1. Safety First:
* Refrigerant Recovery: This is CRUCIAL. You MUST recover the refrigerant from the system using a refrigerant recovery machine. Releasing refrigerant into the atmosphere is illegal and harmful to the environment. Rent or borrow a recovery machine if you don't own one.
* Safety Glasses & Gloves: Wear appropriate safety glasses and gloves throughout the process.
* Disconnect the Battery: Disconnect the negative battery terminal to prevent electrical shorts.
2. Preparation:
* Consult a Repair Manual: Obtain a repair manual specific to your 1999 Ford Windstar. This will provide detailed diagrams, torque specifications, and crucial steps. Haynes and Chilton manuals are readily available.
* Gather Tools: You'll need a variety of tools, including wrenches (metric), sockets, a compressor clutch tool, refrigerant lines disconnect tools, and possibly a torque wrench.
* Jack and Stands: Safely raise the vehicle and secure it on jack stands.
3. Removal Process:
* Locate the Compressor: Identify the AC compressor, usually located near the engine's front.
* Disconnect Electrical Connections: Disconnect the electrical connector to the compressor clutch.
* Disconnect Refrigerant Lines: This is where the specialized tools come in. Use the correct tools to disconnect the high-pressure and low-pressure refrigerant lines. Be prepared for refrigerant to escape even with a recovery machine connected. Cap the lines immediately after disconnecting to prevent contamination.
* Disconnect the Compressor Mount: Carefully loosen and remove the bolts holding the compressor to the engine block or mounting bracket.
* Remove the Compressor: Once all connections are disconnected, carefully remove the compressor from the vehicle.
4. Installation Process:
* Install New Compressor: Carefully install the new compressor, ensuring it is properly aligned and seated.
* Reconnect the Compressor Mount: Tighten the bolts to the manufacturer's specified torque.
* Reconnect Refrigerant Lines: Connect the refrigerant lines securely, using new O-rings if necessary.
* Reconnect Electrical Connections: Reconnect the electrical connector to the compressor clutch.
* Vacuum and Recharge: After reconnecting everything, you must evacuate the system using a vacuum pump to remove any air and moisture. Then, recharge the system with the correct amount and type of refrigerant (specified in your repair manual). This often requires specialized gauges and equipment.
5. Final Steps:
* Lower the Vehicle: Carefully lower the vehicle from the jack stands.
* Test the System: After recharging, test the AC system to ensure proper cooling. A leak detection test might be advisable.
Important Considerations:
* O-rings: Replace all O-rings on the refrigerant lines during reassembly to prevent leaks.
* Clutch Alignment: Ensure the compressor clutch is properly aligned.
* Refrigerant Type: Use the correct type and amount of refrigerant specified for your vehicle.
* Professional Assistance: This is a complex repair. If you're not comfortable with any part of this process, seek professional help. The cost of a professional repair might be less than the cost of a botched DIY job.
This information is for guidance only. Refer to a repair manual specific to your 1999 Ford Windstar for detailed instructions and safety precautions. Improper repair can lead to damage to your vehicle or personal injury. Professional help is strongly recommended.
