2003 Ford Windstar Fuel Pump Relay Location: Complete Guide to Finding, Testing, and Replacing It
The fuel pump relay on a 2003 Ford Windstar is located in the under-hood power distribution box (engine compartment fuse box). It is labeled as relay number 207. This is the most common location across all 1999-2003 Windstar models. If your Windstar is cranking but not starting, or if you hear no fuel pump prime when you turn the key to the ON position, the fuel pump relay is one of the first things you should check before replacing the fuel pump itself.
Where Exactly Is the Fuel Pump Relay Located?
The power distribution box for the 2003 Ford Windstar is located in the engine compartment, on the driver's side near the battery. Open the hood and look for a black plastic box with a removable cover. The cover has a diagram showing the location of each fuse and relay.
Relay 207 is the fuel pump relay. It is a standard four-pin or five-pin relay that looks like a small, rectangular black box. The relay is positioned in the relay bank near the middle of the fuse box. You can identify it by the number "207" stamped on the fuse box cover diagram or on the plastic housing next to the relay socket.
Important note: The fuel pump relay is not the same as the fuel pump fuse. The fuel pump fuse for the 2003 model is fuse #5 in the same power distribution box, rated at 15 amps. The relay controls the high-current flow to the pump, while the fuse protects the circuit from overload.
Two Fuses Power the Fuel Pump Relay System
Many Windstar owners overlook the fact that the fuel pump relay circuit requires two separate fuses to operate correctly.
1. Fuse #5 (15A) in the Power Distribution Box – This fuse is located in the engine compartment fuse box. It provides power directly to the fuel pump motor and to the Powertrain Control Module (PCM). If this fuse is blown, the fuel pump will not receive power even if the relay is working.
2. Fuse #20 (15A) in the Power Distribution Box – This fuse powers the control coil of the fuel pump relay. The relay coil is what energizes the relay to close its contacts and send power to the pump. Fuse #20 also protects the ignition coil, fuel injectors, Mass Air Flow (MAF) sensor, and the PCM. A blown fuse #20 means the relay will never click on, and the pump will not run.
Check both fuses first. If either fuse is blown, the fuel pump will not operate. Replace any blown fuse with one of the same amperage rating. Never use a higher amp fuse, as this can damage the wiring or cause a fire.
How to Test the Fuel Pump Relay
Before you buy a new relay, you can test the existing one to confirm it is faulty. Here is a straightforward way to test it.
Step 1: Locate the relay. Find relay 207 in the power distribution box under the hood.
Step 2: Listen for the click. Have a helper turn the ignition key to the ON position (do not crank the engine). You should hear a distinct click from the relay when the key is turned on. This click means the relay coil is receiving power and the relay is closing. If you hear no click, the relay may be bad, or the control circuit (including fuse #20) is not working.
Step 3: Swap the relay. Find another relay in the fuse box that is the same type and rating. Common relays to swap with include the horn relay (relay 205) or the A/C clutch relay (relay 204). Remove the fuel pump relay and insert the known good relay into its socket. Turn the key to the ON position. If you now hear the fuel pump prime, the original relay was bad.
Step 4: Check for power and ground. If swapping relays does not work, you need to check for power at the relay socket. Use a multimeter set to DC voltage. With the ignition on, you should have battery voltage on two of the relay socket terminals. You should also have a ground signal from the PCM on one of the control coil terminals. If you have no ground signal, the PCM may not be receiving the correct inputs from the transmission range sensor or the Passive Anti-Theft System (PATS).
Other Common Causes of No Fuel Pump Operation
If the relay and fuses are good, but the fuel pump still does not run, there are a few other things to check.
The Inertia Fuel Cutoff Switch – This is a safety switch located in the right rear of the Windstar, usually behind the jack storage compartment or in the rear cargo area. It is designed to trip and cut power to the fuel pump in the event of a collision. Even a hard bump or a pothole can sometimes trip this switch. If the switch is tripped, you will see a red button that is popped up. Push the button down to reset it. This is a very common and easy fix that many people overlook.
The PCM Ground Signal – The fuel pump relay will not close unless the PCM provides a ground path for the relay coil. The PCM checks the transmission range switch to make sure the vehicle is in Park or Neutral. It also checks the PATS system to confirm the correct key is being used. If either of these conditions is not met, the PCM will not ground the relay, and the fuel pump will not run. This is a built-in safety feature to prevent the vehicle from starting in gear or being stolen.
Wiring and Connectors – Over time, wiring connections can corrode or break. The ground for the fuel pump is located at G101 in the lower left front of the engine compartment. Check this ground point for rust or looseness. Also inspect the connector at the fuel pump itself for corrosion or damage.
Symptoms of a Failing Fuel Pump Relay
A bad fuel pump relay can cause a range of symptoms. Here are the most common signs to watch for.
1. Engine cranks but does not start. This is the most common symptom. The starter motor turns the engine over, but the fuel pump never runs, so no fuel reaches the engine.
2. No fuel pump prime sound. When you turn the key to the ON position, you should hear a brief whirring sound from the rear of the vehicle as the fuel pump pressurizes the system. If you hear nothing, the relay may not be engaging.
3. Intermittent starting problems. A failing relay may work sometimes and fail other times. You might find that the car starts fine in the morning but refuses to start after a short drive. This is often due to the relay heating up and failing internally.
4. Engine stalls while driving. If the relay fails while the engine is running, the fuel pump will lose power, and the engine will stall. This can be dangerous if it happens on the highway.
5. Battery drain. A stuck fuel pump relay that remains closed even when the ignition is off can cause the fuel pump to run continuously, draining the battery overnight.
How to Replace the Fuel Pump Relay
Replacing the fuel pump relay is a simple job that most DIYers can do in about 10 minutes. You do not need any special tools.
1. Park the vehicle on a level surface and turn off the engine. Disconnect the negative battery terminal. This is a safety precaution to prevent any accidental shorts.
2. Open the hood and locate the power distribution box. Remove the cover by pressing the release tabs.
3. Find relay 207. Use the diagram on the underside of the cover or the diagram printed on the fuse box itself.
4. Pull the old relay straight out. You can use your fingers or a small pair of pliers. Do not pry on the relay with a screwdriver, as this can damage the socket.
5. Insert the new relay. Push it firmly into the socket until it is fully seated. Make sure it goes in the correct orientation. Most relays are keyed so they only fit one way.
6. Reconnect the negative battery terminal. Replace the fuse box cover.
7. Test the system. Turn the key to the ON position and listen for the fuel pump prime sound. If you hear it, the replacement was successful.
The cost of a replacement fuel pump relay is low. A genuine OEM Ford fuel pump relay for the Windstar has part number 5M5Z-14N089-A and replaces older part numbers FOAZ-14N089-A and GU5Z-14N089-G. Aftermarket relays are also available at most auto parts stores for around $10 to $20. The average cost for a professional replacement is around $117, with about $22 for parts and $95 for labor.
When to Replace the Fuel Pump Instead
If the relay, fuses, inertia switch, and wiring all check out, but the fuel pump still does not run or does not build pressure, the fuel pump itself may be bad. A fuel pump that kicks on but does not build pressure points to a problem within the pump or the fuel delivery system.
Common signs of a bad fuel pump include:
- The engine struggles to start, especially after the vehicle has been running and the pump has heated up.
- Loss of power during acceleration or when climbing hills.
- Sputtering or surging at highway speeds.
- A whining noise coming from the fuel tank area.
Before replacing the fuel pump, check the fuel filter. A clogged fuel filter can restrict flow and mimic the symptoms of a bad pump. The fuel filter is a relatively inexpensive part and is easy to replace.
KEMSO Fuel Pump Recommendation
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KEMSO fuel pumps are built with precision engineering to meet or exceed original equipment specifications. Each pump undergoes rigorous quality checks to ensure consistent fuel pressure and flow. Whether you drive a passenger car, an SUV, or a powersport vehicle, KEMSO has a fuel pump that fits your needs.
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Final Thoughts
The 2003 Ford Windstar fuel pump relay location is straightforward once you know where to look. It is relay 207 in the under-hood power distribution box. Always check the fuses and the inertia cutoff switch before replacing the relay. A systematic approach to diagnosing the fuel system will save you time and money. If you end up needing a new fuel pump, consider KEMSO for a reliable, high-performance replacement that will keep your Windstar on the road for years to come.
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