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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 3.0 V6 GAS
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BRAKE SERVICE PROCEDURES FOR 1991 Ford Aerostar AUTOMOBILES
ANTI-LOCK BRAKE SYSTEM, FORD -> COMPONENT REPLACEMENT -> 1990-91 Models -> COMPUTER MODULE -> EXCITER RING -> REAR ANTI-LOCK BRAKE SYSTEM (RABS) VALVE -> REAR ANTI-LOCK BRAKE SYSTEM SENSOR
Vehicle: 1991 Ford Aerostar 3.0 V6 GAS
All components are serviced as assemblies and should not be disassembled.
COMPUTER MODULE
1990-91 Models
- Disconnect battery ground cable.
- On all models, disconnect wiring harness from RABS module.
- On Bronco II, Ranger and Explorer models, remove module to instrument panel retaining screws behind center of instrument panel.
- On Aerostar models, remove module to instrument panel anti-skid plate retaining screws on lefthand side of engine cover under instrument panel.
- On E-Series models, remove parking brake actuator assembly as follows:
- Loosen adjusting nut at equalizer.
- From inside e...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1991 Ford Aerostar AUTOMOBILES
Ford Motor Co. Light Trucks, SUVs & Vans -> Fuel Filter Replacement -> Except Diesel Engines & Villager
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 has been disconnected and reconnected, some abnormal driveability symptoms may occur. The vehicle may need to be driven 10 miles or more while it relearns its adaptive strategy.
On model...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1991 Ford Aerostar AUTOMOBILES
DRIVESHAFT, Replace -> Front -> Install -> Rear -> Remove
Vehicle: 1991 Ford Aerostar 4.0 V6 GAS
Front
Remove
- Mark driveshaft and axle companion flanges as well as driveshaft boot and transfer case front output, so driveshaft can be reinstalled in same position.
- Release Oetiker low-profile clamp on driveshaft boot with boot clamp pliers tool No. D87P-1090-A or equivalent and free boot from transfer case.
- Remove axle snubber from beneath pinion.
- Remove four bolts retaining front driveshaft to front axle companion flange.
- Remove nuts from transmission mount studs in front crossmember.
- Raise (jack) transfer case so transmission mount studs are almost out of front crossmember.
- Slid...
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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 -> Air Bag Warning Lamp ->
Vehicle: 1991 Ford Aerostar 3.0 V6 GAS
This lamp should light for a approximately 6-8 seconds when the ignition is turned On as a bulb check. If the Air Bag warning ...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1991 Ford Aerostar AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 1991 Ford Aerostar 3.0 V6 GAS
Lower
- Drain cooling system into a suitable container.
- Reposition hose clamp at radiator outlet and remove hose.
- Reposition hose clamp at engine and remove hose.
- Remove hose from vehicle.
- Reverse procedure to install.
Upper
- Drain cooling syste...
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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 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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