Chilton Repair Manual: Ford Full-Size Vans (1989-1996)

Introduction

This Chilton Total Car Care manual provides comprehensive, step-by-step instructions for the repair and maintenance of Ford Full-Size Vans manufactured between 1989 and 1996. It covers all U.S. and Canadian models, including the E150, E250, E350, Club Wagon, Cutaway, and Motor Home Chassis, encompassing both gasoline and diesel engine variants. The manual is designed to assist both professional technicians and home mechanics in performing various procedures, from routine maintenance to complex repairs.

Each procedure is supported by detailed specifications, exploded views, and numerous photographs to ensure clarity and accuracy. The goal of this manual is to provide the necessary information and confidence to perform repairs efficiently and correctly.

Front cover of the Chilton repair manual for Ford Full-Size Vans, model years 1989-1996. The cover features a blue Ford van and highlights that it covers U.S. and Canadian models, including E150, E250, E350, Club Wagon, Cutaway, and Motor Home Chassis with both gasoline and diesel engines.

Safety Information

Always prioritize safety when performing any vehicle maintenance or repair. Failure to follow proper safety procedures can result in serious injury or damage to the vehicle.

• Wear appropriate personal protective equipment (PPE), such as safety glasses, gloves, and sturdy footwear.
• Ensure the vehicle is on a level surface and properly supported with jack stands before working underneath it.
• Disconnect the battery's negative terminal before working on electrical components to prevent accidental shorts.
• Allow engine and exhaust components to cool before servicing to avoid burns.
• Work in a well-ventilated area, especially when dealing with fuel, lubricants, or exhaust fumes.
• Keep a fire extinguisher nearby when working with flammable materials.
• Refer to the specific warnings and cautions provided within each section of this manual.

Vehicle Identification

Accurate vehicle identification is crucial for ensuring that the correct repair procedures and parts are used. This manual specifically covers Ford Full-Size Vans from 1989 to 1996.

Vehicle Identification Number (VIN)

The VIN is a 17-character code that uniquely identifies your vehicle. It is typically located on the driver's side dashboard, visible through the windshield, and on the driver's side door jamb. The VIN contains information about the vehicle's manufacturer, model year, plant of manufacture, and serial number.

Engine Identification

Engine identification codes are often found on a sticker under the hood or stamped on the engine block. This manual covers both gasoline and diesel engine types available in the specified Ford Full-Size Van models.

General Information and Manual Usage

This manual is organized into chapters, each covering a specific system or component of the vehicle. Within each chapter, procedures are presented in a logical, step-by-step format. It is recommended to read through the entire procedure before beginning any work.

• Tips: Provide valuable shortcuts to make jobs easier and may eliminate the need for special tools.
• Notes: Offer additional information that is helpful but not critical to the procedure.
• Cautions: Indicate procedures that, if not followed carefully, could result in damage to the vehicle.
• Warnings: Highlight procedures that, if not followed carefully, could result in personal injury.

The Chilton repair manual for Ford Full-Size Vans, 1989-1996, held by a hand to illustrate its physical size. The image indicates dimensions of 11 inches (27 cm) in length, providing a visual reference for its substantial content.

Maintenance

Regular maintenance is essential for the longevity and reliable operation of your Ford Full-Size Van. This section outlines routine service procedures and recommended intervals.

Fluid Checks and Changes

• Engine Oil and Filter: Check level regularly, change as per manufacturer's schedule.
• Transmission Fluid: Inspect level and condition.
• Coolant: Check level and concentration, flush and refill periodically.
• Brake Fluid: Monitor level and condition.
• Power Steering Fluid: Verify level.

Tire Care

• Tire Pressure: Maintain recommended pressure for optimal performance and safety.
• Tire Rotation: Rotate tires at specified intervals to promote even wear.
• Tread Depth: Inspect regularly for wear and damage.

Filter Replacement

• Air Filter: Replace as needed or per schedule to ensure proper engine breathing.
• Fuel Filter: Replace at recommended intervals to prevent fuel system contamination.

Engine Repair

This section details procedures for diagnosing, removing, overhauling, and reinstalling the gasoline and diesel engines found in 1989-1996 Ford Full-Size Vans. It includes information on cylinder head service, timing components, lubrication systems, and fuel systems.

Gasoline Engines

Specific instructions for various gasoline engine displacements, including tune-up procedures, component removal and installation, and common repair tasks.

Diesel Engines

Dedicated coverage for diesel engine maintenance and repair, focusing on unique aspects such as fuel injection systems, glow plugs, and specific diagnostic procedures.

Chassis and Drivetrain

This chapter covers the components that make up the vehicle's chassis and drivetrain, including the suspension, steering, brakes, axles, and transmission systems.

Suspension and Steering

Procedures for inspecting and replacing suspension components (shocks, springs, bushings) and steering system parts (tie rods, steering gear, power steering pump).

Brake System

Detailed instructions for servicing disc and drum brakes, including pad/shoe replacement, rotor/drum inspection, caliper/wheel cylinder service, and brake fluid bleeding.

Drive Axles and Driveshafts

Information on differential service, axle shaft removal and installation, and driveshaft inspection and repair.

Transmission

Coverage for both manual and automatic transmissions, including fluid and filter changes, linkage adjustments, and removal/installation procedures.

Electrical System

This section provides comprehensive information on the vehicle's electrical system, including wiring diagrams, component testing, and repair procedures for various electrical circuits.

Battery and Charging System

Testing and replacement of the battery, alternator, and voltage regulator.

Starting System

Diagnosis and repair of the starter motor and related components.

Lighting and Accessories

Troubleshooting and repair of exterior and interior lighting, wipers, horn, and other electrical accessories. Includes detailed wiring diagrams for various circuits.

Troubleshooting

This section provides a systematic approach to diagnosing common vehicle problems. It includes troubleshooting charts and diagnostic procedures to help identify the root cause of issues.

Engine Performance Issues

• Hard Starting or No Start
• Rough Idling or Stalling
• Loss of Power or Poor Acceleration
• Excessive Exhaust Smoke

Brake System Problems

• Spongy Brake Pedal
• Brakes Pulling to One Side
• Squealing or Grinding Noises

Electrical Malfunctions

• Lights Not Working
• Wipers Inoperative
• Power Window/Lock Issues

Always consult the specific troubleshooting charts and diagnostic procedures within the manual for detailed guidance.

Specifications

This section provides key specifications related to the Chilton Ford Full-Size Vans 1989-1996 Repair Manual itself.

Warranty and Support

This manual is a reference guide for vehicle repair and maintenance. It does not come with a product warranty for the vehicle itself. For specific vehicle warranty information, please refer to your vehicle's original manufacturer documentation or contact an authorized Ford dealership.

For support regarding the content of this Chilton manual, please refer to the publisher, Cengage Learning, or visit their official website for any available errata or updates.