Windstar

1. Install memory saver, then disconnect battery negative cable.

2. Remove fuel system pressure as follows:

^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge.

^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure.

3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank.

4. Raise and support vehicle.

5. Support fuel tank with adjustable jack.

6. Disconnect fuel filler and vent hoses from fuel tank.





7. Disconnect fuel supply, return and vapor lines. See Figure 20.





8. Disconnect fuel pump electrical connector. See Figure 21.

9. Remove fuel tank straps retaining bolts.

10. Remove fuel tank from vehicle.

11. Clean area around fuel pump to prevent foreign material from entering fuel tank.

12. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel during assembly.





13. Detach fuel lines from routing clips and tie strap. See Figure 22.

14. Remove fuel pump lock-ring.

15. Remove fuel pump.

16. Remove and discard fuel pump seal.





17. Disconnect fuel sender electrical connectors. Refer to Figure 23.

18. Remove fuel sender retaining screw, then remove fuel sender. See Figure 23.

19. Install new fuel sender on fuel pump. Tighten screw to 1 Nm (9 lb/in).

20. Connect fuel sender electrical connectors. Make sure wires are routed correctly.

21. Clean fuel pump-to-gas tank mating surface.

22. Install new fuel pump gasket.

23. Install fuel pump. Align marks made during disassembly. Tighten lock ring until it contact stops.

24. Attach fuel lines to routing clips and install tie strap. Connect fuel lines to fuel pump. Connect electrical connector to pump/sender.

25. Install fuel tank in vehicle. Tighten fuel tank straps to 41-54 Nm (31-39 lb/ft).

26. Connect fuel pump electrical connector.

27. Connect fuel supply, return and vapor lines.

28. Connect fuel filler and vent hoses to fuel tank.

29. Remove adjustable jack.

30. Lower vehicle.

31. Fill fuel tank.

32. Connect battery negative cable, then remove memory saver.

33. Start and run engine.

34. Raise vehicle.

35. Inspect fuel system for leaks.

36. Lower vehicle.