1995 Ford Windstar Fuel pressure lower after new fuel pump

  • 6 CYL
  • FWD
  • 2,000 MILES
New fuel pump, new fuel sending unit, new fuel pressure regulator, new fuel filter

After new OEM fuel pump installed and tank cleaned of severe filth the operating pressure at idle is 27psi and 26 psi under load of 2000 RPMs or higher. New fuel filter only ran for 1 or 2 tanks under filthy gas tank (previous filter was clogged enough to block pressure to 12psi on key flick) and pressure on key flick comes up to 38 psi before starting engine. Spec operating range is 30 - 45psi.

Since the operating pressure has gone down since new fuel pump has been installed and given all the new fuel system items what could this mean is wrong?

Why am I not seeing the spec range? And. There are no leaks either.
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have the same problem?
Saturday, January 31st, 2009 AT 7:08 PM

1 Reply

Here's something that will teach you lot about fuel pressures and solve your problem-Good Luck

Caution: Before hooking up your pressure gauge, relieve all pressure in the fuel system.

Static Fuel Pressure Test
With the key on, engine off (or with the fuel pump energized), fuel pressure should come up quickly and hold steady at a fixed value. Compare the pressure reading to specifications. If you get no pressure reading, check for voltage at the pump. If there is voltage but the pump is not running, you have found the problem: a bad fuel pump.

If you do get a pressure reading but the reading is lower than normal, the cause may be a weak pump, a blockage in the fuel line, filter or tank inlet sock, or a faulty pressure regulator. Also, low voltage at the pump may prevent it from spinning fast enough to build up normal pressure. Check the voltage at the pump. If OK, check the fuel filter and lines for obstructions and the operation of the fuel pressure regulator before you condemn the pump.

Residual Fuel Pressure Test
When the pump is turned off or stops running, the system should hold residual pressure for several minutes (look up the specs to see how much pressure drop is allowed over a given period of time). If pressure drops quickly, the vehicle may have a leaky fuel line, a leaky fuel pump check valve, a leaky fuel pressure regulator or one or more leaky fuel injectors. Low residual fuel pressure can cause hard starting and vapor lock during hot weather.

Running Fuel Pressure Test
With the engine idling, compare the gauge reading to specifications. Fuel pressure should be within the acceptable range given by the vehicle manufacturer. If low, the problem may be a weak pump, low voltage to the pump, a clogged fuel filter, line or inlet sock inside the fuel tank, a bad pressure regulator, or nearly empty fuel tank.

Dead Head Pressure
This checks the maximum output pressure of the fuel pump. With the return line pinched shut, the pump should produce two times its normal operating pressure at idle. If the pressure rating does not go up with the return line blocked, the pump may not be able to deliver enough fuel at higher engine speeds. Possible causes include a worn pump, low voltage at the pump, a plugged fuel filter or inlet sock in the tank, an obstructed fuel line or almost empty fuel tank.
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Saturday, January 31st, 2009 AT 7:25 PM

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