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Cougar Technical Specifications and Duratec 2.5L V-6 Engine Information





The Duratec engine is a Cosworth casted engine. This is important if you are an F1 viewer. Cosworth makes some of the best engine in F1 and world class indy and GT class racing. Ford outsourced the engine design to Cosworth of England for production. This allowed extremely close tolerances and extremely high durability ratings, according to Cosworth near 1.2 million continuous miles. This is the reason for the "DURATEC" nomenclature. Combined with the powertrain in the cougar the combination is capable of much more power than what the engine is producing. The production cougar was kept under 190 HP to not step on the shoes of the Mustang. The Duratec engine is a DOHC 24 Valve engine with a chain driven timing system. The intake utilizes a Dual Stage Throttle system using two sets of runners. One short and one Long. The long runners are opened most of the time allowing good low end grunt. Then when the engine reaches a speed of 4400RPM the short runners open up allowing the second set of valves to open and thus allowing more air. When the second runners open, you feel it. The second condition that will allow both sets of intake runners to be open is WOT (wide open throttle.)The Duratec engine has been used in it's 2.5L fashion for Horsepower reaching 250HP. The engine is fully aluminum head and blocks and uses a bore x stroke of 82.3x79.5. The redline for the Duratec engine is 6800 continuous RPM's and fuel shut off occurs at 7400RPM. However with the right modifications, you can run the engine to a safe speed of 7200RPM's and have the fuel cut-off occur at 7800RPM, according to a Ford Service Technician I know. Just to add this in there for information, the Duratec engine is considered by Ford to be one of their best engines. If you doubt, look at it's record. It is used in Contour/Mystique line since 1995, it is used in the Taurus line as a 3.0L variant, the countour SVT as a 3.0L variant. Also it is used as the base engine for the Lincoln LS and the Jaguar S-Type named the AJ-V6 Engine. This proves that Ford has high hopes and ratings for the Duratec.

Cosworth Casted Intake
This is a close up of the Cosworth Close Tolerances casting process of the intake system. Some tolerance are at less than 2mm clearance between intake and exhaust. To put it in perspective. the best that Honda can do is 14mm.

Suspension Information
The suspension is a Macphearson Strut Front with a lower control arm and in the rear uses a Chapman struts lateral links, and trailing link. Both sides use Anti-roll bars and fully nitrogen pressurizes struts.


Braking System
The Cougar utilizies a combination of the standard Contour and SVT brakes. They use a larger 278mm x 24mm front rotor, but in combination with the standard size Contour ATE 2 pistion caliper that are held in place with slightly different caliper mounting brackets to clear the larger rotor's diameter. In the rear all "Sport Package" 6-cylinder and ABS-equipped 4-cylinder vehicles utilize 253mm x 20mm vented 1 pistion rear discs. Standard 4-cylinder cars and Non Sport 6 cylinders are equipped with 228mm x 45mm rear drums.


HEC (Hybrid Electric Cluster) Diagnostic Mode
On the 1999 and 2000 EEC-V Engine Management System, you can access the Diagnostic Mode by Pressing (RESET) and (UNITS) at the same time while turing on your car. Let go as the dials spin to the right. You scroll through the modes by pressing the (SELECT) Button

Test - (whats happening)

1. Gauge Sweep (5 seconds up 5 seconds down)

2. ROM Level (Revision of ROM software shows R12 or something like that dependant of version)

3. Indicator Bulbs and Display (all the little light bulbs light up)

4. NVM Level (checks the HEC (hybrid electric cluster) revision)

5. A/D Test (Battery, shows Voltage)

6. Port Test (HEC) Input/Output (Unknown)

7. Road Speed (shown in MPH or KPH)

8. Engine Speed (shown in RPMs)

9. Engine Coolant temp ( Shown in degrees F or C)

10. Guage Counts (displayed in Hexidecimal)
t (temp, shown in HEXIDECIMAL)
r (Tach RPMs, shown in HEXIDECIMAL)
s (speedo, shown in HEXIDECIMAL)
f (fuel guage, shown in HEXIDECIMAL)

11. Fuel Pulses (counts fuel pulses, shown in HEXIDECIMAL this relates to the MPG gauge in the cluster)

12. DTC (Diagnostic Trouble Codes) BELOW IS A LIST OF POSSIBLE CODES DISPLAYED

9201 - Fuel sender circuit failure
9204 - Fuel Sender short to ground
9257 - Climate control
9317 - Battery Voltage higher than 16V
9318 - Battery Voltage Lower than 10V
9342 - ECU defective
9359 - Ignition Run/ACC circuit failure
0115 - Engine coolant temperature (ECT) circuit malfunction.

PLEASE NOTE: These codes are very vague and unspecific. They are definitely NOT a substitute for an OBD-II code reader, and they do not cause Check Engine Lights. If you have a Check Engine Light, you must use an OBD-II code reader or equivalent to ascertain the source of the Check Engine Light.

CODES

There is a complete list of OBD-II diagnostic powertrain codes here. If your Check Engine Light has illuminated, your on-board computer will retain one or more of these codes, which will aid in troubleshooting.

Where to Buy Stuff:

Tousley Ford and Team Ford Parts Online for OEM replacement parts.

British American Transfer for upgraded suspension and engine parts, as well as European components.

Nautilus Performance Group for turbo kits and other performance upgrades.

3L Duratec for plug & play 3.0 builds and supercharger kits.


Cougar DataBase (register and post pictures)


If you're really into performance look into the 3L Section

3L engine Fitments - Courtesy of PuckPuck.. --

1999-2003 3.0L DOHC Duratec Engines only from the following vehicles swap with fairly little work.

Ford Taurus
Mercury Sable
Ford Escape
Mazda Tribute

1999-2003 3.0L DOHC Duratec Engines only from the following vehicles swap with some extra customizations needed

Lincoln LS
Jaguar S-Type
Mazda 6

Here are Specs on some of the engines...

2000 Ford Taurus - 3.0-liter 24v V6
· Horsepower (hp @ rpm):200 @ 5750
· Torque (lb.-ft. @ rpm):200 @ 4500

2003 Ford Taurus/Mercury Sable – 3.0-liter 24v V6
· Horsepower (hp @ rpm):200 @ 5650
· Torque (lb.-ft. @ rpm):200 @ 4400

2003 Ford Escape – 3.0-liter 24v V6
· Horsepower (hp @ rpm):201 @ 5900
· Torque (lb.-ft. @ rpm):196 @ 4700

2003 Mazda Tribute – 3.0-liter 24v V6
· Horsepower (hp @ rpm):200 @ 6000
· Torque (lb.-ft. @ rpm):200 @ 4750

More Work…

2003 Lincoln LS -- 3.0-liter dohc 24-valve V6
· Horsepower (hp @ rpm):280 @ 6000
· Torque (lb.-ft. @ rpm):286 @ 4000

2003 Jaguar S-Type -- 3.0-liter dohc 24-valve V6
· Horsepower (hp @ rpm):240 @ 6000
· Torque (lb.-ft. @ rpm): ????


MISC. SPECS
Model Line Overview
Model lineup: Cougar ($16,540); Cougar V-6 ($17,040)
Engines: 2.5-liter dohc 24v V6; 125-hp 2.0-liter dohc 16v inline-4
Transmissions: 5-speed manual; 4-speed automatic
Safety equipment (standard): dual front airbags standard; ABS optional
Basic warranty: 3 years/36,000 miles
Assembled in: Flat Rock, Michigan
Specifications As Tested
Model tested (MSRP): Cougar V-6 ($17,040)
Standard equipment: air conditioning, power windows, locks, and driver's seat, AM/FM/cassette stereo, rear spoiler

Price as tested (MSRP): $19,890
Layout: front-wheel drive
Engine: 2.5-liter dohc 24v V6
Horsepower (hp @ rpm): 170 @ 6250
Torque (lb.-ft. @ rpm): 165 @ 4250
Transmission: 5-speed manual
EPA fuel economy, city/hwy: 19/28 mpg
Wheelbase: 106.4 in.
Length/width/height: 185.0/69.6/52.2 in.
Track, f/r: 59.3/58.7 in.
Turning circle: 35.8 ft.
Seating capacity: 4
Head/hip/leg room, f: 37.8/NA/42.6 in.
Head/hip/leg room, r: 34.7/NA/33.2 in.
Cargo volume: 12.4 cu. ft.
Suspension, f: Independent
Suspension, r: Independent
Ground clearance: N/A
Curb weight: 2941 lbs.
Tires: P215/50VR16
Brakes, f/r: disc/disc with ABS
Fuel capacity: 16.0 gal.

1999 Cougar S CONCEPT ( not actually produced )







The 1999 Mercury Cougar S concept prototype is the product of Ford's Advanced Design and Special Vehicle engineering team. It is an impressive and aggressive package that would have made the Cougar S one of the hottest pieces of equipment in the rapidly expanding sport coupe market. Its unique body is sleeker, lower and wider than the production Cougar, with special lightweight front and rear fascias. Sitting one inch lower and with a front and rear track that is 3 inches wider, the Cougar S concept incorporates a comprehensive aerodynamic package for optimal performance. The concept's exterior presentation is a no-holds-barred performance package highlighted by the large rectangular air intake in the deep front air dam for improved cooling with fog lamps cleverly integrated into scoop shaped recesses. The sides of the concept experimented with extended rocker panel side skirts and curvaceous crisp wheel arches. The distinctively flared fenders cover large 18" specially built 2-piece 6-spoke alloy wheels wearing 235/45ZR-18 Michelin Pilot SX tires. Inside the wheels impressively large Brembo brakes from the SVT Contour demonstrate how seriously Mercury was taking its performance. With 13.1" front discs and 11" rears Cougar S has stopping power to match its uprated power and handling capabilities.

Matching the concept's increased horsepower and improved AWD handling characteristics required meticulous attention to detail from Ford's aerodynamicists. The Cougar S concept has two spoilers, one on the conventional decklid location and another that is integrated with the rear window header . At the rear a new fascia with integrated exhaust pipes flanked by rectangular air vents continues the front air dam's theme. A very Euro-style radio antenna on the windshield header gives a cosmopolitan touch that well suits the image of the Cougar S concept.

The interior features a pair of leather covered Recaro racing seats with unique materials throughout, in addition to the special steering wheel, alloy clutch brake and accelerator pedals. The functional changes are matched by unique graphics on the instrument cluster.





Had the Cougar S been put into production, it would have been a dream come true for "tuners and tweakers." The Cougar S is powered by a modified modular 24 valve V-6 Duratec prototype engine. This strong breathing engine at 3.0 liters is a half liter larger than the production counterpart. It is fed by a modified intake system that feeds cold air through a functional scoop at the base of the wind screen. With available SVT modifications, the motor is capable of over 400 horsepower. Mounted to the modular Duratec powerplant is a drive line taken from the all wheel drive Mondo prototype - A drive line developed in Europe for the Mondo but never put into production. A 5 speed MTX-75 viscous drive, limited slip manual transmission is specially designed to accommodate the drive line.

Even three and a half years after its introduction the Cougar S concept remains a timely expression of the trend toward hot sports coupes. The Cougar S concept is in essentially showroom condition, with excellent exterior paint and an unblemished interior. With Ford's decision to discontinue the production of the Mercury Cougar, the Cougar S concept is the final Cougar Concept.

Good luck, and you're in the right place for Cougar Modifications :)
 

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RE:-- Cougar's 101 --

Originally posted by: Bigoudi
Very nice! Definitely sticky material. :) Only thing I would change is the "Contour SVT as a 3.0L variant" at the end of the first paragraph...

Greg
One more thing... the Lincoln LS data, ex. HP & .lb-ft are incorrect for the 3.0 V6. They are ratings for the V8 model, the V6 was rated around 236 HP, 4 HP less then the Jaguar S type.
 

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This thread has been pruned and closed. If you have anything FACTUAL you would like to have added to this post, please PM one of the moderators of this section to have the info added.
 
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