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Kenny Z.
Kenny Z., Ford Senior Master Tech
Category: Ford
Satisfied Customers: 5247
Experience:  Auto Trans, Drivability and Electrical Specialist
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ford windstar: 2002 ford windstar replaced fuel pressure regulator

Customer Question

2002 ford windstar
replaced fuel pressure regulator and fuel comes out around regulator.
o-rings look good.
Bought new snap ring and still did same thing
Submitted: 4 years ago.
Category: Ford
Expert:  Kenny Z. replied 4 years ago.
Hello and thanks for your question.

There should be 2 o rings and 1 return seal. See below. Were all 3 replaced?

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Customer: replied 4 years ago.
There are two o rings - 1 large and 1 small. I noticed the large o ring fits into a grove around the regulator. Should it be up against the black plastic part or in the groove.
Expert:  Kenny Z. replied 4 years ago.
Here is an assembled view with the orings installed.

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Customer: replied 4 years ago.
ok, ill give it a shot. I had installed it with the large o ring in the groove not right behind the seal
Expert:  Kenny Z. replied 4 years ago.
Great, let me know.
Customer: replied 4 years ago.
didnt help. I went around and compared it to different brands and they all are the same. Fuel still sprays out the cup around the regulator. I could have messed up the cup when i took out the old regulator but I dont see how.
Expert:  Kenny Z. replied 4 years ago.
Wow thats really strange. Are you positive there isn't a little tear in one of the orings?
Or a scratch on the surface where the oring seals against? I cannot think of any other reason it would leak.
Customer: replied 4 years ago.
Ive tried two different regulators. Im going to a motorcraft part next. If it doesnt work then Ill have to take it in.
Expert:  Kenny Z. replied 4 years ago.
Ok then good luck.
Customer: replied 4 years ago.
The aftermarket regulators hav a smaller seal than the motorcraft. It worked.
Expert:  Kenny Z. replied 4 years ago.
Glad thats all it was