1. Identify the Root Cause (Don't Just Keep Replacing the Fuse!):
* Low Fuel Level: A surprisingly common cause. The fuel pump can overheat if it's trying to draw fuel from almost empty. Make sure your tank has a reasonable amount of fuel.
* Faulty Fuel Pump: This is the most likely culprit. A failing fuel pump draws excessive current, blowing the fuse. This often manifests as a whining noise from the fuel tank when the key is turned to the "on" position (but not started). This requires replacing the fuel pump, a more involved repair.
* Wiring Issues: Check the wiring harness leading to the fuel pump for any damage, chafing, or corrosion. Look closely at the connections for any signs of wear or melting. Repairing or replacing damaged wiring is necessary.
* Fuel Pump Relay: The relay controls the power to the fuel pump. A faulty relay can also cause the fuse to blow. Test the relay (often located in the underhood fuse box) or replace it. Many auto parts stores can test relays for you.
* Fuel Filter Clogged: A severely clogged fuel filter restricts fuel flow, forcing the pump to work harder and draw more current. Replacing the fuel filter is relatively inexpensive and easy.
* Fuel Pressure Regulator: A malfunctioning regulator can cause excessive pressure in the fuel lines, potentially leading to the pump drawing extra current. This is less common but possible.
2. Troubleshooting Steps:
* Check the fuse: Make sure it's the correct amperage. Visually inspect the fuse for obvious signs of damage (blown element). If blown, replace it with a fuse of the *exact same amperage*.
* Listen for the fuel pump: Turn the ignition key to the "on" position (without starting the engine). You should hear a brief humming sound from the fuel tank area. If you don't hear it, the pump or the relay might be faulty.
* Check fuel pressure (advanced): This requires a fuel pressure gauge. This will tell you if the fuel pump is delivering the correct pressure. If the pressure is low, it points to a pump, filter, or regulator issue.
* Inspect wiring: Carefully examine the wiring harness leading to the fuel pump for any signs of damage or corrosion.
3. If you continue to blow fuses after trying the above:
* Professional Help: Take your Windstar to a qualified mechanic. Diagnosing and repairing fuel system issues can be complex and require specialized tools. Continuing to run the car with a blown fuel pump fuse can damage the pump.
Important Safety Note: Work on the fuel system requires caution. Fuel is flammable, so avoid sparks or open flames. Disconnect the negative battery terminal before working on any electrical components.
