How to Replace the Alternator in a Mercury Cougar

The alternator in a Mercury Cougar operates various accessories in the vehicle by transmitting an electrical current while the engine is running. The alternator assembly frequently includes a voltage regulator that maintains a constant voltage level. If your headlights become dimmer while driving or your battery keeps running down, you may need to replace the alternator.

Instructions

1

Determine which alternator your Mercury Cougar will need. You'll want to be sure the new alternator is compatible with your Cougar's engine. There have been many different vehicles made under the Mercury Cougar label. Models made from 1967 to 1970 were equipped with 289 cubic inch (ci), 302 ci, 351 ci, 390 ci, 427 ci and 428 ci engines. Models built from 1970 to 1973 used 351 ci and 429 ci engines.

2

Look at the next generations of the Mercury Cougar. Models made from 1974 to 1976 used a 351 ci, 400 ci or 460 ci engine. Models manufactured from 1977 to 1979 had 302 ci, 351 ci and 400 ci engines. Engine options for 1980 to 1988 models include a 140 ci, 255 ci, 302 ci, 2.3 L or 3.8 L engine.

3

Examine the most recent versions of the Mercury Cougar. Models built from 1989 to 1997 are equipped with a 3.8 L, 4.6 L or 5.0 L engine. The last generation was made from 1999 and 2002 and came equipped with a 2.0 L Zetec or 2.5 L Duratec engine.

4

Disconnect the negative battery cable with a socket wrench. Remove the air intake resonators, air cleaner-to-throttle body tube and mass air flow sensor. Remove the terminal nut from the alternator and unplug the electrical connectors and remove the cables. Raise the vehicle and release the tensioner for the drive belt so you can remove the drive belt from the alternator.

5

Remove the alternator's mounting bracket with a socket wrench and lower the vehicle. Remove the power steering pressure hose bracket from the engine lifting eye. Take out the mounting bolts from the alternator and remove the alternator.

6

Install the new alternator and tighten the mounting bolts with your fingers. Replace the power steering hose bracket and tighten its retaining nut to between 70 and 106 inch pounds with a torque wrench. Raise the vehicle so you can install the alternator's mounting bracket and torque the retaining bolts to between 15 and 22 foot pounds. Release the tensioner for the drive belt and install it over the alternator pulley.

7

Lower the vehicle and torque the alternator mounting bolts to between 15 and 22 ft. lbs. Install the cable and electrical connectors for the alternator. Torque the terminal nut to between 80 and 97 inch pounds Install the air cleaner-to-throttle body tube, mass airflow sensor, and air intake resonators. Connect the negative battery cable with a socket wrench.