1990 Ford Aerostar Service and Repair Manual

This factory service and repair manual for the 1990 Ford Aerostar covers two naturally aspirated gasoline V6 engines, the 4.0L and the 3.0L, both OHV designs. Three body styles are documented, the two-door mini passenger van, the two-door mini cargo van and the two-door extended passenger van, across six trims from Base and XL through XL Plus, XLT and XLT Plus to Eddie Bauer. Because the two V6s share a book, the procedures, specifications, torque values, wiring diagrams and diagnostics are separated by displacement wherever the figures differ.

Engines covered

• 4.0L V6 (245 cu in) — OHV, naturally aspirated, gasoline
• 3.0L V6 (182 cu in) — OHV, naturally aspirated, gasoline

Body styles covered

• 2-door mini passenger van
• 2-door mini cargo van
• 2-door extended passenger van

Trims covered

• Base
• Eddie Bauer
• XL
• XL Plus
• XLT
• XLT Plus

Known issues on the 1990 Aerostar. Seven recalls are on federal record for this van. Among them are a brake master cylinder whose secondary circuit could lose pressure in cold weather, lengthening pedal travel and stopping distance; a park pawl that may not fully engage the park gear; and a rear sofa seat belt anchorage bar that failed to hold the required load. Owners have filed 238 complaints with NHTSA, clustering on the electrical system, the power train and the service brakes. The brake procedures, transmission specifications and wiring diagrams in this manual line up directly with those three systems.