Tools You'll Need:
* New spark plug wires: Make sure you get the correct ones for your year and engine.
* Socket set: Likely need a socket to remove the spark plugs (though you're not replacing the plugs themselves in this case). The size depends on your engine.
* Ratchet and extensions: To reach those hard-to-get-to wires.
* Pliers (needle-nose are helpful): For gently gripping and pulling wire ends.
* Wire routing diagram (crucial): Your repair manual will have this. Do not skip this.
* Gloves: To keep your hands clean.
* Possibly a spark plug wire puller: These tools can make removing stubborn wires easier.
Steps:
1. Safety First: Disconnect the negative (-) battery cable.
2. Locate the Spark Plug Wires: Identify each wire's connection to both the spark plug and the distributor (if applicable; some Windstars have coil-on-plug ignition).
3. Mark the Wires: Before removing anything, carefully note the location of each wire. Take pictures, label them with tape and a marker, or use the diagram from your repair manual. Getting them back in the wrong order will cause misfires and potentially engine damage. This is the most important step to avoid problems.
4. Remove the Old Wires: Gently pull each wire off the spark plug. Some may be tricky, and a wire puller can be helpful. If a wire is stuck, don't yank; you could damage the spark plug or the wire itself. Try gently rocking it back and forth while pulling.
5. Install the New Wires: Carefully feed the new wires into place, following the order you noted earlier. Make sure the wires are seated securely on both the spark plug and the distributor cap (or coil pack).
6. Secure the Wires: Some wires have clips or retainers to help keep them in place. Ensure all are properly secured to prevent arcing or damage.
7. Reconnect the Battery: Reconnect the negative battery cable.
8. Test the Engine: Start the engine and listen for any misfires (rough running, sputtering). If you hear any, you likely have a wire in the wrong place. Double-check your routing using the diagram.
Important Considerations:
* Coil-on-Plug (COP) Systems: If your Windstar has a COP system (more likely on newer models), there's no distributor cap. The ignition coil is mounted directly on each spark plug. The process is similar but simpler, as you're just connecting the wires to the coil packs.
* Routing: The routing of the wires is important to prevent interference and arcing. Follow the factory routing as closely as possible. Do not let them rub against hot engine components.
* Repair Manual: Seriously, get a repair manual. It will have specific diagrams and torque specifications for your year and model. This will make the job much easier and safer.
If you're not comfortable working on your vehicle, take it to a qualified mechanic. Improperly installed spark plug wires can cause significant engine problems.
