain Sprockets
- Torque Converter Housing
- Final Drive Carrier and Differential Assembly
- Forward-Coast-Direct Clutch Cylinder and Reverse Clutch Drum - Assembly
- Forward One-Way Clutch
- Forward-Coast-Direct Clutches
- Low One-Way Clutch Assembly
- Main Control Valve Body
- Transaxle Case
- Pump Assembly
- Reverse Clutch
- Torque Converter One-Way Clutch Check
- Planetary Gearsets and Chain Drive Parts
Assembly2 pages
307-02 Transmission-Transaxle Cooling4 pages
- Specifications
Description and Operation3 pages
Diagnosis and Testing2 pages
- Transaxle Cooling
307-05 Automatic Transmission-Transaxle External Controls8 pages
- Specifications
Description and Operation7 pages
- External Controls
Diagnosis and Testing6 pages
- External Controls
General Procedures5 pages
308 Manual Transmission-Transaxle, Clutch and Transfer Case55 pages
308-00 Manual Transmission-Transaxle and Clutch - General Information16 pages
- Specifications
Description and Operation15 pages
- Manual Transaxle and Clutch
Diagnosis and Testing14 pages
- Manual Transaxle and Clutch
General Procedures13 pages
- Clutch Master Cylinder Check
- Clutch Disc Check
- Clutch Pedal Inspection
- Clutch Pedal Freeplay Adjustment
- Clutch Pressure Plate Check
- Clutch Slave Cylinder Check
- Flywheel Runout Check
- Clutch System Bleeding
- Release Hub and Bearing Check
- Pilot Bearing Check
- Gearshift Cable Adjustment
Removal and Installation2 pages
308-01 Clutch4 pages
Description and Operation3 pages
- Clutch
Diagnosis and Testing2 pages
- Specifications
308-02 Clutch Controls5 pages
- Specifications
Description and Operation4 pages
Diagnosis and Testing3 pages
- Clutch Controls
Removal and Installation2 pages
- Clutch Controls
308-03 Manual Transmission-Transaxle24 pages
- Specifications
Description and Operation23 pages
- Manual Transaxle
Diagnosis and Testing22 pages
- Manual Transaxle
General Procedures21 pages
- Drain Procedure
- Fill Procedure
- Bearing Check
In-vehicle Repair18 pages
- Halfshaft Seal
- Vehicle Speed Sensor (VSS) - 2.0L
- Transaxle LH Support Insulator
- Vehicle Speed Sensor (VSS) - 2.5L
- Transaxle RH Support Insulator
- Transaxle Rear Support Insulator - 2.5L
- Transaxle Rear Support Insulator - 2.0L
Removal11 pages
- Transaxle - 2.0L
- Transaxle - 2.5L
Disassembly9 pages
- Transaxle
Disassembly and Assembly of Subassemblies8 pages
- Input Shaft
- Output Shaft
- Synchronizers
- Differential
- Selector Mechanism
Assembly3 pages
- Transaxle
Installation2 pages
308-06 Manual Transmission-Transaxle External Controls6 pages
- Specifications
Description and Operation5 pages
- External Controls
Diagnosis and Testing4 pages
- External Controls
Removal and Installation3 pages
309 Exhaust System › 309-00 Exhaust System9 pages
Description and Operation8 pages
- Exhaust System
Diagnosis and Testing7 pages
- Specifications
310 Fuel System28 pages
310-00 Fuel System - General Information › Description and Operation5 pages
- Fuel System
Diagnosis and Testing4 pages
- Fuel System
General Procedures3 pages
310-01 Fuel Tank and Lines9 pages
- Specifications
Description and Operation8 pages
- Fuel Tank and Lines
Diagnosis and Testing7 pages
310-02 Acceleration Control5 pages
- Specifications
Description and Operation4 pages
Diagnosis and Testing3 pages
- Acceleration Control
Removal and Installation2 pages
- Acceleration Control
310-03 Speed Control9 pages
- Specifications
Description and Operation8 pages
- Speed Control
Diagnosis and Testing7 pages
4 Electrical121 pages
412 Climate Control System44 pages
412-00 Climate Control System - General Information12 pages
- Specifications
Description and Operation11 pages
- Climate Control System
Diagnosis and Testing10 pages
- Climate Control System
General Procedures9 pages
412-01 Air Distribution and Filtering › Description and Operation4 pages
- Air Distribution and Filtering
Diagnosis and Testing3 pages
- Air Distribution and Filtering
Removal and Installation2 pages
412-02 Heating and Ventilation7 pages
Description and Operation6 pages
Diagnosis and Testing5 pages
- Heating-Defrosting
- Specifications
412-03 Air Conditioning12 pages
- Specifications
Description and Operation11 pages
- Air Conditioning
Diagnosis and Testing10 pages
412-04 Control Components9 pages
- Specifications
Description and Operation8 pages
- Control Components
Diagnosis and Testing7 pages
413 Instrumentation and Warning Systems19 pages
413-00 Instrument Cluster and Panel Illumination › Diagnosis and Testing2 pages
413-01 Instrument Cluster › Description and Operation4 pages
413-06 Horn5 pages
Description and Operation4 pages
- Specifications
413-08 Information and Message Center › Description and Operation3 pages
Diagnosis and Testing2 pages
- Information and Message Center
413-09 Warning Devices › Description and Operation3 pages
413-13 Parking Aid › Description and Operation2 pages
414 Battery and Charging System15 pages
414-00 Charging System - General Information › Description and Operation3 pages
- Charging System
Diagnosis and Testing2 pages
414-01 Battery, Mounting and Cables7 pages
- Specifications
Description and Operation6 pages
Diagnosis and Testing5 pages
- Battery
Removal and Installation4 pages
- Battery and Cables
414-02 Generator and Regulator5 pages
415 Information and Entertainment Systems9 pages
- 415-00 Information and Entertainment System - General Information › Diagnosis and Testing › Audio System
415-01 Audio Unit › Description and Operation3 pages
- Audio System
Removal and Installation2 pages
- 415-02 Antenna › Description and Operation › Antenna
417 Lighting16 pages
417-01 Exterior Lighting12 pages
- Specifications
Description and Operation11 pages
- Exterior Lighting
Diagnosis and Testing10 pages
- Headlamps
- Stoplamps
- Turn Signal and Hazard Lamps
- Parking, Rear and License Plate Lamps
- Fog Lamps
- Reversing Lamps
General Procedures4 pages
- Headlamp Adjustment
- Headlamp Masking
Removal and Installation2 pages
417-02 Interior Lighting › Description and Operation2 pages
417-04 Daytime Running Lamps (DRL) › Description and Operation2 pages
418 Electrical Distribution › 418-00 Module Communications Network › Description and Operation4 pages
- Communications Network
Diagnosis and Testing3 pages
419 Electronic Feature Group14 pages
419-01A Anti-Theft - Active › Description and Operation4 pages
419-01B Anti-Theft - Passive › Description and Operation6 pages
419-10 Multifunction Electronic Modules › Description and Operation4 pages
5 Body and Paint193 pages
501 Body and Paint186 pages
501-00 Body System - General Information › Description and Operation4 pages
501-02 Front End Body Panels6 pages
Description and Operation5 pages
- Front End Body Panels
General Procedures4 pages
- Hood Alignment
Removal and Installation3 pages
- Specifications
501-03 Body Closures2 pages
501-05 Interior Trim and Ornamentation10 pages
Description and Operation9 pages
- Specifications
501-08 Exterior Trim and Ornamentation2 pages
501-09 Rear View Mirrors › Description and Operation5 pages
- Rear View Mirrors
Diagnosis and Testing4 pages
501-10 Seating16 pages
Description and Operation15 pages
- Seats
Diagnosis and Testing14 pages
- Specifications
501-11 Glass, Frames and Mechanisms10 pages
Description and Operation9 pages
- Glass, Frames and Mechanisms
Diagnosis and Testing8 pages
- Specifications
501-12 Instrument Panel and Console › Description and Operation5 pages
501-14A Handles, Locks, Latches and Entry Systems12 pages
- Specifications
Description and Operation11 pages
501-14B Handles, Locks, Latches and Entry Systems › Description and Operation4 pages
- Handles, Locks, Latches and Entry Systems
Diagnosis and Testing3 pages
501-16 Wipers and Washers8 pages
- Specifications
Description and Operation7 pages
- Wipers and Washers
Diagnosis and Testing6 pages
- Wipers and Washers
General Procedures5 pages
501-17 Roof Opening Panel10 pages
- Specifications
Description and Operation9 pages
- Roof Opening Panel
Diagnosis and Testing8 pages
- Roof Opening Panel - Vehicles Built Up To: 05-1999
- Roof Opening Panel - Vehicles Built From: 05-1999
General Procedures6 pages
501-19 Bumpers6 pages
- Specifications
Description and Operation5 pages
- Bumpers
Removal and Installation4 pages
501-20A Safety Belt System6 pages
Description and Operation5 pages
- Safety Belt System
Diagnosis and Testing4 pages
- Safety Belt System
Removal and Installation3 pages
- Specifications
501-20B Supplemental Restraint System13 pages
- Specifications
Description and Operation12 pages
501-25 Body Repairs - General Information26 pages
- Specifications
Description and Operation25 pages
- Description and Usage of Body Repair Literature
- Symbols
- Environmental Regulations
- Health and Safety Precautions
- Body Construction
- Diagnosis and Damage Evaluation
- Body Sheet Metal
- Establish Repair Method
- Tools and Equipment for Body Repairs
- Alignment Check
- Complete Panel Replacement-Partial Replacement
- Straightening
- Corrosion Damage-Corrosion Repair
- Corrosion Prevention
- Cutting Technique
- Sealer, Underbody Protection Material and Adhesives
- Panel Beating Technique and Smart Repairs
- Paintless Dent Removal
- Plastic Repairs
- Joining Techniques
- Special Repair Techniques
- Impact of Insufficient Repair Quality
- Water Leaks
- Wind Noise
- Noise, Vibration and Harshness
501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks › Description and Operation4 pages
- Body and Frame
General Procedures3 pages
501-27 Front End Sheet Metal Repairs › Removal and Installation2 pages
501-28 Roof Sheet Metal Repairs4 pages
- Specifications
Removal and Installation3 pages
501-29 Side Panel Sheet Metal Repairs › Removal and Installation6 pages
501-30 Rear End Sheet Metal Repairs9 pages
501-36 Paint - General Information16 pages
- Specifications
Description and Operation15 pages
- Description and Usage of Paint Literature
- Symbols
- Environmental Regulations
- Health and Safety Precautions
- Factory Paint Application
- Paintwork Defects and Damage
- Tools and Equipment for Paint Repairs
- Refinishing Materials
- Additional Materials
- Paint Repairs
- Painting Plastic Parts
- Spot Repairs
- Corrosion Prevention
- Color Identification and Chromatics
- Tips and Tricks
502 Frame and Mounting › 502-00 Uni-Body, Subframe and Mounting System7 pages
- Specifications
Description and Operation6 pages
- Frame Assembly
General Procedures5 pages