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1991 Ford Aerostar CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Ford REPAIR SHOPS DON'T WANT YOU TO KNOW
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- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 1991 Ford Aerostar car and truck
repair procedures including Ford engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
your Ford Aerostar automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 1991 Ford Aerostar AUTOMOBILES
A/C & Cooling System Maintenance -> Ford Motor Co. -> 1990-93 Ford Aerostar, Bronco II & Explorer & 1990-94 Ranger
Vehicle: 1991 Ford Aerostar 4.0 V6 GAS
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BRAKE SERVICE PROCEDURES FOR 1991 Ford Aerostar AUTOMOBILES
POWER BRAKE UNITS, FORD -> Bendix Hydro-Boost Brake Booster -> BRAKE BOOSTER SERVICE -> INSTALLATION -> REMOVAL
Vehicle: 1991 Ford Aerostar 3.0 V6 GAS
The hydra-boost power brake booster is serviced as a unit.
REMOVAL
- With engine off, depress brake pedal several times to discharge the accumulator.
- Remove master cylinder from brake booster and position up and out of the way. Do not apply booster with master cylinder removed.
- Disconnect three hydraulic lines from booster, then disconnect input pushrod from brake pedal assembly, Fig. .
- Remove booster mounting nuts, then remove booster from vehicle. Do not carry booster by the accumulator and be careful not to drop booster on the accumulator. The snap ring on the accumulator shou...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1991 Ford Aerostar AUTOMOBILES
Ford Motor Co. Light Trucks, SUVs & Vans -> Fuel Filter Scheduled Maintenance -> 1985-93 Aerostar -> Normal Service -> Severe Service
Vehicle: 1991 Ford Aerostar 3.0 V6 GAS
Normal Service
Service as ...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1991 Ford Aerostar AUTOMOBILES
CV AXLE SHAFT, Replace -> Install -> Remove
Vehicle: 1991 Ford Aerostar 4.0 V6 GAS
Remove
- Remove front wheel cover/hub cover from wheel and tire and loosen lug nuts.
- Raise vehicle on a frame contact hoist.
- Remove wheel and tire, and hub retainer nut and washer. Discard hub retainer nut. It is a torque prevailing design and cannot be reused.
- Mark differential shaft flange in relation to halfshaft so they may be installed in their original position.
- Remove four bolts and disconnect halfshaft inboard joint from differential axle shaft flanges. Only four of the six bolts hold CV halfshaft to axle shaft. The other two bolts retain the spacer.
- Support end of shaft ...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1991 Ford Aerostar AUTOMOBILES
Alternator, Replace
Vehicle: 1991 Ford Aerostar 4.0 V6 GAS
- Disconnect battery ground cable.
- Remove air cleaner assembly, if required.
- Disconnect wire harness connectors from voltage regulator.
- Remove accessory drive belt.
- Remove alternator mounting bolts, then alternator from vehi...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1991 Ford Aerostar AUTOMOBILES
Ford Motor Co. Trucks -> Check Gauge Warning Lamp ->
Vehicle: 1991 Ford Aerostar 3.0 V6 GAS
This indicator should light if any of the following conditions appear:
- Engine oil pressure drops below approxi...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1991 Ford Aerostar AUTOMOBILES
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 1991 Ford Aerostar 4.0 V6 GAS
Inlet
- Drain cooling system into a suitable container.
- Reposition hose clamp at heater core and remove hose.
- Reposition hose clamp at engine and remove hose.
- Remove hose from vehicle.
- Reverse procedure t...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1991 Ford Aerostar AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 1991 Ford Aerostar 4.0 V6 GAS
- Raise tensioner by turning counterclockwise, then remove belt.
- Install new be...
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COMPONENT LOCATION DIAGRAMS FOR 1991 Ford Aerostar AUTOMOBILES
Component location diagrams for most 1991 Ford Aerostar cars and light trucks sold in the U.S. from 1990+.
 Engine Compartment Components Diagram for 1991 Ford Aerostar 4.0 V6 GASComponents on diagram: |
 Engine Components Diagram for 1991 Ford Aerostar 3.0 V6 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 1991 Ford Aerostar AUTOMOBILES
OEM drawn wiring diagrams for most 1991 Ford Aerostar cars and light trucks sold in the U.S.
 1991 Ford Aerostar 3.0 V6 GAS Wiring DiagramComponents on diagram: |
 1991 Ford Aerostar 4.0 V6 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1991 Ford Aerostar AUTOMOBILES
OEM TSB listings for most 1991 Ford Aerostar cars and light trucks sold in the U.S. from 1985+.
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Document: MERCON ATF IS BEING REPLACED BY MERCON V AS A SERVICE FLUID FOR SOME MANUAL TRANSMISSIONS Vehicle: 1991 Ford Aerostar 3.0 V6 GAS Auto Systems: |
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Document: MERCON ATF IS BRING REPLACED BY MERCON V ATF AS A SERVICE FLUID Vehicle: 1991 Ford Aerostar 3.0 V6 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1991 Ford Aerostar AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1991 Ford Aerostar cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 1991 Ford Aerostar cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 1991 Ford Aerostar cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 1991 Ford Aerostar cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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