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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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- Component Locations
- Wiring Diagrams
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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 3.0 V6 GAS
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BRAKE SERVICE PROCEDURES FOR 1991 Ford Aerostar AUTOMOBILES
DISC BRAKES, FORD -> Ford Sliding Calipers -> CALIPER OVERHAUL
Vehicle: 1991 Ford Aerostar 4.0 V6 GAS
- Remove caliper and linings.
- Drain brake fluid from caliper housing, then position housing in a vise.
- Pad area between piston(s) and caliper bridge, then apply compressed air to caliper fluid port to remove piston(s). If piston is seized and cannot be forced from caliper, tap lightly around cylinder bore area while applying air pressure. Use caution when applying air pressure, as piston(s) may develop considerable force from pressure build-up.
- Remove and discard molded rubber boot(s) and square cut seal(s) from caliper assembly.
- Thoroughly clean piston(s) and caliper assembly using ...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1991 Ford Aerostar AUTOMOBILES
Ford Motor Co. Light Trucks, SUVs & Vans -> Fuel Pressure Relief -> Gasoline Fuel Injected Engines Except Escape, Freestar, Mariner, Monterey, Villager, 2005-06 Aviator, Explorer & Mountaineer, 2005-06 Expedition & Navigator & 2004-06 F150 & Mark LT
Vehicle: 1991 Ford Aerostar 3.0 V6 GAS
The fuel system remains under high pressure even when the engine is not running. This residual pressure must be relieved before servicing the fuel system. To avoid injury or fire, release pressure from the fuel system before disconnecting any fuel line.
The fuel system pressure must be relieved prior to disconnecting fuel lines to prevent accidental spray of fuel.
After the battery ...
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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
Starter, Replace
Vehicle: 1991 Ford Aerostar 3.0 V6 GAS
- Disconnect battery ground cable.
- Raise and support vehicle, if required.
- Disconnect electrical connector or solenoid relay wire from starter motor.
- Remove starter motor attachi...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1991 Ford Aerostar AUTOMOBILES
Ford Motor Co. Trucks -> Electronic Throttle Control ->
Vehicle: 1991 Ford Aerostar 4.0 V6 GAS
Electronic throttle displays when the system has malfunctioned and the engine has defaulted to a limp-home operation. On vehicles equipped with ...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1991 Ford Aerostar AUTOMOBILES
Radiator, Replace
Vehicle: 1991 Ford Aerostar 3.0 V6 GAS
- Disconnect negative battery cable at battery.
- Drain cooling system into a suitable container.
- Detach radiator hose at bottom right of radiator and position aside.
- Remove upper radiator hose and position aside.
- Disconnect transmission cooler lines ...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1991 Ford Aerostar AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 1991 Ford Aerostar 3.0 V6 GAS
- Loosen adjustment and pivot bolts.
- On models equipped with automatic tensioners,lift tensioner by rotating it counterclockwise.
- On all models, remove old belts.
- Install new belts, ensure proper belt groove contact.
- On models less automatic tensioners, adjust belt tension as follows:
- Install a suitable belt tension gauge tool, ...
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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 Components Diagram for 1991 Ford Aerostar 3.0 V6 GASComponents on diagram: |
 Engine Compartment 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 4.0 V6 GAS Wiring DiagramComponents on diagram: |
 1991 Ford Aerostar 3.0 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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