1990 Aerostar 4.0
Engine apart. Problems: engine surging, missing, blows black smoke, smells like gas, bad gas mileage.

Replaced oxygen sensor, coolant temperature sensor, throttle air bypass valve, throttle position sensor, cleaned mass air flow, new plugs and wires, new pcv valve and new thermostat. Some people have mentioned the fuel regulator. What am I looking for when I pull the vacuum line off, fuel coming out of the regulator or the vacuum line? Does the vehicle have to be running? What is the proper way to reset the computer? Just unhook negative and not positive? With lights on? Thanks for everybodys help and I hope this solves the problem. Is there anything else I should check before I put everything back together?
Thanks again

 

The fuel regulator sounds likely. To test it, disconnect vac line. stay where you can see the regulator. turn on key or have someone do it for you because if it's bad you will want to turn it off in a hurry! If NO gas leaks the it might be ok, might not. To reset the computer, just disconnect either terminal for about 30 minutes. If pressure regulator is stuck and giving too much pressure you will still have a problem. check the return lines for flow before running. If you've done work on something else recently, be sure you didn't cause this problem yourself. I know I hate it when I do that!
Also, there could be a coolant temp sensor. If this is not working/hooked up properly, the system could always be adjusted like the motor was cold. This also can give ya a problem if the coolant is low. Good luck

 

How do you get the swivel top off of a regulator? Can't get the fuel line off.

 

To check for regulator diaphragm leakage, remove the std rubber vacuum line and sniff it.

To remove the fuel line (to replace the regulator), you'll need a special Springlok removal tool. I bought a set of six for about $16 by Lisle (from the Ford parts department, really!):

[link:www.lislecorp.com/tools/catalog/general/gen1.htm#37000|http://www.lislecorp.com/tools/catalog/general/gen1.htm#37000]
You can get it online for $10

I see that KD lists a different tool for '90-on 4.0l fuel lines, so perhaps you need this one instead (I don't have a 4.0l):
[link:www.mytoolstore.com/kd/kdengi04.html#3408|http://www.mytoolstore.com/kd/kdengi04.html#3408]
It's $14

I had so many PS pumps in my '89 that I bought this tool to remove/replace the pulley. It's still requires a breakfast of Wheaties to get the thing off, but at least with this tool, it's possible!
[link:www.mytoolstore.com/kd/kdbatt07.html#28|http://www.mytoolstore.com/kd/kdbatt07.html#28]
$59

&l;Damn!
This board text mangling software mangles stuff you don't want mangled. That link above was supposed to be:
http://www.mytoolstore.com/kd/kdbatt07.html#2897
(don't click on the "289", its become a link to somebody else!)
but the URL contains "289", and the posting software automatically finds words like that and makes them links. So I can't have a URL with "289" in it, because the software won't post what I type, it inserts a URL into a URL and both end up broken. Sorry. Anyway, the puller/installer is the last item on the page, and the partial URL bounces to the bottom of the page, so just scroll up a little bit. Damned computers!

I've sent a note off to about this issue.
&r;

Check out the Ford fan clutch removal tools:
[link:www.lislecorp.com/tools/catalog/general/gen1.htm#41800|http://www.lislecorp.com/tools/catalog/general/gen1.htm#41800]

Here's a cheaper version:
[link:www.mytoolstore.com/astro/asthan15.html#7867|http://www.mytoolstore.com/astro/asthan15.html#7867]
$40

And a different version:
[link:www.mytoolstore.com/kd/kdengi06.html#3136|http://www.mytoolstore.com/kd/kdengi06.html#3136]
$41

Well, I'll be damned! An aftermarket heater hose removal tool for Aerostar. This is the tool I tried to buy from Ford, gave up and just bought new hoses when I had to replace the heater core:
[link:www.mytoolstore.com/kd/kdspec17.html#3409|http://www.mytoolstore.com/kd/kdspec17.html#3409]
$45

Here's the special late Ford radio removal tool. I don't need this for my '89, but I had to buy it for a '91 I was working on:
[link:www.mytoolstore.com/astro/asthan15.html#7885|http://www.mytoolstore.com/astro/asthan15.html#7885]
$6

Regards,
Al S.