A 93 Aerostar 3.0, 2wd, A.O.D., trans, 3:55 rear, 109K..now 120K

It had a syptom that recently showed up when it rains heavy out, and my van sits out all night in it or all day, it cranks and cranks, and cranks, then eventually starts up. (some days starts on the second attempt to start, others, starts after 10 minutes of trying)

Well it rained really hard before Christmas, and I was taking the van to get the oil changed for our Gattlinburg, Church Youth trip, it started( on second attempt) put it in gear backed about 4 -feet and it died....hasn't started since....( now let me correct that, it will start and run if you shoot starting fluid down the T-Body, but only for brief seconds)

I did contact my old Dealership and the only mechanic that was left there ( rest where dismissed like myself do the the Ford audit, even the svc mgr) he suggested replacing the ign module on the side of the dist, and replace the coil wire, cause they had a bulletin on them that wet weather could effect them and give no start conditon, due to the age of my van he really thought that would take care of it.
So I get the stuff, well........ no module on the side of the dist , even tho the Ford parts says there one in the van , but not sure or not if at or on the dist,I did replace coil wire..nothing..

So... I'm asking for help....
#1 where is the dag gone ign module? (the mechanic stated that a half of that module could go out, shutting down the fuel injection, but leaving the ign portion of it, thats why I'm able to start it with starting fluid)
#2 I can't hear the pump turn on, maybe fuel injection relay? there are 4 relays in a row under the hood, could one of these be the relay?
#3 I have checked the crash switch, it HAS NOT been activated.
#4 Has any of you out there experinced in the Ford repairs? ( that mechanic now is no longer with them ,he left under his will)
#5 If it narrows down to the fuel pump how hard is it to change out?
Again Thanks

 

Hello anyone ever had this problem or knows what and where to look for first?

I finally got the Haynes repair manual and It states about changing out the ing module, but no references to what relays are what and located where.

Any Ideas want to do the repairs myself to save some change.

Iv'e seen these vans run forever for people that basicly abuse them.

Like I said it only showed up when it rained, started on dry day perfectly fine.

I did read down thru and back thru the forum and found One guys 89 F150 with a V8 just not starting cranks no fire, replace the fuel pump relay, and then found there is another relay related to fuel also and his truck now starts up when that second relay was replaced.
Could or would this also apply to my van?

Again thanks....

 

my 87 had a similar problem, turns out the relays by the battery were full of water..worth a look I guess.

 

I have a 93 4.0 AWD. It could be fuel pump, relay or computer. You should hear the relays click if they are working. The EEC relay & fuel pump should both click. Check the voltage at the fuel pump. You should be getting voltage. If none you have a bad relay EEC or fuel pump.If voltage you have a bad pump. I replaced my fuel pump and the major part is getting all the gas out. The tank is plastic.You have some bolts holding the bands that support the tank. Use some liquid Wrench, oil etc on the bolt threads. Take off the gas filler hose wires etc & disconnect the fuel lines after you can get to them. A good half days work. Easy to get the pump off and use a BRASS drift to undo the locking ring. Do not use steel as you do not want sparks to blow up the tank. Good luck.

 

Avanti thanks for the reply...

I tried working on it this afternoon, the ign module was checked and reads fine.
The Relays were my next concern, so I picked up 2...installed them,
Well nothing happened, I did rotate out the orginal Ford relays to see if the one I didn't change was the bad one.... still nothing.
There are 3 relays and 1 diode in that relay box mounted on the inside of the drivers side fender, the diode was first,
wich one of those relays is the fuel pump, and the EEC?

Someone posted about finding water in his relays on a 87 Areostar, was that "in" the relays? or down in the panel where the relays plugged into?

Again thanks

 

Check for fuel pressure at the fuel rail next to the injectors.

 

There are 4 relays. According to the factory book. The 3 rd relay from the front is the fuel relay. it has 3 pins. Wires are red, yellow & light blue & orange.I can't check my van because it is elsewhere. I still would check the voltage at the fuel pump with the switch on. That way if you get voltage you can for sure say it is the fuel pump & not anything else. Also check the connection for corrison.

 

What the freak happened to my reply???? It was half a page long!!

 

Well , I've been through just about every possible thing to check except the the fuel pump and it's connection.

Is this connection easy to get to?
Or does the tank have to come down to get to it?
And if the the connection is corroded what oe how is a way to prevent that from happing again , and how would one clean it up for service again?

(sorry for all the questions)
But... a friend told me of fuseable link for the fuel pump relay power (or something like that)
is that possible that has also maybe corroded and failed?

I have a 89 Sable wagon 3.0 and it did the same thing ( same scenerio wet and damp out) and a repair shop stated that the wires in that area corroded and they were repaired.

Maybe?.......

Thanks again guys