1987 Ford Aerostar Repair Manual

The 1987 Ford Aerostar Repair Manual provides comprehensive guidance for maintaining and repairing the Ford Aerostar minivan. This manual covers engine systems, transmission, suspension, brakes, electrical systems, and routine maintenance procedures for both 2.3L and 3.0L engine variants. Below are key sections for safety precautions, technical specifications, troubleshooting, and step-by-step repair procedures.

1. Vehicle Specifications 2. Safety Precautions 3. Routine Maintenance 4. Engine Systems 5. Transmission 6. Brake System 7. Suspension & Steering 8. Electrical System 9. Cooling System 10. Fuel System 11. Troubleshooting Guide

Vehicle Specifications

Technical specifications for the 1987 Ford Aerostar minivan models.

Specification	Details
Engine Options	2.3L 4-cylinder, 3.0L V6
Transmission	4-speed automatic, 5-speed manual
Drivetrain	Rear-wheel drive
Fuel System	Electronic Fuel Injection
Brake System	Front disc, rear drum
Wheelbase	118.9 inches
Curb Weight	3,200 - 3,600 lbs
Fuel Capacity	15 gallons
Tire Size	P195/75R14
Oil Capacity	4.5 quarts (with filter)

Safety Precautions

Essential safety procedures before performing any repairs.

Disconnect battery: Always disconnect negative terminal before electrical work.
Use jack stands: Never work under vehicle supported only by jack.
Wear protective equipment: Safety glasses and gloves required.
Proper ventilation: Ensure adequate airflow when working with fuels or chemicals.

WARNING! Hot engine components can cause severe burns. Allow engine to cool before performing repairs.

Routine Maintenance

Scheduled maintenance intervals and procedures.

Oil change: Every 3,000 miles or 3 months
Air filter: Replace every 15,000 miles
Spark plugs: Replace every 30,000 miles
Coolant flush: Every 30,000 miles or 2 years
Brake fluid: Replace every 2 years
Tire rotation: Every 6,000 miles

CAUTION! Use only recommended fluids and parts specified in this manual.

Engine Systems

2.3L 4-cylinder: Overhead cam, 8 valves, 90 horsepower
3.0L V6: Overhead valve, 12 valves, 140 horsepower
Ignition System: Electronic distributorless ignition
Compression Ratio: 9.0:1 (2.3L), 8.8:1 (3.0L)
Torque Specifications: Cylinder head bolts 65-72 ft-lbs
Timing Belt: Replace every 60,000 miles (2.3L)
Valve Clearance: Hydraulic lifters, no adjustment required

Transmission

Automatic and manual transmission service procedures.

Automatic Transmission: A4LD 4-speed, fluid capacity 10 quarts, filter replacement every 30,000 miles.

Manual Transmission: Mazda M5OD 5-speed, fluid capacity 3.5 pints 80W-90 gear oil. Clutch adjustment: 1/2 inch free play at pedal.

Shift linkage adjustment: Ensure proper alignment for smooth shifting. Transmission mount inspection: Check for cracks and deterioration.

Brake System

Front disc and rear drum brake maintenance.

Brake pad replacement: Minimum thickness 1/8 inch
Rotor resurfacing: Maximum removal 0.030 inch
Brake shoe replacement: Adjust after installation
Bleeding procedure: Start with wheel farthest from master cylinder

Tip: Always replace brake fluid when servicing hydraulic components.

Suspension & Steering

Front and rear suspension components and steering system.

Front suspension: MacPherson struts with coil springs
Rear suspension: Leaf spring with solid axle
Ball joints: Check for play every 15,000 miles
Tie rod ends: Replace if excessive play detected
Wheel alignment: Camber 0° ± 0.5°, toe-in 1/16 inch
Shock absorbers: Replace if leaking or poor damping

WARNING! Always support vehicle properly when working on suspension components.

Electrical System

Battery, alternator, starter, and wiring diagrams.

Component	Specification
Battery	12V, 550 CCA
Alternator	65 amp output
Starter	1.4 kW
Fuse Box	Under dashboard, driver side
Spark Plug Gap	0.044 inch

Cooling System

Radiator, thermostat, and coolant maintenance.

Coolant capacity: 11 quarts (with heater). Thermostat: Opens at 192°F. Radiator pressure cap: 16 psi. Cooling fan: Thermostatically controlled electric fan.

Fuel System

Fuel pump, injectors, and fuel filter service.

Fuel pressure: 35-45 psi. Fuel filter: Replace every 15,000 miles. Fuel pump: In-tank electric type. Injector resistance: 14-16 ohms.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Engine won't start	Battery, fuel, ignition	Check battery voltage, fuel pressure, spark at plugs
Overheating	Coolant, thermostat, fan	Check coolant level, thermostat operation, fan operation
Poor fuel economy	Air filter, sensors, tires	Replace air filter, check oxygen sensor, inspect tire pressure
Brake vibration	Rotors, pads, alignment	Resurface rotors, replace pads, check wheel balance
Transmission slipping	Fluid level, bands, filter	Check fluid level and condition, adjust bands, replace filter

Technical Support: 1-800-392-3673; www.ford.com/support