1991 Mercury Capri Service and Repair Manual

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Factory-Grade Data

The 1991 Mercury Capri Service and Repair Manual is a practical, workshop-ready reference for maintenance, diagnostics, and repairs. Use it to troubleshoot symptoms, follow step-by-step procedures, verify specifications, and confirm wiring and connector locations before replacing parts.

Ideal for technicians and DIY owners, it supports everything from routine service to deeper mechanical and electrical work—including drivability, no-start, warning lights, overheating, brake and suspension issues, HVAC faults, and circuit testing.

Trims covered

  • Base Convertible 2-Door
  • XR2 Convertible 2-Door

Engines covered

  • 1.6L 1598CC 98Cu. In. l4 GAS DOHC Naturally Aspirated
  • 1.6L 1598CC 98Cu. In. l4 GAS DOHC Turbocharged

What’s inside

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

Why this manual matters

  • Faster diagnostics with system-based troubleshooting and wiring diagrams
  • Clear procedures and reference sections to reduce guesswork and rework
  • Helpful for maintenance planning and verifying parts/specs before repairs

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Vehicle Safety Data

1991 Mercury Capri Recalls & Complaints

NHTSA #91V00900008/01/1991Component: POWER TRAIN:AUTOMATIC TRANSMISSION:COOLING UNIT AND LINES

THE RUBBER TUBE THAT CONNECTS THE TRANSMISSION TO THE TRANSMISSION OIL COOLER (IN THE RADIATOR) MAY DISCONNECT CAUSING DISCHARGE OF FLUID.

Consequence

DISCHARGED TRANSMISSION FLUID MAY STRIKE THE EXHAUSTMANIFOLD OR THE EXHAUST PIPE AND RESULT IN A FIR

Remedy

INSTALL REVISED LINE AND CLAMPS TO IMPROVE LINE RETENTION TO THE TRANSMISSION.

NHTSA #92V08000002/06/1992Component: AIR BAGS

THE AIR BAG MODULES DO NOT MEET THE FORD SPECIFICATIONS FOR HIGH AMBIENT TEMPERATURE PERFORMANCE.

Consequence

AT HIGH AMBIENT INTERIOR VEHICLE TEMPERATURES ABOVE140 DEGREES, THE AIR BAG MAY TEAR AND MALFUNCTION

Remedy

REPLACE THE AIR BAG MODULES WITH MODULES THAT MEET SPECIFICATIONS.

TSB #623988

INFORMATION REGARDING TRANSMISSION FLUID USAGE CHARTS. *SLC

TSB #601010

RECOMMENDED GUIDELINES FOR TOWING BEHIND RECREATIONAL VEHICLES. *TT

TSB #612203

INFORMATION REGARDING THE NEW TRANSMISSION COOLER FLUSHER- SERVICE TIP. *MJS

TSB #6090087

INFORMATION ON IDENTIFYING NON-APPROVED / ALTERNATE REFRIGERANTS WHICH COULD CAUSE SAFETY, AND PERFORMANCE CONCERNS IF INSTALLED IN FORD A/C SYSTEMS. *TT

TSB #606420

FORD MOTOR COMPANY NOW RECOMMENDS SAE 5W-30 VISCOSITY GRADE FOR SERVICING ANY FORD GASOLINE-POWERED VEHICLE REGARDLESS OF MODEL YEAR. *TT

TSB #604059

FORD MOTOR COMPANY HAS RELEASED A NEW ELECTRICAL GREASE ( F8AZ - 19G208-AA ) TO REDUCE THE POSSIBILITY OF MOISTURE CORROSION AT THE TERMINALS. *YC

TSB #601312

INFORMATION ON A BUZZING OR RATTLE NOISE FROM THE EXHAUST SYSTEM. *TT

TSB #601290

INFORMATION ON TIRE COMPANY TELEPHONE NUMBERS FOR CUSTOMER ASSISTANCE. *YC

Showing the 8 most recent of 21 technical service bulletins on file with NHTSA.

20030710Component: AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULECrash reported1 injured

VEHICLE COLLIDED HEAD-ON WITH A POLE TRAVELING APPROXIMATELY 60MPH. CONSUMER STATES THAT DRIVER'S FRONT AIR BAG "EXPLODED", CRACKING THE FRONT WINDSHIELD, AND CAUSING INJURY TO DRIVER'S HEAD, CHIN,

20010716Component: AIR BAGS:FRONTALCrash reported1 injured

CONSUMER'S SON DROVE AND WAS INVOLVED IN A HEAD-ON COLLISION, AND AIR BAGS DID NOT DEPLOY. CONSUMER WAS SLIGHTLY INJURED. *AK

19950301Component: AIR BAGS:FRONTALCrash reported

AFTER COLLIDING HEAD ON WITH GUARD RAIL, AIR BAG DID NOT DEPLOY. TT

19960917Component: POWER TRAIN:AUTOMATIC TRANSMISSIONFire reported

ON THE FIRST OCCASION CONSUMER WAS DRIVING AND THE TRANSMISSION OIL LEAKED OUT OF THE CAR AND THE SECOND TIME CONSUMER WAS DRIVING AND CAR CAUGHT ON FIRE, NO ONE WAS HURT . PLEASE DESCRIBE .*AK CONS

19960724Component: ENGINE AND ENGINE COOLING:ENGINE:GASOLINEFire reported

ENGINE FIRE. *AW

Showing the 5 most serious of 33 complaints filed with NHTSA.

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