Mercury Cougar, XR-7 Hardtop & Convertible 1969 Shop Manual | PDF Download

Looking after a 1969 Mercury Cougar takes the right information, and this shop manual has plenty of it. Over 1,400 pages of step-by-step procedures, measurements and torque settings that suit DIY owners and professional technicians alike.

Convertible top repairs, hidden headlight service, Cobra Jet engine rebuilds, 4-speed gearbox work and sun roof adjustments are covered, alongside all the usual brake, steering and tune-up jobs.

Models covered

• Mercury Cougar Hardtop
• Mercury Cougar Convertible
• Mercury Cougar XR-7 2-Door Hardtop
• Mercury Cougar XR-7 Convertible

Engines

• 351 V8
• 390 V8
• 428 V8 (including the Cobra Jet and Ram Air)

Transmissions

• 3-speed manual
• 4-speed manual
• Automatic

What’s included

Engine

• Engine removal and installation
• Cylinder head removal, overhaul and installation
• Valves, valve springs, push rods and hydraulic lifters
• Valve clearance adjustment
• Camshaft removal and installation
• Timing chain and front cover, front oil seal replacement
• Crankshaft, main bearings and connecting rod bearings
• Pistons, piston pins and rings
• Cylinder block cleaning and inspection
• Oil pump, oil pan and oil filter
• Intake and exhaust manifolds
• Engine mounts
• Flywheel and clutch pilot bushing
• Compression test, vacuum test, camshaft end play
• Crankcase ventilation system
• Thermactor emission control system tests (428)
• Engine specifications and torque figures

Ignition and tune-up

• Points and condenser replacement and adjustment
• Distributor, cap, rotor and coil testing and overhaul
• Ignition timing and timing mark locations
• Spark plugs and spark plug wires

Fuel system

• Carburetor overhaul and adjustment (2-barrel and 4-barrel, including Holley and Autolite)
• Fuel pump testing
• Fuel tank and fuel lines
• Air cleaner service
• Accelerator pump and throttle linkage

Cooling and exhaust

• Radiator and radiator hoses
• Thermostat testing and replacement
• Fan, fan belt and fan drive
• Cooling system pressure test and cleaning
• Exhaust pipes, mufflers and mounting brackets

Clutch, manual and automatic transmissions

• Clutch adjustment, removal and installation
• 3-speed and 4-speed manual transmission overhaul
• Gear shift linkage adjustment
• Automatic transmission overhaul, fluid checks, drain and refill
• Band and linkage adjustments
• Engine idle speed check
• Fluid leak diagnosis

Driveshaft and rear axle

• Driveshaft balance and angle checks
• Universal joint overhaul
• Rear axle removal, overhaul and installation
• Pinion bearing preload and ring gear backlash
• Gear tooth contact patterns
• Differential and axle shaft service
• Limited-slip differential testing
• Rear axle ratio codes

Brakes

• Disc brake service
• Drum brake service
• Brake adjustment
• Master cylinder and wheel cylinder overhaul
• Power brake booster
• Hydraulic system bleeding
• Brake pedal height and travel checks
• Parking brake adjustment

Suspension, steering and wheels

• Front end inspection and lubrication
• Caster, camber and toe-in adjustment
• Ball joints and front springs
• Shock absorber checks
• Power steering pump and steering gear service
• Steering columns and linkage
• Steering wheel spoke position adjustment
• Wheel balancing, tire service and wheel bearings

Electrical

• Starter motor testing and overhaul
• Alternator and regulator testing
• Battery service
• Headlight system and alignment
• Hidden headlight covers: motor, reservoir, vacuum tests and adjustment
• Instrument panel, gauges and clusters
• Turn signals, emergency flasher and horns
• Windshield wipers and washers
• Wiring diagrams, fuses and circuit protection

Heating, ventilation and comfort

• Heater core, hoses and blower motor
• Control cables and vacuum actuators
• Defroster nozzles and vents
• Speed control: adjustment, testing and repair
• Radio and stereo tape player service

Body and interior

• Door removal, trim panels and window regulators
• Door lock and handle service
• Side window mechanisms
• Windshield and back window replacement
• Grille, bumpers and exterior mouldings
• Seats, interior trim and headlining
• Roof outside cover
• Sliding sun roof: alignment, drive motor, cables and drain tubes

Convertible top

• Top adjustments
• Fabric top and back window replacement
• Hold-down clamps and weatherstripping
• Lift cylinders and hydraulic system bleeding

Servicing and identification

• Lubrication chart and service intervals
• Maintenance schedule
• Pre-delivery checks
• Body, paint, trim, engine, transmission and rear axle codes
• Specifications, torque figures and special service tools

Please Note: This manual covers all 1969 Ford, Mercury and Lincoln range of passenger cars.