99 Windstar won't start when warm

[rickbass4001]

Hoping someone can help me out there. I have a 1999 Windstar that won't start when the engine is hot. I had a trouble code in the system on the MAP sensor and have replaced that. To be safe I have also replaced the following... Ignition switch, Gas pump relay, Cam sensor. I have checked the fuel pressure and I am at 30-32psi and the voltage going to the pump is at 13.75 volts. Both pressure and voltage were the same when the engine was hot. I have done the screwdriver test to the fuel injectors and they all seem to be working well. I have fresh plugs and wires in it and they are all firing. I have checked my connections to the PCM and everything looks to be in order there. The gas filter is relatively fresh and the inertia switch are in working order as well as the fuel regulator. If you can help i would appreciate it, this oone has me ready for a drink!!!

[tempfixit]

Originally Posted by rickbass4001

Hoping someone can help me out there. I have a 1999 Windstar that won't start when the engine is hot. I had a trouble code in the system on the MAP sensor and have replaced that. To be safe I have also replaced the following... Ignition switch, Gas pump relay, Cam sensor. I have checked the fuel pressure and I am at 30-32psi and the voltage going to the pump is at 13.75 volts. Both pressure and voltage were the same when the engine was hot. I have done the screwdriver test to the fuel injectors and they all seem to be working well. I have fresh plugs and wires in it and they are all firing. I have checked my connections to the PCM and everything looks to be in order there. The gas filter is relatively fresh and the inertia switch are in working order as well as the fuel regulator. If you can help i would appreciate it, this oone has me ready for a drink!!!

Possible crankshaft position sensor.

[rickbass4001]

Well i have replaced the Crankshaft Position sensor and still get the same response. We idled the van till it warmed up turned it off and then shortly after started it back up, it ran for about a minute stalled out and wouldn't start again. We checked the fuel pressure and i am at 28-30psi. If you can help i would appreciate it this van has me at my wits end...

[12Ounce]

Pressure gauges can be misleading .... is there any chance you could read the fuel pressure on a vehicle, hopefully a Windstar, that has no problem? That way you will know what your particular gauge should be reading.
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Your symptoms kinda sound like a failing fuel pump to me.

[rickbass4001]

It appears that the fuel pressure gauge was holding pressure and wasn't giving me a true reading so i am now heading towards doing the fuel pump. However i am having difficulty with removing one of the hoses, it have a green clip on it unlike the whit clips from the pressure fuel lines, I'm pretty sure it is a vent hose. Any ideas how this one comes apart? Thanks for all the help!!! Got a feeling I will be on this sight a lot when I start the Camaro project!

[12Ounce]

There are two hoses-to-tube connectors ... each a different diameter ... but I remember the "action" of the two clamps to be similar. ?? Perhaps if you drop a few drops of motor oil on it , it will release easier. Try "pushing the connector together".
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Good luck ... I think you are on the right trail.

[rickbass4001]

Fuel pump is changed and it looks like it has solved my problem. Thanks for all your help!!!

[12Ounce]

Congrats! You are welcome ... and thanks for the feedback.

[northern piper]

glad to hear your problems have been solved. While I don't tend to post the same suggestion when I agree with someone else's answer, I really did believe it was fuel pump related as 12ounce had proposed. Anyway, glad you're back up and running.

[scubacat]

And don't forget to change the fuel filter too. A plugged fuel filter could cause the new pump to die sooner than later!

[12Ounce]

QUESTION:

Which one of us, who, will take one for the team ... and design a removable service door in the floorboard for servicing the fuel pump without removing the tank?

Who is that brave soul?

[northern piper]

gawd... this is too funny.. I was thinking to myself, with all the activity surrounding the fuel pump issue that's "next" on the issues I'll have undoubtedly. My 2000 3.8 has the OEM pump in it and I KNOW it's only a matter of time.

I'll do my share on this job... if someone wants to draw up a plan for the access door, I'll make a prototype.

I know it's only a matter of time..

[12Ounce]

Ford really put one to us by not providing a service door. Wonder what was the reason .... heck, Escorts/Tracers had them!

[scubacat]

Some nice person posted a video of the process. Looks like a lot to manage, especially lifting the tank back up into position...

https://www.youtube.com/watch?v=CKv5v31Rzj8

[12Ounce]

Yeah, I think I have done this 4 or 5 times ... thanks to one pump that was bad in the box! I'd like to do it one more time ... just to install a service door.