1996 FORD AEROSTAR service

277 %
*
[SV09300(ALL)08/95]
Fuel quality
*
[SV09450(ALL)06/95]
If you are experiencing starting, rough idle or
hesitation problems when the engine is cold, it
may be caused by fuel with low volatility. Try a
different brand of fuel. If the condition persists,
see your dealer or a qualified service technician.
*
[SV09455(ALL)08/95]
Using a high-quality fuel makes your vehicle
more responsive and maintains its good fuel
economy and emissions by:
*
[SV09460(ALL)08/95]
q
minimizing deposits in fuel injectors,
combustion chambers and on intake valves.
*
[SV09465(ALL)08/95]
q
assuring quick starting and smooth warm-up.
*
[SV09470(ALL)08/95]
q
protecting the fuel system from vapor lock in
very hot weather, which causes the engine to
hesitate or stall and makes restarts difficult.
*
[SV09475(ALL)08/95]
q
protecting your fuel system from rusting.
*
[SV09480(ALL)08/95]
q
preventing the fuel lines from freezing.
*
[SV09485(ALL)08/95]
q
preventing the fuel system from ªgumming
upº when your vehicle is not used for long
periods of time.
*
[SV09500(ALL)06/95]
It should not be necessary to add any
aftermarket products to your fuel tank if you
continue to use a high-quality fuel.
%*
[SV09600(ALL)04/95]
Gasolines for clean air
*
[SV09900(ALL)06/95]
Fuels in certain areas of the country are required
to contain oxygenates to improve air quality.
Common oxygenates are ethanol or grain alcohol
(blended at no more than 10%), methanol or
wood alcohol (blended at no more than 5% with
cosolvents and additives), and MTBE or methyl
tertiary butyl ether (blended at no more than
15%).
File:15cpsva.ex
Update:Tue Aug 29 17:51:51 1995

289 %
*
[SV20700(ALL)08/95]
Engine Coolant Drain and Flush
*
[SV20800(ALL)10/89]
To drain your vehicle's engine coolant:
*
[SV20900(ALL)03/94]
1. Turn off the engine and let it cool. Fully
depressurize the engine cooling system by
covering the radiator cap with a thick cloth
and turning it slowly counterclockwise to the
first stop. Step back while the pressure
releases.
*
[SV20950(ALL)05/90]
2. Remove the cap.
*
[SV21000(ALL)05/90]
3. Attach a small hose to the drain tube at the
bottom of the radiator.
*
[SV21200(ALL)05/90]
4. Let the engine coolant drain into a suitable
container. Disconnect the lower radiator hose
at the radiator connector and drain any
remaining engine coolant into a container.
*
[SV21225(ALL)05/94]
5. Reconnect the lower radiator hose and close
the radiator drain cock.
*
[SV21250(ALL)05/95]
Proper procedures for flushing the cooling
system can be found in theService Manual.
%*
[SV21300(ALL)08/95]
Engine coolant refill procedure
*
[SV21400(ALL)10/89]
After you have drained the engine cooling
system:
*
[SV21500(ALL)01/89]
1. Fill the radiator with a 50/50 mixture of the
specified engine coolant concentrate and
water. Allow several minutes for trapped air
to escape (bubble out) and for engine coolant
to flow through the radiator.
*
[SV21900(ALL)03/94]
2. Replace the radiator cap to its fully installed
position, then back off to the first stop. This
will prevent high pressure from building up
in the cooling system during this part of the
fill procedure.
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Update:Tue Aug 29 17:51:51 1995

304
*
[SV31968(ALL)03/95]
If you have whitewall tires that are difficult to
clean with regular detergent, use Ford Extra
Strength Whitewall Tire Cleaner or equivalent.
Follow the directions on the container and rinse
the tires with plenty of clean water.
%
*
[SV32100(ALL)03/95]
Battery
*
[SV32200(ALL)02/95]
Your vehicle may have a Motorcraft
maintenance-free battery. The Motorcraft
maintenance-free battery does not require
additional water during its life of service. The
vents are part of the cover and cannot be
removed. For longer, trouble-free operation, keep
the top of the battery clean and dry. Also, make
certain the battery cables are tightly fastened to
the battery terminals.
*
[SV32300(ALL)02/95]
If you see any corrosion on the battery cables or
terminals, remove the cables from the terminal
and clean them both with a wire brush. You can
neutralize the acid with a solution of baking
soda and water. Reinstall the cables when you
are done cleaning them, and apply a small
quantity of grease to the top of each battery
terminal to help prevent corrosion.
*
[SV32400(ALL)07/95]
Battery replacement
*
[SV32500(ALL)02/95]
If your original equipment battery requires
replacement (under warranty), it may in some
cases be replaced by a Motorcraft
low-maintenance battery. The low-maintenance
battery has removable vent caps for checking the
electrolyte level and for adding water, if needed.
*
[SV32600(ALL)07/95]
Check your battery's electrolyte level, at least
every 12 months or 12,000 miles (20,000 km), in
temperatures up to90ÊF (32ÊC) andmore often
in temperatures above90ÊF (32ÊC).Keep the
electrolyte in each cell up to the ªlevelº
indicator. Do not overfill the battery cell.
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Update:Tue Aug 29 17:51:51 1995

331
%*
[SV48600(ALL)03/95]
Emission Control System
*
[SV48700(ALL)05/95]
Your vehicle is equipped with a catalytic
converter which enables your vehicle to comply
with applicable exhaust emission requirements.
*
[SV48800(ALL)05/95]
To make sure that the catalytic converter and the
other emission control parts continue to work
properly:
*
[SV48900(ALL)01/95]
q
Use only unleaded fuel.
*
[SV49000(ALL)01/95]
q
Avoid running out of fuel.
*
[SV49100(ALL)01/95]
q
Do not turn off the ignition while your
vehicle is moving, especially at high speeds.
*
[SV49200(ALL)03/95]
q
Have the services listed in yourMaintenance
Schedule and Recordbooklet performed
according to the specified schedule.
*
[SV49300(ALL)05/95]
RWARNING
Do not park, idle, or drive your vehicle in
dry grass or other dry ground cover. The
emission system heats up the engine
compartment and exhaust system, which
can start a fire.
*
[SV49400(ALL)05/95]
RWARNING
On vehicles without original equipment
floor covering or insulation, do not let
passengers ride in your truck in a manner
that allows contact between skin and the
metal floor.
*
[SV49500(ALL)05/95]
Watch for fluid leaks, strange odors, smoke, loss
of oil pressure, the charge warning light, the
check engine light, or the temperature warning
light. These sometimes indicate that the emission
system is not working properly.
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Update:Tue Aug 29 17:51:51 1995

332
*
[SV49600(ALL)01/95]
Do not make any unauthorized changes to your
vehicle or engine. Changes that cause more
unburned fuel to reach the exhaust system can
increase the temperature of the engine or
exhaust system.
*
[SV49700(ALL)01/95]
By law, anyone who manufactures, repairs,
services, sells, leases, trades vehicles, or
supervises a fleet of vehicles is not permitted to
intentionally remove an emission control device
or prevent it from working. In some of the
United States and in Canada, vehicle owners
may be liable if their emission control device is
removed or is prevented from working.
*
[SV49800(ALL)02/92]
Never use a metal exhaust collector when you
service your vehicle. If the metal collector
contacts any of your vehicle's plastic trim or
bumper parts they could melt or deform.
*
[SV49900(ALL)01/95]
Do not drive your vehicle if it does not operate
properly. See your dealer if the engine runs on
for more than five seconds after you shut it off
or if it misfires, surges, stalls, or backfires.
%*
[SV50000(ALL)05/95]
Information about your vehicle's emission
control system is on the Vehicle Emission
Control Information decal located on or near the
engine. This decal identifies engine displacement
and gives some tune-up specifications.
%*
[SV50010(ALL)07/95]
Readiness for Inspection/Maintenance
Testing
*
[SV50020(ALL)07/95]
In some localities it may become a legal
requirement to pass an
Inspection/Maintenance (I/M) test of the
On-Board Diagnostic (OBD) II system. If the
vehicle's powertrain system or its battery has
just been serviced, the OBD II system is reset to
a not ready for I/M testing condition. To
prepare for I/M testing, the law specifies a
ªneed for additional mixed city and highway
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Update:Tue Aug 29 17:51:51 1995

333
driving to complete the checkº of the OBD II
system. As soon as all of the OBD II system
checks are successfully completed, the OBD II
system is set to the ready condition. The amount
of driving required to reach the ready condition
varies with individual driving patterns. To
complete this requirement in the minimum
amount of time, refer to the OBD II Drive Cycle
defined below. If the vehicle owner cannot or
does not want to do the additional driving
required by law, a service center can perform
this drive cycle as it would any other type of
repair work.
*
[SV50030(ALL)07/95]
OBD II Drive Cycle
*
[SV50040(ALL)06/95]
The following steps must be run in the order
shown. If any steps are interrupted, repeat the
preceding step. Any safe driving mode is
acceptable between steps.
*
[SV50050(ALL)06/95]
Always drive vehicle in safe manner according
to traffic conditions and obey all traffic laws.
[SV50055(ALL)08/95]
NOTE: When instructions read ªin drive,º use
the standard Overdrive gear. It is not
necessary to turn Overdrive off with
the OVERDRIVE OFF button. For more
information on Overdrive, refer to the
Automatic Overdrive Transmission
section of theDriving Your Aerostar
chapter.
*
[SV50060(ALL)07/95]
The engine must be warmed up and at
operating temperature before proceeding with
the drive modes of the following OBD II Drive
Cycle.
*
[SV50070(ALL)06/95]
1. Start the engine. Drive or idle (in neutral)
the vehicle for 4 minutes.
*
[SV50080(ALL)06/95]
2. Idle the vehicle in drive for 40 seconds.
*
[SV50090(ALL)07/95]
3. Accelerate the vehicle to 45 mph (70 km/h)
at 1/4 to 1/2 throttle for 10 seconds.
File:15cpsva.ex
Update:Tue Aug 29 17:51:51 1995

Index 359
Index
A
Accessory position on the ignition..... 61
Additives, engine oil.......... 282
Air bag supplemental restraint system . . . 26
and child safety seats.......... 34
description............. 26,28
disposal................ 32
driver air bag........... 26,28
indicator light............. 81
operation............... 28
proper seating............. 27
service and information labels...... 28
tone generator............. 31
wearing safety belts........... 27
Air cleaner filter
location............... 269
specifications............. 337
Air conditioning
auxiliary heater and air conditioner . . . 98
manual heating and air conditioning
system............... 92
Alcohol, in fuel............. 277
Antenna, radio
(see Electronic sound system) . . . 149, 182
Antifreeze (see Engine coolant)...... 284
Anti-lock brake system (ABS)
description.............. 193
see also Brake............ 193
Appeals (see Dispute settlement board) . . 248
Assistance (see Customer assistance) . . . 245
Audio system
(see Electronic sound system)..... 149
Autolamp system (see Headlamps) . . 102, 104
File:cpixa.ex
Update:Tue Aug 29 17:47:05 1995

360 Index
Automatic transmission
driving an automatic overdrive..... 188
fluid, adding............. 308
fluid, checking............ 307
fluid, refill capacities......... 335
fluid, specification........... 338
Axle
lubricant specifications......... 338
refill capacities............ 335
traction lok............201, 297
B
Backing up............... 188
Basic vehicle warranty........... 4
Battery................. 304
acid, treating emergencies.....225, 305
charging system warning light...... 81
disconnecting............. 228
how to service............ 304
jumping a disabled battery....... 225
maintenance-free........... 304
proper disposal, recycling....... 305
replacement, specifications....... 337
servicing............... 304
voltage gauge.............. 82
when storing your vehicle....... 344
Brake fluid............... 309
brake warning light........... 75
checking and adding......... 309
description.............. 309
specifications...........310, 338
Brakelamp, high-mount......... 106
Brakes................. 193
adjustment.............. 193
anti-lock............... 193
applying the brakes.......... 196
brake warning light........... 75
File:cpixa.ex
Update:Tue Aug 29 17:47:05 1995