1991 Ford Aerostar Service and Repair Manual

This factory service and repair manual for the 1991 Ford Aerostar takes in the 4.0L and 3.0L OHV V6 engines, both naturally aspirated and gasoline-fueled, and four body styles: the two-door mini passenger van, the two-door mini cargo van, the two-door extended passenger van and the three-door mini passenger van. Eight trims are covered, Base, Eddie Bauer, XL, XL Plus, XL Sport, XLT, XLT Plus and XLT Sport. The procedures, specifications, torque values, wiring diagrams and diagnostics are organized by system, which is the practical way to handle a lineup with this many body and trim combinations.

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
• 3-door mini passenger van

Trims covered

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

Known issues on the 1991 Aerostar. Four recalls are on federal record. An ignition switch that could develop an internal short and overheat in the steering column, an automatic transmission park pawl that may not engage the park gear, and a rear sofa seat belt anchorage bar that could not sustain its required load are the subjects of three of them. Owners have filed 260 complaints with NHTSA, led by the electrical system, then the power train and the service brakes. Wiring diagrams, transmission procedures and brake specifications in this manual cover exactly those areas.