If you're determined to do it yourself, here's a general overview. Remember, this is a general guide and specific steps may vary slightly depending on your Windstar's configuration. Always consult a repair manual specific to your vehicle's year and model for detailed instructions and diagrams.
Safety Precautions:
* Refrigerant Handling: Automotive air conditioning systems contain refrigerant under high pressure. Improper handling can cause serious injury or death. You'll need to properly recover the refrigerant using a refrigerant recovery machine. This is not a DIY-friendly step; it requires specialized equipment and knowledge. Do not attempt to discharge the refrigerant into the atmosphere.
* Eye Protection: Wear safety glasses or goggles throughout the process.
* Gloves: Wear gloves to protect your hands from sharp edges and refrigerant.
* Cleanliness: Keep the area clean to prevent debris from entering the system.
General Steps (Consult your repair manual for precise details):
1. Recover Refrigerant: This is the most crucial step. You must recover the refrigerant from the system using a properly calibrated refrigerant recovery machine. This prevents environmental damage and protects you from injury. If you don't have this equipment, take it to a professional.
2. Disconnect Battery: Disconnect the negative (-) terminal of the battery to prevent electrical shorts.
3. Access the Condenser: The condenser is located in front of the radiator. You'll likely need to remove the front bumper and/or other components (radiator support, possibly the radiator itself) to gain access. Consult your repair manual for specific instructions.
4. Disconnect Lines and Electrical Connections: Carefully disconnect the high- and low-pressure refrigerant lines from the condenser. These lines are usually secured with retaining clips or flare nuts. Note: There might be some residual pressure even after refrigerant recovery. Use caution. You may need to use a flare nut wrench to carefully loosen the connections. Also disconnect any electrical connectors.
5. Remove the Condenser: Once all connections are disconnected, carefully remove the condenser. It's usually held in place by bolts or clips.
6. Install the New Condenser: Install the new condenser in the reverse order of removal, ensuring all connections are secure and tight.
7. Reconnect Lines and Electrical Connections: Reconnect all refrigerant lines and electrical connectors.
8. Vacuum and Recharge System: After installation, the system needs to be vacuumed to remove any air and moisture. This requires a vacuum pump. Then, the system must be recharged with the correct amount and type of refrigerant. This requires specialized equipment and knowledge. Incorrectly charging the system can damage the compressor and other components.
9. Reconnect Battery: Reconnect the negative (-) battery terminal.
10. Test the System: After recharging, test the A/C system to ensure it's functioning correctly.
Tools You'll Likely Need:
* Refrigerant recovery machine (essential)
* Vacuum pump (essential)
* Manifold gauge set (for refrigerant charging)
* Flare nut wrenches
* Socket set
* Screwdrivers
* Repair manual specific to your 2000 Ford Windstar
Again, this is a simplified overview. Attempting this repair without the proper knowledge, tools, and safety precautions can lead to serious damage to your vehicle and potential injury to yourself. Consider the cost of a professional repair versus the risk of doing it yourself. A professional mechanic has the right tools, experience, and knowledge to perform this repair safely and correctly.
