How it Works
Ford
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Aerostar 1996
User Manual
347 pgs1.76 Mb0
Owner's Manual
353 pgs3.01 Mb0
Service Guide
52 pgs191.01 Kb0
Table of contents
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Ford Aerostar 1996 User Manual

Table of Contents
Introduction ....................................................1
Instrumentation .............................................. 7
Audio .............................................................. 21
Controls and Features ................................ 59
Seating and Safety Restraints ..................97
Reporting Safety Defects

Introduction

At Ford Motor Company, excellence is the continuous commitment to achieve the best result possible. It is dedication to learning what you want, determination to develop the right concept, and execution of that concept with care, precision, and attention to detail. In short, excellence means being the standard by which others are judged.
Our Guiding Principles
Quality comes first. For your satisfaction, the
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quality of our products and services must be our number one priority.
You are the focus of everything we do. Our
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work must be done with you in mind, providing better products and services than our competition.
Continuous improvement is essential to our
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success. We must strive for excellence in everything we do: in our products — in their safety and value — and in our services, our human relations, our competitiveness, and our profitability.
Employee involvement is our way of life.
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We are a team. We must treat one another with trust and respect.
Dealers and suppliers are our partners. We
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must maintain mutually beneficial relationships with dealers, suppliers, and our other business associates.
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Integrity is never compromised. Our conduct
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worldwide must be pursued in a manner that is socially responsible and commands respect for its integrity and for its positive contributions to society.
NOTES and WARNINGS
NOTES give you additional information about
the subject matter you are referencing. WARNINGS remind you to be especially careful
in those areas where carelessness can cause damage to your vehicle or personal injury to yourself, your passengers or other people. Please read all WARNINGS carefully.
RWARNING
Finding Information in This Guide
After you have read this guide once, you will probably return to it when you have a specific question or need additional information. To help you find specific information quickly, you can use the Quick Index, Table of Contents, or the Index.
The Quick Index at the end of the book provides a page number following each item which indicates where detailed information can be found.
To use the Index, turn to the back of the book and search in the alphabetical listing for the word that best describes the information you need. If the word you chose is not listed, think of other related words and look them up. We have designed the Index so that you can find information under a technical term.
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Canadian Owners — French Version
French Owner Guides can be obtained from your dealer or by writing to Ford Motor Company of Canada, Limited, Service Publications, P.O. Box 1580, Station B, Mississauga, Ontario L4Y 4G3.
Record Booklet
The Maintenance Schedule booklet lists the services that are most important for keeping your vehicle in good condition. A record log is also provided to help you keep track of all services performed.
Your vehicle is covered by three types of warranties: Basic Vehicle Warranty, Extended
Warranties on certain parts, and Emissions Warranties.
Read your Warranty Information Booklet carefully to find out about your vehicle’s warranties and your basic rights and responsibilities.
If you lose your Warranty Information Booklet, you can get a new one free of charge. Contact any Ford or Lincoln-Mercury dealer, or refer to the addresses and phone numbers on the first page of this Owner’s Guide.
Ford Extended Service Plan
More Protection for Your Vehicle
You can get more protection for your new car or light truck by purchasing a Ford Extended Service Plan (Ford ESP). Ford ESP is the only extended service program with the Ford name on it and the only service contract backed by Ford Motor Company.
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Ford ESP is an optional service contract, backed and administered by Ford. It provides:
protection against repair costs after your
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Bumper to Bumper Warranty expires;
other benefits during the warranty period
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(such as: reimbursement for rentals; coverage for certain maintenance and wear items).
You may purchase Ford ESP from any participating Ford Motor Company dealer. There are several Ford ESP plans available in various time-and-mileage combinations. Each plan can be tailored to fit your own driving needs, including reimbursement benefits for towing and rental. (In Hawaii, rules vary. See your dealer for details.)
When you purchase Ford ESP, you receive peace-of-mind protection throughout the United States and Canada, provided by a network of more than 5,100 participating Ford Motor Company dealers.
NOTE: Repairs performed outside the United
States and Canada are not eligible for ESP coverage.
This information is subject to change. Ask your dealer for complete details about Ford ESP coverage.
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E-4WD VEHICLES
As with other vehicles of this type, failure to operate this vehicle correctly may result in loss of control or an accident. Be sure to read the special driving instructions in the section Electronic 4-Wheel Drive (E-4WD) in this book.
Federal Highway Administration Regulation
Regulations such as those issued by the Federal Highway Administration or issued pursuant to the Occupational Safety and Health Act (OSHA), and/or state and local laws and regulations may require additional equipment for the way you intend to use the vehicle. It is the responsibility of the registered owner to determine the applicability of such laws and regulations to your intended use for the vehicle, and to arrange for the installation of required equipment. Your Ford dealer has information about the availability of many items of equipment which may be ordered for your vehicle.
Your new vehicle goes through an adjustment or break-in period during the first 1,000 miles (1,600 km) that you drive it. During the break-in period, you need to pay careful attention to how you drive your vehicle.
Avoid sudden stops. Because your vehicle
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has new brake linings, you should take these steps:
— Watch traffic carefully so that you can
anticipate when to stop.
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— Begin braking well in advance. — Apply the brakes gradually.
The break-in period for new brake linings lasts for 100 miles (160 km) of city driving or 1,000 miles (1,600 km) of highway driving.
Wheel lug nuts must be retightened to proper
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torque specifications at 500 miles/800 km of new vehicle operation. Proper torque specifications are provided in the Roadside Emergencies chapter. Also retighten to proper torque specifications at 500 miles/800 km after any wheel change or any other time the wheel lug nuts have been loosened.
Use only the type of engine oil that Ford
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recommends. See Engine oil recommendations in the Index. Do not use special “break-in” oils.
This Guide
Congratulations on the purchase of your new vehicle. This guide has information about the equipment and the options for your new vehicle. You may not have bought all of the options available to you. If you do not know which information applies to your vehicle, talk to your dealer.
This guide describes equipment and gives specifications for equipment that was in effect when this guide was approved for printing. Ford may discontinue models or change specifications or design without any notice and without incurring obligation.
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Instrumentation

The instrument panel (dashboard) on your vehicle is divided into several different sections. The illustrations on the following pages show the major parts of the instrument panel that are described in this chapter. Some items shown may not be on all vehicles.
In your vehicle, the warning lights and gauges are grouped together on the instrument panel. We call this grouping a cluster. Your vehicle has a mechanical cluster.
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Aerostar mechanical cluster
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The following warning lights and gauges are on the mechanical cluster. All of the warning lights and gauges alert you to possible problems with your vehicle. Some of the lights listed are optional. The following sections detail what each of these indicators means.
Brake System Warning Light
The warning light for the brakes can show two things — that the parking brake is not fully released, or that the brake fluid level is low in the master cylinder reservoir. If the fluid level is low, the brake system should be checked by your dealer or a qualified service technician.
This light illuminates when you turn the ignition key to START to verify that the indicator bulb is working. If the light stays on or illuminates after you have released the parking brake fully, have the hydraulic brake system serviced.
RWARNING
The BRAKE light indicates that the brakes may not be working properly. Have the brakes checked immediately.
Brake warning light symbol
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Rear Anti-Lock (ABS) Brake Warning Light
To check the rear ABS brake warning light, turn the ignition key to the ON position. The rear ABS brake warning light should glow momentarily.
NOTE: If it does not glow momentarily, have
your vehicle’s electrical system checked immediately.
NOTE: If the rear ABS brake warning light
begins to flash in a repeating flash sequence, check the rear anti-lock brake system continuous power fuse and brake lights for proper operation.
Rear anti-lock warning light symbol
RWARNING
If the anti-lock brake system warning light remains on or comes on while driving, have the braking system checked by a qualified service technician as soon as possible.
NOTE: If a fault occurs in the anti-lock
system, and the brake warning light is not lit, the anti-lock system is disabled but normal brake function remains operational.
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Safety Belt Warning Light and Chime
This warning light and chime remind you to fasten your safety belt. One of the following will take place:
If the safety belt is not buckled when the key
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is turned to the ON position, the light comes on for 1 to 2 minutes and the chime sounds for 4 to 8 seconds.
If the safety belt is buckled while the light is
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on and the chime is sounding, both the light and chime turn off.
If the safety belt is buckled before the
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ignition is turned to the ON position, neither the light nor the chime will come on.
Safety belt warning light
Door Ajar Light and Chime
This light illuminates along with an audible chime if one of the doors is not completely shut when you turn the ignition to the ON position.
Door ajar light
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Check Engine Warning Light
This light illuminates when the engine’s Emission Control System requires service. It will also illuminate when the ignition key is in the ON position and the engine is off.
Check engine warning light
Electronic 4-Wheel Drive Warning Light (If equipped)
The Electronic 4-Wheel Drive Warning Light illuminates when the Electronic 4-Wheel Drive system is not working properly. This light illuminates briefly when you turn the ignition key to the ON position, but should turn off when the engine starts. If the light does not illuminate when you turn the ignition to the ON position, or if it illuminates and stays on when you are driving, have your vehicle serviced as soon as possible.
The 4WD light will go off after a few seconds and stay off if all systems are operating correctly. If a problem is detected, the 4WD warning light will flash a certain number of times indicating the location of the problem. The flashing will continue until the problem is corrected. Each time the ignition key is turned on, the controller will detect the problem and flash the signal. The 4WD system remains safe to operate and the vehicle should be returned for service.
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Electronic 4-wheel drive warning light
Charging System Light
This light indicates that your battery is not being charged and that you need to have the electrical system checked.
Charging system light
This light illuminates every time you turn the ignition to the ON or START position (engine off). The light should go off when the engine starts and the alternator begins to charge.
If the light stays on or illuminates when the engine is running, have the electrical system checked as soon as possible.
Supplemental Air Bag Readiness Light and Tone Generator
This light illuminates for six seconds when the ignition is turned to the ON position. If the light fails to illuminate, continues to flash, remains on, or if a series of five beeps is heard, have the system serviced as soon as possible.
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Supplemental air bag readiness light
High Beam Light
This light illuminates when the headlamps are turned to high beam or when you flash the lights.
High beam indicator light
Chime for Headlamps On
This chime sounds if the driver or passenger door is open when the parking lamps or headlamps are on. The chime sounds until you close the door, turn off the lamps or turn the ignition to the ON position.
NOTE: The chime will not sound when the
autolamp has activated the shutoff delay.
Ignition Key Buzzer or Chime
The buzzer or chime will sound if you open the driver’s door while the key is in the ignition and in the OFF, LOCK, or ACCESSORY position. Never leave your vehicle unattended with the key in the ignition.
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Battery Voltage Gauge (Voltmeter)
This gauge shows you the battery voltage when the ignition key is in the ON position.
If you are running electrical accessories (when the engine is off, or idling at a low speed), the pointer may move toward the lower end of the normal band. If it stays outside the normal band area, have your vehicle’s electrical system checked as soon as it is safely possible.
If the battery is operating under cold weather conditions, the pointer may indicate in the upper range of the NORMAL band while the battery is charging. If you are running electrical accessories with the engine off or idling at a low speed, or the battery is not fully charged, the pointer may move toward the lower end of the NORMAL band.
If it stays outside the NORMAL band, have your vehicle’s electrical system checked as soon as it is safely possible.
Battery voltage gauge
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Engine Oil Pressure Gauge
This gauge indicates the engine’s oil pressure, not the oil level. However, if your engine’s oil level is low, it could affect the oil pressure. With the engine running, the pointer should move into the NORMAL band. If the pointer drops below the NORMAL band while the engine is running, you have lost oil pressure and continued operation will cause severe engine damage.
If you lose engine oil pressure:
1. Pull off the road as soon as safely possible.
2. Shut off the engine immediately or severe engine damage could result.
3. Check the engine’s oil level, following the instructions on checking and adding engine oil. Refer to Engine oil in the Index. If you do not follow these instructions, you or others could be injured. To assure an accurate reading, your vehicle should be on level ground.
4. If the level is low, add only as much oil as necessary before you start the engine again. Do not overfill. Do not operate the engine if the pointer is below the NORMAL band, regardless of the oil level. Contact your nearest dealer for further service actions.
Engine oil pressure gauge
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Fuel Gauge
The fuel gauge displays approximately how much fuel is in the fuel tank only when the ignition switch is ON.
For a proper fuel gauge indication after adding fuel, the ignition switch should be in the OFF position while the vehicle is being refueled.
The fuel gauge indicator may vary slightly while the vehicle is in motion. This is the result of fuel movement within the tank. An accurate reading may be obtained with the vehicle on smooth, level ground.
Fuel gauge
Engine Coolant Temperature Gauge
This gauge indicates the temperature of the engine coolant, not the coolant level. If the coolant is not at its proper level or mixture, the gauge indication will not be accurate.
The pointer moves from the C (cold) mark into the NORMAL band as the engine coolant warms up. It is acceptable for the pointer to fluctuate within the NORMAL band under normal driving conditions. Under certain driving conditions, such as heavy stop and go traffic or driving up hills in hot weather, the pointer may move to the top of the NORMAL band.
If, under any circumstances, the pointer moves above the NORMAL band, the engine is overheating and continued operation may cause engine damage.
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If your engine overheats:
1. Pull off the road as soon as it is safely possible.
2. Turn off the engine.
3. Let the engine cool. DO NOT REMOVE
COOLANT SYSTEM FILL CAP UNTIL THE ENGINE IS COOL.
4. Check the coolant level following the instructions on checking and adding coolant to your engine. Refer to Engine coolant in the Index. If you do not follow these instructions, you or others could be injured.
Engine coolant temperature gauge
Speedometer
The speedometer tells you how many miles (kilometers) per hour your vehicle is moving.
Your vehicle contains a speedometer which receives its input from the Anti-Lock brake sensor. The speedometer is also used to provide a speed signal for correct operation of the vehicle’s Powertrain Control Module (PCM), electronic transmission, and speed control (if so equipped). Because of this, it is very IMPORTANT to change the speedometer’s internal conversion constant if the size of the tires on the vehicle is changed. Changing the conversion constant to the proper value when
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the tires are changed will also ensure that the speedometer retains the original factory-set accuracy.
NOTE: The conversion constant can only be
changed six times once the vehicle leaves the factory. Your Ford dealership service personnel can change the conversion constant.
Some vehicles are equipped with a vehicle speed (mph/km/h) limiting device that is contained within the Powertrain Control Module (PCM). The purpose of this device is to maintain peak vehicle speed below a specified limit. (Vehicle speed limits may vary based on engine displacement.)
If you are experiencing an “engine cut-out” condition at high speeds, it may be the result of this limiting device. It is a normal condition and can be avoided by reducing vehicle/engine speed.
Speedometer
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Odometer/Trip Odometer
The Liquid Crystal Display (LCD) odometer is a combination trip odometer and total odometer. The total odometer is normally displayed. To see the trip odometer, press and release the SELECT control on the upper right side of the speedometer. To zero out the trip odometer, press and release the RESET control on the upper left side of the speedometer while the trip odometer is displayed. If the trip odometer is displayed, press and release the SELECT control to return the display to the total odometer value.
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Compact Disc Radio

Electronic Sound Systems

The Compact Disc Radio combines the Electronic Stereo Radio with the Ford Compact Disc Player.
Using the Controls on Your New Radio/CD Player
Most of the features of this unit work for both radio and CD operation. Also, some of the knobs and buttons control several different functions, so be sure to read all of the operating instructions carefully.
How to turn the radio on and off
Press the “POWER” button to turn the radio on. Press it again to turn it off.
How to adjust the volume
Press the (R/S) end of the “VOL” button to increase/decrease the volume. Bars illuminate in the display to show the relative volume level.
NOTE: If the volume level is set above a
certain listening level when the ignition switch is turned off, when the ignition switch is turned back on, the volume will come back to a “nominal” listening level. However, if the radio power is turned off, the volume will remain in the position it was set at when radio power was switched off.
Selecting the AM or FM frequency band
Push the “AM/FM” button to select the desired frequency band. When in the radio mode, pushing the button more than once will alternate between AM, FM1 and FM2. These functions are used with the station memory buttons described under How to tune radio stations.
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How to tune radio stations
There are four ways for you to tune in a particular station. You can manually locate the station using the “SCAN/TUNE” button, “SEEK” the station, “SCAN” to the station or select the station by using the memory buttons, which you can set to any desired frequency. These four methods are described below.
Using the “SCAN/TUNE” button to manually
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tune
You can change the frequency up or down one increment at a time (FM changes in increments of 200kHz; AM changes in increments of 10kHz) by first pressing the “SCAN/TUNE” button twice (display shows “TUNE”), then — within approximately five seconds —pressing and releasing either the top (a) or bottom (b) half of the “SEEK” button. To change frequencies quickly, press and hold down either the top or bottom half of the “SEEK” button. While you are manually tuning, the display will show a blinking “M.”
Manual tuning adjusts your radio to any allowable broadcast frequency, whether or not a station is present on that frequency. (See All About Radio Frequencies in this section.)
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Using the “SEEK” function
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This feature on your radio allows you to automatically select listenable stations up or down the frequency band. Press the top (a) half of the “SEEK” button to select the next listenable station up the frequency band. Press the bottom (b) half of the button to select the next listenable station down the frequency band. By pressing and holding the button, listenable stations can be passed over to reach the desired station.
Using the “SCAN/TUNE” button to scan
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radio stations
Pressing the “SCAN/TUNE” button once enters the scan mode (display will indicate “SCN”). Pushing the top (a) half of the “SEEK” button will begin the scan mode up the frequency band, stopping on each listenable station for approximately five seconds. Pushing the bottom (b) half of the “SEEK” button will begin the scan mode down the frequency band, again stopping on each listenable station for approximately five seconds.
To stop the scan mode on the presently sampled station, press the “SCAN/TUNE” button again.
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Setting the Station Memory Preset buttons
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Your radio is equipped with 5 station memory buttons. These buttons can be used to select up to 5 preset AM stations and 10 FM stations (5 in FM1 and 5 in FM2). Follow the easy steps below to set these buttons to the desired frequencies.
1. Select a band, then select a frequency.
2. Press one of the memory preset buttons and hold the button until the sound returns. That station is now held in memory on that button.
3. Follow the two steps above for each station memory preset button you want to set.
NOTE: If the vehicle’s battery is disconnected,
the clock and station memory preset buttons (if programmed in auto mode) will need to be reset.
Using the Automatic Memory Load feature
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You can activate the Auto Memory Load feature by pressing and holding the “AUTO PRESET” button for approximately three seconds. Auto Memory Load sets all memory buttons in AM, FM1 and FM2 sequentially by seeking out the first five strong stations for the respective band and storing them in memory buttons 1-5. (FM2 will store the second set of strong stations from the FM band.)
With Auto Memory Store, you can continually set strong stations into your memory buttons without losing your existing memory presets, which is especially helpful while traveling. Your radio will automatically set your memory buttons to the strong local stations so you don’t have to continually manually tune to existing stations.
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Activate Auto Memory Store by pushing the “AUTO PRESET” button once. Your radio will set the first five strong stations of the band you are in (AM, FM1 or FM2) into the memory buttons. The display will show “AUTO,” then run through the frequencies, stopping momentarily on the stations being set into the memory buttons. The radio is now in the “AUTO” mode and the display will show “AUTO” each time a preset is activated.
NOTE: If there are fewer than five strong
stations in the frequency band, the remaining unfilled buttons will store the last strong station detected on the band.
After all stations have been filled, the radio will begin playing the station stored on memory button 1.
To deactivate the Auto Memory Store mode and return to the manually-set memory button stations (or those stations set using Auto Memory Load), simply push the “AUTO PRESET” button. Display will show “AUTO” then “OFF.” The next time Auto Memory Store is activated on that band, the radio will store the next set of five strong stations.
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Using the “AUDIO” button to adjust the tone balance and speaker output
Increasing or decreasing bass response
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Push the “AUDIO” button repeatedly until the display reads “BASS.” Push the “+” side of the “VOL” button to increase bass (more “lows”), and push the “-” side to decrease bass (less “lows”).
Increasing or decreasing treble response
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Push the “AUDIO” button repeatedly until the display reads “TREB.” Push the “+” side of the “VOL” button to increase treble (more “highs”), and push the “-” side to decrease treble (less “highs”).
Adjusting speaker balance
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Balance control allows you to adjust the sound distribution between the right and left speakers. Push the “AUDIO” button repeatedly until the display reads “BAL.” Push the “+” side of the “VOL” button to shift the sound to the right speakers, and push the “-” side to shift the sound to the left speakers.
Adjusting speaker fader
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Fade control allows you to adjust the sound distribution between the front and rear speakers. Push the “AUDIO” button repeatedly until the display reads “FADE.” Push the “+” side of the “VOL” button to shift the sound to the front speakers, and push the “-” side to shift the sound to the rear speakers.
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