engine FORD AEROSTAR 1997 1.G Service Manual

226 %
*
[ER24660(ALL)02/96]
Removing jumper cables
*
[ER24670(ALL)02/96]
1.Always remove the jumper cables in the
reverse order.Remove the negative (S) end
of the jumper cable from the metallic surface
on the engine or frame of the disabled
vehicle.
*
[ER24680(ALL)03/96]
2. Remove the negative (S) cable from the
booster battery.
*
[ER24690(ALL)02/96]
3. Remove the positive (+) cable from the
booster battery.
*
[ER24692(ALL)02/96]
4. Remove the other end of the positive (+)
cable from the discharged battery.
*
[ER24694(ALL)02/96]
After the vehicle is started, let it idle for a while
to let the engine ªrelearnº its idle conditions.
Drive it around for a while with all electrical
accessories turned off to let the battery recharge.
Driveability may be deteriorated slightly until all
drive modes are ªrelearned.ºYou may need to
use a battery charger to fully recharge the
battery.
*
[ER24695(ALL)03/96]
If you need to replace your battery, seeBattery
in theMaintenance and Carechapter.
%
*
[ER24700(ALL)04/96]
Towing Your Vehicle
[ER24750(ALL)01/96]
The recommended method to tow your Aerostar
is with flatbed or wheel lift equipment.
However, slingbelt towing is acceptable. On
vehicles equipped with an under-vehicle spare
tire carrier, remove the tire assembly from the
carrier and store it in a secure area before
towing. For E-4WD vehicles, the 4-wheel drive
system must be disabled prior to towing. The
transmission must be in N (Neutral) and the
ignition switch must be in the OFF position to
disable the Electronic 4-Wheel Drive System.
File:10cpera.ex
Update:Thu Jun 6 14:45:00 1996

229
Maintenance and Care
%*
[MC00300(ALL)01/96]
Service Made Easy
*
[MC00400(ALL)01/96]
Ford has two goals for servicing your vehicle.
*
[MC00500(ALL)01/96]
1. When we can, we design parts that do not
need to be serviced.
*
[MC00600(ALL)01/96]
2. We want to make servicing your vehicle as
easy as possible. To help you:
*
[MC00700(ALL)01/96]
q
We highlight do-it-yourself items in yellow in
the engine compartment so that you can find
them easily.
*
[MC00800(ALL)03/96]
q
When possible, we design parts that can be
replaced without tools.
*
[MC00900(ALL)02/96]
q
We give you a Maintenance Schedule that
makes tracking routine service for your
vehicle easy. The maintenance schedule is
located in theMaintenance Schedulebooklet.
*
[MC01000(ALL)01/96]
This chapter tells you about the basic parts that
you need to check and service regularly.
*
[MC01050(ALL)01/96]
If your vehicle needs professional servicing, your
dealership can provide the parts and service
required. Check yourWarranty Information Booklet
to find out which parts and services are covered.
Also see theCustomer Assistancechapter of this
Owner Guide.
*
[MC01300(ALL)03/96]
Ford Motor Company recommends that you
perform the Owner Maintenance Checks listed in
theMaintenance Schedulebooklet. These services
are important for the proper operation of your
vehicle. In addition to the conditions listed in
the Owner Maintenance Checklist, be alert for
File:11cpmca.ex
Update:Fri Jun 7 14:30:56 1996

230any unusual noise, vibration, or other indication
that your vehicle may need service. If you do
notice something unusual, see that your vehicle
is serviced promptly.
*
[MC01350(ALL)01/96]
Use only recommended fuels, lubricants, fluids,
and service parts conforming to Ford
specifications. Motorcraft parts are designed and
built to provide the best performance in your
vehicle. Using these parts for replacement is
your assurance that Ford-built quality stays in
your vehicle.
%*
[MC01400(ALL)05/96]
NOTE: Always dispose of used automotive
fluids in a responsible manner. Follow
your community's standards for
disposing of these types of fluids. Call
your local recycling center to find out
about recycling automotive fluids.
%
*
[MC01600(ALL)01/96]
Precautions When Servicing Your
Vehicle
*
[MC01700(ALL)01/96]
Be especially careful when inspecting or
servicing your vehicle. Here are some general
precautions for your safety:
*
[MC01900(ALL)01/96]
q
If you must work with the engine running,
avoid wearing loose clothing or jewelry that
could get caught in moving parts. Take
appropriate precautions with long hair.
*
[MC02000(ALL)01/96]
q
Do not work on a vehicle in an enclosed
space with the engine running, unless you are
sure you have enough ventilation.
*
[MC02100(ALL)01/96]
q
Never get under a vehicle while it is
supported only by a jack. If you must work
under a vehicle, use safety stands.
*
[MC02200(ALL)01/96]
q
Keep all lit cigarettes and other smoking
materials away from the battery and all
fuel-related parts.
File:11cpmca.ex
Update:Fri Jun 7 14:30:56 1996

231
*
[MC02500(ALL)01/96]
If you disconnect the battery, the engine must
ªrelearnº its idle conditions before your vehicle
will drive properly. To find out how the engine
does this, seeBatteryin this chapter.
*
[MC02600(ALL)01/96]
Working with the engine off:
*
[MC02650(ALL)01/96]
1. Set the parking brake fully and make sure
that the gearshift is securely latched in P
(Park).
*
[MC02700(ALL)01/96]
2. Remove the key from the ignition after you
turn the engine off.
*
[MC02725(ALL)01/96]
3. Block the wheels. This will prevent your
vehicle from moving unexpectedly.
*
[MC02750(ALL)01/96]
Working with the engine on:
*
[MC02785(ALL)01/96]
1. Set the parking brake fully and make sure
that the gearshift is securely latched in P
(Park).
*
[MC02800(ALL)01/96]
2. Block the wheels. This will prevent your
vehicle from moving unexpectedly.
*
[MC02900(ALL)01/96]
RWARNING
Do not start your engine with the air
cleaner removed and do not remove it
while the engine is running.
%*
[MC02950(ALL)02/96]
Opening the Hood
*
[MC03000(ALL)01/96]
1. Pull the hood release handle, located next to
the parking brake pedal.
File:11cpmca.ex
Update:Fri Jun 7 14:30:56 1996

233
%*
[MC06000(ALL)01/96]
Engine Oil Recommendations
*
[MC06010(ALL)01/96]
We recommend using Motorcraft oil or an
equivalent oil meeting Ford Specification
WSS-M2C153-F and displaying the American
Petroleum Institute CERTIFICATION MARK on
the front of the container.
*
[MC06020(ALL)01/96]
one third page art:0060021-E
The API Certification Mark
*
[MC06030(ALL)01/96]
Neveruse:
*
[MC06040(ALL)01/96]
q
ªNon-Detergentº oils
*
[MC06050(ALL)02/96]
q
Oils labeled API SA, SB, SC, SD, SE, SF or SG
%*
[MC06060(ALL)01/96]
q
Additional engine oil additives, oil treatments
or engine treatments
%*
[MC06070(ALL)03/96]
Engine oils with anSAE 5W-30viscosity are
PREFERREDfor your vehicle. They provide the
best engine performance, fuel economy and
engine protection for all climates down to-15ÊF
(-25ÊC).
%*
[MC06080(ALL)03/96]
Synthetic engine oils which are CERTIFIED and
of the preferred viscosity may be used in your
engine. The engine oil and oil filter must still be
changed according to the maintenance schedule.
File:11cpmca.ex
Update:Fri Jun 7 14:30:56 1996

234
*
[MC06085(ALL)05/96]
NOTE: Ford production and aftermarket
(Motorcraft) oil filters are designed for
added engine protection and long life.
If a replacement oil filter is used that
does not meet Ford material and design
specifications, startup engine noises or
knock may be experienced. It is
recommended you use the appropriate
Motorcraft oil filter (or another brand
meeting Ford specifications) for your
engine application.
%*
[MC06090(ALL)01/96]
Checking and Adding Engine Oil
*
[MC06095(ALL)01/96]
Since the proper amount of engine oil is
important for safe engine operation, check the oil
using the dipstick each time you put fuel in
your vehicle. Remember the engine must be off,
the oil must be warm and the vehicle must be
parked on level ground.
%*
[MC06100(ALL)01/96]
Checking the engine oil level:
*
[MC06110(ALL)01/96]
1. Turn the engine off after it has warmed up
and allow a few minutes for the engine oil
to drain back into the oil pan.
*
[MC06120(ALL)01/96]
2. Set the parking brake, making sure the
gearshift is securely latched in P (Park).
*
[MC06130(ALL)01/96]
3. Open the hood. Protect yourself from engine
heat.
*
[MC06140(ALL)01/96]
4. Locate the engine oil dipstick (highlighted in
yellow) and carefully pull it out of the
engine.
*
[MC06150(ALL)01/96]
5. Wipe the dipstick clean and put it back into
position, making sure it is fully seated.
File:11cpmca.ex
Update:Fri Jun 7 14:30:56 1996

235 [MC06160(ALL)01/96]
quarter page art:0095016-A
Engine oil dipstick
*
[MC06170(ALL)03/96]
6. Carefully pull the dipstick out again. If the
oil level is below the ªADD 1 QTº line, add
engine oil as necessary. If the oil level is
beyond the letter ªFº in Full, engine damage
or high oil consumption may occur and
some oil must be removed from the engine.
*
[MC06180(ALL)01/96]
7. Put the dipstick back in and make sure it is
fully seated.
%*
[MC06190(ALL)01/96]
Adding engine oil
*
[MC06200(ALL)01/96]
It may be necessary to add some oil between oil
changes. Make sure you use a CERTIFIED
engine oil of the preferred viscosity. Your
vehicle's warranty coverage may not apply if
engine damage is caused by the use of improper
engine oil.
*
[MC06210(ALL)01/96]
Add engine oil through the oil filler cap
highlighted in yellow. To add oil, remove the
filler cap and use a funnel to pour oil into the
opening. Be careful not to overfill the engine.
Recheck the oil level after you finish adding oil.
[MC07000(ALL)05/96]
Engine Oil and Filter Changes
*
[MC07100(ALL)05/96]
Change your engine oil and oil filter according
to these mileage and time requirements,
whichever occurs first.
File:11cpmca.ex
Update:Fri Jun 7 14:30:56 1996

238 [MC08300(ALL)01/96]
quarter page art:0095017-ABrake master cylinder reservoir
%*
[MC08500(ALL)02/96]
Windshield Washer Fluid
*
[MC08520(ALL)02/96]
Check the level of the windshield washer fluid
every time you stop for fuel. The reservoir for
the windshield washer fluid is located in the
engine compartment.
*
[MC08530(ALL)01/96]
RWARNING
Do not put windshield washer fluid in the
container for the engine coolant.
[MC08540(ALL)01/96]
quarter page art:0020358-A
Windshield washer reservoir
File:11cpmca.ex
Update:Fri Jun 7 14:30:56 1996

240 [MC08590(ALL)05/96]
one third page art:0020362-CLiftgate window washer reservoir
%*
[MC08700(ALL)01/96]
Engine Coolant
%*
[MC08710(ALL)01/96]
Checking the Engine Coolant
*
[MC08720(ALL)05/96]
NOTE: Be sure to read and understand
Precautions When Servicing Your
Vehicleat the beginning of this chapter.
[MC08725(ALL)05/96]
Your vehicle's engine coolant protects the engine
from overheating in the summer and from
freezing in the winter. Check the level of the
engine coolant at least once a month, but
preferably each time you stop for fuel. Simply
look at the engine coolant recovery reservoir
located in the engine compartment. To locate
this reservoir, see the diagram of your vehicle's
engine underEngine Compartmentin the
Capacities and Specificationschapter.
File:11cpmca.ex
Update:Fri Jun 7 14:30:56 1996

241
*
[MC08755(ALL)05/96]
Adding Engine Coolant
[MC08760(ALL)01/96]
quarter page art:0020354-A
Adding engine coolant to reservoir
*
[MC08765(ALL)05/96]
RWARNING
Do not put engine coolant in the container
for the windshield washer fluid.
*
[MC08770(ALL)05/96]
When the engine is cool, add a 50/50 mixture of
engine coolant and water to the engine coolant
recovery reservoir Ð DO NOT ADD DIRECTLY
TO THE RADIATOR. Add straight water only in
an emergency, but you should replace it with a
50/50 mixture of coolant and distilled water as
soon as possible.
*
[MC08772(ALL)05/96]
Check the coolant level in the coolant recovery
reservoir the next few times you drive the
vehicle. If necessary, add enough of a 50/50
mixture of coolant and water to bring the liquid
level to the fill line on the reservoir.
*
[MC08775(ALL)05/96]
RWARNING
Never remove the coolant recovery cap
while the engine is running or hot.
[MC08780(ALL)01/96]
If you must remove the coolant recovery cap,
follow these steps to avoid personal injury
caused by escaping steam or engine coolant:
File:11cpmca.ex
Update:Fri Jun 7 14:30:56 1996