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1991 Ford E-250 Econoline CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Ford REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Section
- Component Locations
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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 E-250 Econoline 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 E-250 Econoline automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 1991 Ford E-250 Econoline AUTOMOBILES
A/C & Cooling System Maintenance -> Ford Motor Co. -> 1990-93 Ford Bronco, E-Series, Expedition, F-Series & F-Super Duty
Vehicle: 1991 Ford E-250 Econoline 5.8 V8 GAS
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BRAKE SERVICE PROCEDURES FOR 1991 Ford E-250 Econoline AUTOMOBILES
DISC BRAKES, FORD -> General Information -> SERVICE PRECAUTIONS -> BLEEDING DISC BRAKES -> BRAKE DISC SERVICE -> BRAKE LININGS -> BRAKE ROUGHNESS -> GENERAL PRECAUTIONS -> INSPECTION OF CALIPER
Vehicle: 1991 Ford E-250 Econoline Club Wagon 7.3 V8 DIESEL
BRAKE LININGS
Remove both front wheels and inspect the brake discs, calipers and linings. (Wheel bearings should be inspected at this time and repacked if necessary).
Do not get any oil or grease on the linings. It is recommended that both front wheel sets be replaced whenever a respective shoe and lining is worn or damaged. Inspect and, if necessary, replace rear brake linings also.
If the caliper is cracked or fluid leakage through the casting is evident, it must be replaced as a unit.
BRAKE ROUGHNESS
The most common cause of brake chatter on disc brakes is a variation in thick...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1991 Ford E-250 Econoline 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 E-250 Econoline HD 5.8 V8 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 E-250 Econoline AUTOMOBILES
DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble -> Single Cardan, Flange Yoke -> Single Cardan, Slip Yoke
Vehicle: 1991 Ford E-250 Econoline Super 4.9 L6 GAS
Single Cardan, Slip Yoke
Disassemble
Do not, under any circumstance, clamp the shaft in the jaws of a vise or similar holding fixture. Denting or localizing fracture can result, causing shaft failure during vehicle operation. Place the shaft on a suitable workbench. Do not damage the tube. If components are not marked and installed incorrectly, driveline imbalance can occur.
- Index-mark the shaft components.
- Remove and discard all four snap rings.
- Clamp bearing cup removal tool No. 205-086 or equivalent in a vise.
- If necessary, use a pair of pliers to remove a bearing cup t...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1991 Ford E-250 Econoline AUTOMOBILES
Alternator, Replace
Vehicle: 1991 Ford E-250 Econoline Club Wagon 7.3 V8 DIESEL
- Disconnect battery ground cable.
- Remove air cleaner assembly, if required.
- Disconnect wire harness connectors from voltage regulator.
- Remove accessory drive belt.
- Remove alter...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1991 Ford E-250 Econoline AUTOMOBILES
Ford Motor Co. Trucks -> Low Fuel Level Warning Lamp ->
Vehicle: 1991 Ford E-250 Econoline Super 5.8 V8 GAS
When fuel level drops below a predetermined level, the CHECK GAUGE indicator should light. The CHECK GAUGE indicator shoul...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1991 Ford E-250 Econoline AUTOMOBILES
Radiator, Replace
Vehicle: 1991 Ford E-250 Econoline 5.8 V8 GAS
- Disconnect negative battery cable at battery.
- Drain cooling system into a suitable container.
- Remove overflow tube from coolant recovery bottle and detach it from radiator shroud.
- Remove four shroud attaching bolts and position it over fan.
- Remove lower radiator hose and position aside.
- Remove upper radiator hose and p...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1991 Ford E-250 Econoline AUTOMOBILES
Serpentine Drive Belt, Replace -> Automatic Tension -> Manual Tension
Vehicle: 1991 Ford E-250 Econoline Super 5.0 V8 GAS
Automatic Tension
- Install suitable 5/16 inch closed end wrench on tensioner pulley bolt, then lift tensioner arm away from belt. Do not use socket and ratchet.
- Remove belt, slowly release tensioner. Do not allow tensioner to snap back, as damage may result.
- Reverse procedure to install.
Manual Tension
- Loosen accessory adjustment bolt and pivot bolt.
- Remove belt.
- Reverse procedure to install, adjust belt tension as follows:
- Lo...
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COMPONENT LOCATION DIAGRAMS FOR 1991 Ford E-250 Econoline AUTOMOBILES
Component location diagrams for most 1991 Ford E-250 Econoline cars and light trucks sold in the U.S. from 1990+.
 Engine Component Locations Diagram for 1991 Ford E-250 Econoline Super 4.9 L6 GASComponents on diagram: |
 Body Component Locations Diagram for 1991 Ford E-250 Econoline 5.8 V8 GASComponents on diagram: |
CLICK HERE TO GET FULL ACCESS TO 1991 Ford E-250 Econoline PARTS/COMPONENTS LOCATION DIAGRAMS!
WIRING DIAGRAMS FOR 1991 Ford E-250 Econoline AUTOMOBILES
OEM drawn wiring diagrams for most 1991 Ford E-250 Econoline cars and light trucks sold in the U.S.
 1991 Ford E-250 Econoline 4.9 L6 GAS Wiring DiagramComponents on diagram: |
 1991 Ford E-250 Econoline Club Wagon 5.8 V8 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1991 Ford E-250 Econoline AUTOMOBILES
OEM TSB listings for most 1991 Ford E-250 Econoline cars and light trucks sold in the U.S. from 1985+.
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Document: MERCON ATF IS BRING REPLACED BY MERCON V ATF AS A SERVICE FLUID Vehicle: 1991 Ford E-250 Econoline 5.0 V8 GAS Auto Systems: |
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Document: TRANSMISSION - 4R100/E40D - TORQUE CONVERTER ACCESS EXTERNAL DUST PLUG MAY BECOME DISLODGED Vehicle: 1991 Ford E-250 Econoline 5.0 V8 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1991 Ford E-250 Econoline AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1991 Ford E-250 Econoline 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 E-250 Econoline 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 E-250 Econoline 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 E-250 Econoline 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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