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Chuck
Chuck, ASE Certified Technician
Category: Mercury
Satisfied Customers: 2100
Experience:  33 Years experience,Ford Senior Master,ASE Master,L1 Advanced Engine Performance
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2000 mercury cougar: many problems likethis but not the solution

Resolved Question:

I have a 2000 mercury cougar thats burning up alternators. I've heard many problems like
this but not the solution, can you help
Submitted: 4 years ago.
Category: Mercury
Expert:  Chuck replied 4 years ago.

There is a technical service bulletin out that may be your concern here. Here is a copy of it.

 

Printable View (48 KB)
TSB
00-25-6
  • CHARGING SYSTEM - HEADLAMPS, INSTRUMENT CLUSTER, RADIO OR INTERIOR LIGHTS FLICKER WHEN COLD - VEHICLES EQUIPPED WITH 2.5L ENGINE ONLY
  • ELECTRICAL - HEADLAMPS, INSTRUMENT CLUSTER, RADIO OR INTERIOR LIGHTS FLICKER WHEN COLD - VEHICLES EQUIPPED WITH 2.5L ENGINE ONLY
Publication Date: DECEMBER 4, 2000

MERCURY:1999-2000 COUGAR

ISSUE:

Some vehicles equipped with a V6 engine may exhibit a flickering condition of the headlamp, instrument cluster, radio, and interior lights during engine start-up and may continue during the first several minutes of engine idle. After several minutes, the flickering will subside but may not completely diminish. This may be caused by excessive electrical resistance in the battery voltage sensing circuit. Vehicle operation is not affected by this condition.

ACTION:

Reroute the battery sense line from the engine compartment power distribution box to the B+ terminal on the alternator. Refer to the following Service Procedure for details.

SERVICE PROCEDURE

  1. Verify condition.
  2. Disconnect battery ground.
  3. Disconnect EVAP emissions line at back of engine (Figure 1).
  4. Remove battery voltage sensing/alternator fuse (circuit 30-BA8) from the engine compartment power distribution box (fuse 7 for vehicles built before 5/24/1999 and fuse 2 for vehicles built after 5/24/1999).
  5. Raise vehicle on hoist. Refer to appropriate year Workshop Manual, Section 100-01.
  6. Disconnect battery cable at B+ terminal, -12A522- harness connector and single wire stator connector from alternator.
  7. Push wire harness up toward top of engine.
  8. Lower vehicle down to ground.
  9. Pull harness out on top of engine for access.
  10. Take the battery voltage sensing/alternator wire (circuit 30-BA8 red) out of the harness bundle.
  11. Measure 100mm (4") from connector and cut wire.
  12. Splice the 100mm (4") wire with Wire 1S8Z-14A411-AA (6.3mm (1/4") eyelet terminal pigtail) using wire splicing procedure outlined in TSB 99-22-2 and fold back and shrink wrap the harness side of the cut wire.
  13. If L-shaped plastic shield is on the battery cable, untape and remove.
  14. Slide eyelet terminal through rubber boot on battery cable such that the new terminal is on the bottom (Figure 2).
  15. Retape L-shaped shield back to battery cable.
  16. Put excess wire length of spliced wire (circuit 30-BA8) into protective sleeve and tape to secure.
  17. Push wire assemblies down toward alternator.
  18. Reattach EVAP emissions line.
  19. Raise vehicle.
  20. Connect -12A522- harness and stator connector to alternator.
  21. Connect battery cable and new terminal to B+ stud (new terminal on stud first) and torque nut to 8.0 ±1.2 N-m(70 ±10 lb-in).
  22. Lower vehicle.
  23. Connect battery ground cable.
  24. Verify repair.


PART NUMBERPART NAME
1S8Z-14A411-AAEyelet Terminal Pigtail Wire - 6.3mm (1/4")

 

 

graphic

 

 

graphic

 

Here is the wiring schematic,I have circled the circuit in question

 

graphic

 

Chuck, ASE Certified Technician
Category: Mercury
Satisfied Customers: 2100
Experience: 33 Years experience,Ford Senior Master,ASE Master,L1 Advanced Engine Performance
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