Replacing Fuel Pressure Regulator In A 1990 Ford Aerostar

The fuel pressure regulator in a car helps the fuel injector dispense the right amount of fuel and maintains constant fuel pressure for optimal fuel usage. This article will discuss the steps involved in replacing the fuel pressure regulator in a 1990 Ford Aerostar.

Removing the old fuel pump

To remove the old fuel pump from your 1990 Ford Aerostar, you will need to first gather the necessary tools and materials, including fuel-resistant gloves and a small flat-tip screwdriver. Park your vehicle on a flat, hard surface and secure it by following these steps:

• Engage the parking brake to lock the rear tires from moving.
• Place wheel chocks around the front tires, as they will remain on the ground.
• If you have a nine-volt battery saver, install it into your cigarette lighter to keep your computer live and settings current.
• Disconnect the battery by opening the vehicle's hood and taking the ground cable off the battery's negative post. This will disable the power going to the fuel pump. Ensure you are wearing protective gloves when handling the battery.

Now, you can begin to remove the fuel pressure sensor:

• Remove the engine cover and any brackets that may be obstructing the fuel pressure regulator.
• Locate the Schrader valve or test port on the fuel rail. Put on safety glasses and protective clothing. Place a drip pan under the rail and cover the port with a towel.
• Using the small flat-tip screwdriver, open the valve by pushing on the Schrader valve to release the pressure in the fuel rail.
• If there is no Schrader valve or test port, you will need to remove the supply fuel hose from the fuel rail using a drip pan and a fuel hose quick-disconnect tool kit.
• Remove the vacuum line and mounting hardware from the fuel pressure regulator.
• Take off the fuel pressure regulator from the fuel rail.
• Clean the fuel rail with a lint-free cloth and inspect the condition of the vacuum hose.

At this stage, you have successfully removed the old fuel pump, and you can now install the new fuel pressure regulator.

Disconnecting the battery

Park your vehicle on a flat, hard, and level surface. This is important to ensure your car is stable and secure while you work. Make sure the transmission is in park if it's an automatic or in first gear if it's a manual. This will prevent the vehicle from moving unintentionally during the process.

Secure the front tires with wheel chocks to prevent any accidental rolling. You can use blocks of wood or specialized chocks for this purpose. Engage the parking brake as well to ensure the rear tires are locked and won't move.

Open the vehicle's hood to access the battery. Before proceeding, put on protective gloves to shield your hands from any corrosion or acid on the battery terminals. It is also recommended to refer to the vehicle's owner's manual for specific instructions related to your car model.

Locate the battery and identify the ground cable connected to the negative post. The negative post will typically have a "-" symbol or a black cover. Using the appropriate tools, carefully loosen and remove the cable from the negative terminal. This step is crucial as it disables the power going to the fuel pump, which is essential for your safety.

Once the cable is disconnected, move it away from the battery to prevent any accidental contact or arcing. Ensure that the cable does not touch any metal parts of the vehicle to avoid short circuits.

At this point, you have successfully disconnected the battery. You can now proceed with the next steps of replacing the fuel pressure regulator, ensuring that you follow the necessary safety precautions throughout the process. Remember to refer to the owner's manual or seek guidance from a qualified mechanic if you have any doubts or concerns.

Removing the engine cover

To remove the engine cover of a 1990 Ford Aerostar, first remove the screw in the center cupholder and then remove the cupholder itself. Next, take out the two 8mm nuts that hold the rear ABS module in place under the dash. Unhook the three retaining hinges, then push up on the cover, wiggling it a little left and right until it comes loose. Finally, pull the cover down and out.

According to a forum post by user "rickm5", there are four clips holding the engine cover in place—two on each side, one low and one higher up. You may need to feel the outline of the cover with your hand and follow it up under the dash to find them. Even after undoing these clips, the cover is still wedged in, so you'll need to rotate it downward and rearward while lifting up a bit on the lower lip and jiggling it to get it out. If you have a floor shift, you'll need to take it out of park to gain the extra room necessary to remove the cover.

Another forum user, "eehoepp", notes that on their 1995 Ford Aerostar, there are only three clips holding the cover in place: two on the passenger side and one on the driver's side. They also mention that the PCM (engine computer) is bolted up under the instrument panel and will need to be unbolted (but not disconnected) to remove the cover.

A third forum user, "Shadeaux", describes a similar process for their 1994 Ford Aerostar, noting that they were able to remove the cupholder and engine cover without unbolting anything under the dash. However, they found it challenging to get the cover back on.

Installing the new regulator

To install the new fuel pressure regulator, first attach it to the fuel rail. Screw in the mounting hardware until it is finger tight, then tighten it to 12 inch-pounds, followed by a 1/8 turn. This will secure the regulator to the fuel rail. Put on the vacuum hose, and install any brackets that you had to remove to detach the old regulator. If you had to remove the pressure fuel line to the fuel rail, be sure to connect the hose back on.

Put the engine cover back on by snapping it into place. Reconnect the battery by attaching the ground cable back to the battery's negative post. Remove the wheel chocks from the rear wheels. Turn the ignition key on and listen for the fuel pump to activate. Turn off the ignition after the fuel pump stops making noise. You will need to cycle the ignition key on and off 3 to 4 times to ensure the fuel rail is full of fuel and pressurized.

Check for leaks by using a combustible gas detector to check all the connections. Also, sniff the air for any fuel odours.

Testing for leaks

To test for leaks in your 1990 Ford Aerostar's fuel pressure regulator, you can perform a vacuum test. This will allow you to spot any leaks in the regulator's vacuum port, which is a common area for leaks to occur.

Step 1: Locate the fuel pressure regulator. It is usually found at the end of the fuel rail containing the injectors.

Step 2: Inspect the vacuum hose for any signs of damage and ensure that it is tightly connected.

Step 3: Disconnect the vacuum line and replace it with clear tubing. This will help you to spot any leaks.

Step 4: Have an assistant rev the engine up and down repeatedly to mimic the act of accelerating. This is when fuel pressure regulator failures usually occur.

Step 5: Look inside the clear tubing for any signs of fuel, such as spraying or seeping gasoline. If you see any fuel inside the tube, it indicates a leak in the diaphragm located inside the regulator, and the fuel pressure regulator will need to be replaced.

Additionally, there are several warning signs that may indicate a leak in your fuel pressure regulator:

• The engine is hard to start, also known as a "hard start".
• A long crank is required when starting.
• Rough idling.
• You can smell fuel.
• Fuel is dripping from the tailpipe.
• The engine is frequently stalling, misfiring, or hesitating.

If you notice any of these signs, it is important to perform a leak test as soon as possible to confirm the issue and address it accordingly.

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