How to Change the Fuel Pump in a Ford Windstarby Dan Ferrell; Updated November 07, 2017
Items you will need
Hand-held vacuum pump
Fuel approved container
Hand siphon pump
2 jack stands
Ratchet and socket
Lock ring removal tool
Slip joint pliers
New seal gasket
The fuel pump on your Ford Windstar provides the pressure necessary to the fuel system for proper operation. However, internal pump components may wear out after years of service and fail to provide adequate pressure. In this case, you will not be able to start the engine and will have to replace the pump, which is located inside the fuel tank. Once you have the correct replacement for your particular model, follow these steps to install it.
Loosen the fuel filler cap.
Disconnect the vacuum hose from the fuel pressure regulator with your hand. The regulator is located on the fuel rail leading to the fuel injectors, inside the engine compartment.
Connect a hand vacuum pump to the fuel pressure regulator and apply 25-inches Hg of vacuum to the regulator. Disconnect the vacuum pump from the regulator and re-connect the vacuum hose.
Remove as much fuel form the fuel tank through the filler neck into an approved container using a hand siphon pump.
Jack up the rear of the Windstar using a floor jack and support it on two jack stands.
Support the fuel tank with the floor jack and disconnect the tank straps using a ratchet, ratchet extension and socket.
Lower the fuel tank just enough to disconnect the fuel lines, vapor line and unplug the pump electrical connector from the fuel sending unit/pump assembly on top of the tank.
Lower the fuel tank and detach the sending unit/pump assembly using a lock ring removal tool. Turn the lock ring counterclockwise. See Resources below for more information.
Lift the sending unit/pump assembly from the tank and discard the seal gasket.
Remove the fuel pump from the assembly using a pair of slip joint pliers and standard screwdriver.
Mount the new pump on the sending unit/pump assembly using the slip joint pliers and standard screwdriver.
Apply a light coat of automotive grease to the new seal gasket to hold it in place and lay the gasket on the tank assembly opening.
Set the sending unit/pump assembly in place and turn the lock ring clockwise using the lock ring removal tool.
Raise the fuel tank with the floor jack just enough to connect the fuel lines, vapor line and plug the fuel pump electrical connector.
Set the fuel tank in place and connect the tank straps using the ratchet, ratchet extension and socket.
Lower the Ford Windstar.
Refill the fuel tank with at least 10 gallons of fuel.
Turn the ignition switch On for three seconds and then turn it Off. Repeat this operation at least 10 times to build pressure in the fuel system.
Check for leaks.
If you do not have access to a lock ring tool, you may be able to rent it at your local auto parts store.
When replacing the fuel pump on your Ford Windstar, make sure to work away from appliances with open flames like dryers and water heaters to avoid a possible accident.
- Photo courtesy of IFCAR at Wikipedia.org.