2002 Mercury Sable Service & Repair Manual Software

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🏷️ Basic Information Identification Make: Mercury Model: Sable Year: 2002 Codes Platform: DGS Platform (Ford CDW27 derived) 👋 Introduction Market Position Vehicle Segment: Mid-size Sedan/Wagon Brand Positioning: Mercury offered a...

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Stichworte: 2002 Car Cars Mercury Sable

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Beschreibung

🏷️ Basic Information

Identification

Make:

Mercury

Model:

Sable

Year:

Codes

Platform:

DGS Platform (Ford CDW27 derived)

👋 Introduction

Market Position

Vehicle Segment:

Mid-size Sedan/Wagon

Brand Positioning:

Mercury offered a slightly more upscale and styled alternative to Ford's mainstream offerings.

Competitive Analysis

Key Competitors:

Chevrolet Impala, Buick LeSabre, Toyota Camry, Honda Accord, Dodge Intrepid.

Key Features

Design Philosophy:

Comfort-oriented, spacious interior, smooth ride, distinctive styling for the Mercury brand.

Manual Value Proposition:

Provides comprehensive factory-level diagnostic and repair information, essential for maintaining and repairing the 2002 Mercury Sable.

📋 Manual Details

Coverage Areas

Diagnostic Procedures:

Comprehensive diagnostic procedures for all major systems.

Repair Procedures:

Detailed step-by-step repair procedures for mechanical and electrical components.

Maintenance Schedules:

Scheduled maintenance intervals and required fluid specifications.

Page Count

Estimated Pages:

1,500+

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

Software (CD-ROM/Digital Download)

📖 Manual Coverage

Systems Covered

Engine:

3.0L Vulcan V6 (2V OHV), 3.0L Duratec V6 (24V DOHC)

Transmission:

4-Speed Automatic (AX4N/AX4S)

Brakes:

Front Disc, Rear Drum / Front Disc, Rear Disc (ABS)

Suspension:

Front MacPherson Struts, Rear Multi-link Beam Axle

Steering:

Rack and Pinion, Power Assisted

Electrical:

Complete wiring diagrams, charging system, starting system, lighting, accessories, instrument cluster.

Body:

Exterior body panels, interior trim, climate control, body hardware.

Procedures Included

Engine Overhaul:

Complete engine overhaul procedures, including component specifications.

Transmission Service:

Transmission fluid changes, filter replacement, internal component repair and adjustment.

Brake System Repair:

Brake pad/shoe replacement, caliper/wheel cylinder overhaul, ABS diagnostics.

Suspension Component Replacement:

Strut replacement, control arm replacement, ball joint replacement, alignment procedures.

Fuel System Diagnosis:

Fuel pump testing, injector cleaning, fuel pressure diagnosis.

Cooling System Service:

Radiator and hose replacement, thermostat replacement, coolant flush and fill.

Exhaust System Repair:

Muffler, catalytic converter, and pipe replacement.

HVAC System Service:

Evaporator, condenser, heater core replacement, refrigerant recharge.

Diagnostics Troubleshooting:

Systematic troubleshooting guides for common and uncommon problems.

Technical Depth

Depth:

Comprehensive factory-level technical information suitable for professional technicians and advanced DIY enthusiasts.

Diagnostic Troubleshooting Level:

Includes diagnostic trouble codes (DTCs), pinpoint tests, and fault tree analysis.

Torque Specifications:

Detailed torque specifications for all critical fasteners.

Alignment Specifications:

Wheel alignment specifications for front and rear suspension.

Wiring Diagrams:

Full color, detailed electrical wiring diagrams for all circuits.

📊 Manual Specifications

File Format

Software Platform:

Proprietary software, typically requiring a PC with Windows OS compatibility.

Searchability:

Full text search capabilities for quick information retrieval.

Illustration Quality:

High-resolution diagrams, illustrations, and exploded views.

Print Quality

Print Capability:

Printable pages for offline use and on-the-job reference.

Binding Type

Binding:

N/A (Software)

Paper Type

Paper:

N/A (Software)

⚙️ Engine Specifications

Primary Engine

Engine 1 Displacement:

3.0 Liters (182 cu in)

Engine 1 Configuration:

V6, 2-Valve Overhead Valve (OHV) - Vulcan

Engine 1 Bore X Stroke:

89.0 mm x 79.5 mm (3.50 in x 3.13 in)

Engine 1 Horsepower:

150 hp @ 5200 rpm

Engine 1 Torque:

185 lb-ft @ 3700 rpm

Optional Engine

Engine 2 Displacement:

3.0 Liters (182 cu in)

Engine 2 Configuration:

V6, 4-Valve per cylinder Overhead Cam (DOHC) - Duratec

Engine 2 Bore X Stroke:

89.0 mm x 79.5 mm (3.50 in x 3.13 in)

Engine 2 Horsepower:

155 hp @ 5200 rpm

Engine 2 Torque:

185 lb-ft @ 4700 rpm

Fuel System

Fuel Induction:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline

Fuel Octane Requirement:

87 Octane Recommended

🔧 Transmission

Standard

Transmission Type:

4-Speed Automatic

Transmission Model:

AX4N / AX4S

Features

Transmission Control:

Electronic Control with Overdrive

Transmission Fluid Type:

Mercon V Automatic Transmission Fluid (ATF)

📐 Dimensions

Exterior

Wheelbase:

112.9 inches (2868 mm)

Length:

201.4 inches (5115 mm)

Width:

74.4 inches (1890 mm)

Height:

56.0 inches (1422 mm)

Weights

Curb Weight Sedan:

3,521 - 3,684 lbs (1597 - 1671 kg)

Curb Weight Wagon:

3,765 - 3,872 lbs (1708 - 1756 kg)

Cargo

Cargo Volume Sedan:

16.7 cu ft

Cargo Volume Wagon:

81.1 cu ft (max with rear seats folded)

🛡️ Safety Features

Ratings

NHTSA Front Crash Test Driver:

NHTSA Front Crash Test Passenger:

NHTSA Side Impact Front Seat:

NHTSA Side Impact Rear Seat:

Active Features

Standard on most trims (optional on base models)

Traction Control:

Optional

Passive Features

Airbags Front:

Dual front airbags

Airbags Side:

Optional front side-impact airbags

Seat Belts:

Front 3-point height-adjustable, rear 3-point belts

💡 Technology Features

Infotainment

Audio System:

Optional premium audio systems, CD player, cassette player, AM/FM radio.

Climate Control:

Manual or optional automatic climate control.

Driver Assistance

Cruise Control:

Standard on most trims.

Keyless Entry:

Optional keyless entry system.

Connectivity

Connectivity Features:

Limited by modern standards; primarily focused on audio and basic vehicle functions.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 miles or 6 months (conventional oil); 7,500 miles or 6 months (synthetic oil).

Air Filter Replacement:

Every 30,000 miles or 2 years.

Spark Plug Replacement Vulcan:

Every 100,000 miles (Long-life Spark Plugs)

Spark Plug Replacement Duratec:

Every 100,000 miles (Long-life Spark Plugs)

Transmission Fluid Change:

Every 50,000 - 100,000 miles (depending on driving conditions, consult manual)

Fluid Specifications

Engine Oil Type:

API SG, SH, SJ or ILSAC GF-2 SAE 5W-30 (all temperatures)

Engine Oil Capacity:

4.5 US quarts (4.3 L) with filter for both 3.0L engines

Coolant Type:

Ford Premium Engine Coolant (Green) or equivalent

Coolant Capacity:

Approx. 11.0 US quarts (10.4 L)

Known Issues

Common Issue Intake Manifold Gaskets:

Leaking plastic intake manifold gaskets (especially on Duratec engines).

Common Issue Transmission Harsh Shifting:

Harsh shifting or delayed engagement, often related to valve body issues or transmission fluid degradation.

Common Issue Idler Pulley:

Squealing or rattling noise from the idler pulley bearing on the Vulcan engine.

Common Issue Power Window Motors:

Failure of power window motors or regulators.

📚 Vehicle History

Brand Heritage

Mercury Brand Legacy:

Mercury was positioned as a premium division of Ford, offering stylish and comfortable vehicles.

Model Evolution

Third Generation Sable:

The 2002 model represents the third generation of the Mercury Sable, introduced for the 1996 model year and updated through the years.

Facelift Timing:

Received styling updates for the 1999 model year, influencing the 2002 version.

Production

Production Location:

Chicago Assembly Plant, Illinois, USA

Production Years:

1986-2005

🏆 Awards & Recognition

Recognitions

Safety Awards:

Received good ratings in NHTSA crash tests for its time.

Ratings

Consumer Reports Typicality:

Consumer Reports often rated the Sable average to below average for reliability compared to segment leaders.

Certifications

Manual Certification:

Derived from OEM factory service data, providing accurate and reliable repair procedures.