Replacing The Fuel Pump In Your 1998 Ford Windstar

If your 1998 Ford Windstar is having trouble starting, it could be due to a faulty fuel pump. The fuel pump is located inside the fuel tank and provides the necessary pressure for the fuel system to operate. To replace it, you'll need to remove the fuel tank, disconnect the fuel lines, and replace the pump with a new one. This process requires several tools and safety precautions, so it's recommended to have a professional handle the job. The cost of replacing a fuel pump can range from $644 to $1,041, depending on labour and parts.

Disconnect the fuel tank filler pipe and vent hoses

Disconnecting the fuel tank filler pipe and vent hoses is a crucial step when replacing the fuel pump in a 1998 Ford Windstar. Here is a detailed guide on how to do this safely and effectively:

Firstly, ensure the vehicle is safely raised and supported, and the fuel system pressure is properly relieved. It is important to work away from any appliances with open flames to avoid accidents. Now, place a safety support under the fuel tank and remove the support strap bolts. This will allow you to lower the fuel tank slightly, giving you access to the various connections.

Before disconnecting the fuel tank filler pipe and vent hoses, you should label and disconnect the fuel tubes, electrical harness connectors, and vacuum lines from the fuel tank. This will make the process easier and reduce the risk of mistakes. Now, you are ready to disconnect the fuel tank filler pipe and vent hoses.

When disconnecting the hoses, it is important to be gentle yet firm. Use the appropriate tools, such as a ratchet, ratchet extension, and socket, to loosen any clamps or connectors holding the hoses in place. Once disconnected, set them aside and ensure they are not damaged or clogged.

Inspect the hoses for any signs of wear, leaks, or damage. If they are in good condition, you can proceed to the next step. If not, it may be necessary to replace them to ensure the fuel system functions optimally.

After disconnecting the hoses, you can continue with the fuel pump replacement process by removing the fuel tank and accessing the pump assembly. Remember to work carefully and refer to a trusted repair guide for further instructions on replacing the fuel pump.

Loosen the fuel filler cap

The fuel filler cap is located on the fuel tank, which is found inside the vehicle. The fuel filler cap needs to be loosened to relieve the fuel system pressure. This is an important step to avoid accidents when working with the fuel system.

Loosening the fuel filler cap will help to reduce the pressure in the fuel tank, making it safer to work on. It is a crucial step when replacing the fuel pump in a 1998 Ford Windstar, as it ensures that the fuel system is depressurized before any work is carried out.

This step should be carried out before disconnecting any hoses or electrical components, and it is important to work away from any open flames or potential sources of ignition.

Remove the fuel tank

To remove the fuel tank from a 1998 Ford Windstar, follow these steps:

Firstly, depressurise the fuel system and remove the filler cap. Disconnect the vacuum hose from the fuel pressure regulator, which is located on the fuel rail leading to the fuel injectors inside the engine compartment.

Next, drain the fuel from the tank. Jack up the rear of the Windstar and place a safety support under the fuel tank. Disconnect the support strap bolts, filler pipe, and vent hoses. Lower the fuel tank and disconnect the fuel tubes, electrical harness connectors, and vacuum lines.

Now, remove the fuel tank from the vehicle. To install the new tank, simply reverse the above steps.

Once the tank is out, you can access the fuel pump. To do this, turn the fuel pump module locking ring counterclockwise using a locking ring removal tool or a brass drift, and remove the locking ring. Remove the fuel pump module and the seal gasket, and install a new seal ring.

Insert the new fuel pump module into the fuel tank and secure it with the locking ring. Reinstall the tank in the vehicle, and fill it with at least 10 gallons of fuel.

To finish, install a pressure gauge on the throttle body valve and turn the ignition on for 3 seconds, repeating this key cycle 5-10 times until the pressure gauge shows at least 30 psi. Check for fuel leaks at the fittings and, if none are apparent, start the engine and check again.

Disconnect the fuel lines, vapor line and electrical connector

To disconnect the fuel lines, vapor line, and electrical connector, you will need to first jack up the rear of the Ford Windstar using a floor jack and support it on two jack stands.

Next, support the fuel tank with the floor jack and disconnect the tank straps using a ratchet, ratchet extension, and socket.

Now, lower the fuel tank just enough to access the fuel lines, vapor line, and electrical connector.

To disconnect the fuel lines, you will need to relieve the pressure in the lines. This can be done by pressing and holding pressure on the green tab with a small screwdriver, then pushing the line towards the pump and removing it. You may need to rotate the line slightly and can spray plastic-safe lubricant to help loosen it.

For the vapor line, simply disconnect it from the fuel sending unit/pump assembly on top of the tank.

Finally, unplug the electrical connector from the fuel sending unit/pump assembly.

Once these connections are disconnected, you can lower the fuel tank further and detach the sending unit/pump assembly using a lock ring removal tool. Turn the lock ring counterclockwise.

Remove the fuel pump from the assembly

To remove the fuel pump from the assembly of your 1998 Ford Windstar, you will first need to remove the fuel tank from the vehicle. This will involve the following steps:

• Depressurise the fuel system.
• Remove any dirt that has accumulated around the fuel pump module attaching flange.
• Loosen and remove the support strap bolts and lower the fuel tank slightly.
• Disconnect the fuel tank filler pipe and vent hoses.
• Disconnect the fuel tubes, electrical harness connectors, and vacuum lines from the fuel tank.
• Remove the fuel tank from the vehicle.

Now that the fuel tank has been removed, you can focus on detaching the fuel pump from the assembly:

• Use a lock ring removal tool or a brass drift to turn the fuel pump module locking ring counterclockwise and remove it.
• Remove the fuel pump module from the assembly.
• Discard the old seal gasket.

At this stage, you should be able to lift the fuel pump out of the assembly. Remember to exercise extreme caution when working with the fuel system to avoid any accidents or injuries.

Frequently asked questions