'99 Windstar SEL won't start after long drives

[WallyWest]

I have two issues which may be related, I'm not sure yet. Mostly looking for some ideas on what the most likely culprits are before I start taking things apart. It has 110,000 miles, no real issues before, just normal wear and tear.

1. Drive it around town, short trips and it's fine. Starts right back up no problems. Take it on a long drive, where everything under the hood gets fully heated up and you're screwed. Turn the ignition on and the fuel pump doesn't cycle. Let it sit a while and it's fine. This appears to be getting progressively worse, the other day it did it and after 45 minutes was still dead. I was close enough to walk home, so I went back out a few hours later and it started right back up. But in the past waiting 15 minutes or so is all it took. Granted, this was a warmer day than we've had in a while and I had been driving it for over an hour on the interstate. I'm 99% sure it's directly related to how hot things get, which makes me think it's not the fuel pump itself but rather something under the hood.

2. At idle it sometimes runs a little rough, the revs will bounce up and down a bit. Not wildly, just a little blip of the needle. Seems to be more of an issue from a cold start, as it warms up it does it less. But even warm if you leave it idling long enough, I'd say 5 minutes or more, it will start acting up. Ignore it and eventually it will die. I've always been able to just put it in neutral and give it a little gas to keep it from dying. Cleaning the IAC this weekend as a first step, but it actually looks pretty clean.

Fuel pump maybe? I plan on checking fuel pressure. I'm thinking the two issues are not the same thing, but not sure about that. Seems a failing fuel pump would be flaky all the time, not just after long drives. I have never had it die or lose power or anything while driving down the road. Just the weirdness at idle, and the fuel pump not responding after long drives. Not a battery issue as the battery was just replaced a few months ago, and I've checked it when it wouldn't start. It actually will crank and run for a few seconds, but it's not getting fuel so it just coughs and dies.

Anyway, thanks for any advice.

[12Ounce]

I have had these symptoms many times. I have learned to carry a few NEW relays loose in the glove box. I also carry a copy of the layout of components for the fuse-relay box under the hood, and for the box by the driver's foot. These are single sheet copies of the info that is right on the owner's hand book.
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Your current problem, I believe is one of two relays ... perhaps both of them. There is one relay under the hood that feeds the PCM and the fuel pump, and one (in the same location) that feeds only the fuel pump. Replace both of these with new relays ... please, please don't start swapping old relays around.
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If you need more direct guidance, come back to us.

[WallyWest]

Ok, I will give that a shot. Is there any specific brand you like for the replacement relays?

As for my idling issue I checked out the IAC today and it looked pretty clean inside, the valve seemed to move easily enough. Cleaned it out anyway and put it back on, no change. Guess I'm gonna hunt for vacuum leaks next.

Thx.

[12Ounce]

If possible, get ahold of a inductive type timing light ... test all of the spark cables for firing ... the light should be periodic with no "misses" or "skips", showing misfire ... if you detect misfire in the lamp, even tho you don't have code ... start the repair process ... plugs, cables, ( I like Belden Wires), coil pack, crank position sensor ... etc, etc.

[12Ounce]

You can test for vacuum leaks while the engine is idling ... lift-disconnect each vacuum connection from the plastic manifold upper. There are three on the back side alone. Plug with your finger ... does it change the engine speed?

[White4940]

I have an 02 windstar and had the same symptoms. Hooked up fuel pressure gauge and when the fuel pump would not prime (after some short trips and it warmed up). I had no zero fuel pressure. Changed fuel pressure regulator and fuel filter and still had the same issue. Finally broke down and bought a new fuel pump. Replaced the fuel pump (about 2 hr job with two people) and have not had a problem since. My guess is that is what is causing your problem. I recommend getting a fuel pressure gauge and testing the fuel pressure when the pump is not priming.