Ford Aerostar repair manuals - exclusive information on Ford Aerostar repair: the detailed description of works and all necessary diagrams for all Ford Aerostar models with 2.3l, 2.9l, 3.0l and 4.0l engines.
| Ford Aerostar 2.3 | 100 hp | 2.3L | 1986-1987 |
| Ford Aerostar 2.9 | 115 hp | 2.9L | 1987-1997 |
| Ford Aerostar 3.0 | 135 hp | 3.0L | 1987-1997 |
| Ford Aerostar 3.0 | 147 hp | 3.0L | 1987-1997 |
| Ford Aerostar 3.0 Long | 135 hp | 3.0L | 1987-1997 |
| Ford Aerostar 4.0 | 155 hp | 4.0L | 1987-1997 |
| Ford Aerostar 4.0 Long 4WD | 155 hp | 4.0L | 1987-1997 |
Table of contents:
- General Information;
- Body;
- Frame and Mounting;
- Engines: 2.3L Lima SOHC inline-4, 2.9L Cologne OHV V6, 3.0L Vulcan OHV V6, Cologne OHV V6;
- Suspension;
- Driveline;
- Brake;
- Transmissions: A4LD Ford 4-speed automatic, 4R44E Ford 4-speed automatic, 4R55E Ford 4-speed automatic, 5R55E Ford 5-speed automatic, TK5 Toyo-Kogyo (Mazda) 5-speed manual, M5OD Mazda 5-speed manual;
- Clutch;
- Exhaust;
- Fuel;
- Steering;
- Climate Control;
- Gauge and Warning Device;
- Battery and Charging;
- Audio;
- Lighting;
- Electrical Power Supply.
For example: Timing Cover Removal and Installation from Ford Aerostar repair manuals: Engines.
Removal:
Disconnect negative battery terminal and move out of the way. Remove air cleaner fresh air tube. Drain cooling system and crankcase. Remove cooling fan. Refer to Ford Aerostar repair manuals: Accessory Drive. Loosen water pump hub bolts. Loosen and remove accessory drive belts. Refer to Ford Aerostar repair manuals: Accessory Drive. Remove water pump pulley. Remove auxiliary heater coolant tube (if equipped) retaining nut from water pump stud bolt. Remove lower tube retaining bracket bolt from cylinder block. Move assembly out of way. Remove alternator adjusting arm and the brace to throttle body attaching stud. Move alternator assembly out of the way. Remove four air conditioner compressor bolts (if equipped). Wire tie compressor out of the way. Remove air conditioner bracket. Remove crankshaft pulley and damper as outlined. Remove water pump if required. Disconnect lower radiator hose and heater hose. Refer to Ford Aerostar repair manuals: Engine Cooling. Remove oil pan assembly and discard old gasket. Disconnect oil level sensor (if equipped) before pan removal. Remove timing cover to cylinder block attaching bolts.
Carefully remove timing cover from cylinder block. Discard old gasket.
Installation:
Clean cylinder block mating surface. Clean timing cover gasket surface carefully. Replace crankshaft seal as outlined under Crankshaft Pulley/Damper/Front Oil Seal in this section. Align new timing cover gasket to cylinder block dowel pins. Install timing cover and attaching bolts. Refer to the Front Cover, Water Pump Fastener Chart under Water Pump Removal in this section. Note bolts that require pipe sealant on the chart. Tighten bolt numbers 1 thru 10 to 25 N-m (19 ft-lb) and bolt numbers 11 thru 15 to 10 N-m (7 ft-lb). Install oil pan and new gasket as outlined in this section. Tighten attaching bolts to 12 N-m (9 ft-lb). Install water pump as outlined (if removed). Install crankshaft damper, attaching bolt and pulley as outlined in this section. Install lower radiator hose and heater hose. Refer to Ford Aerostar repair manuals: Engine Cooling. Install air conditioner bracket, compressor and brace (if equipped) as outlined in Ford Aerostar repair manuals: Body/Electrical Manual. Install alternator assembly, bracket, oil fill tube support and throttle body brace as outlined. Install auxiliary heater coolant tube bracket to water pump stud bolt. Hand-tighten retaining nut. Install lower tube bracket bolt to cylinder block. Tighten as outlined. Install water pump pulley and accessory drive belts as outlined. Tension belts to specification. Refer to Ford Aerostar repair manuals: Accessory Drive. Install cooling fan and shroud as outlined in Ford Aerostar repair manuals: Engine Cooling. Fill and bleed cooling system with proper coolant mixture. Fill crankcase with specified amount and viscosity of engine oil. Connect negative battery terminal. Install air cleaner fresh air hose. Run engine and check for oil and coolant leaks.
from Ford Aerostar repair manuals
