The exhaust gas recirculation (EGR) valve allows certain amount of emission gasses to re-enter the combustion chamber to lower exhaust emissions. This valve may be periodically cleaned of most carbon deposits. However, once the diaphragm is damaged or the mechanism that operates the valve breaks, a new valve is necessary. This guide will help you replace the EGR valve on your Ford Contour.
Open the hood and disconnect the black, negative battery terminal from the battery.
Remove the air intake resonator, if you have a 2.0L engine. The resonator is a rectangular, plastic pipe toward the back and top of the engine and part of the air intake system. If you have a 2.5L engine, remove the air cleaner outlet tube. This will provide access to the EGR valve.
Locate the EGR valve on one side of the engine. The valve resembles a flat, metal mushroom of about 2 to 3 inches in diameter and has a vacuum hose attached to the top.
Disconnect the EGR valve-to-exhaust manifold nut attached to the bottom of the EGR valve using a 22-mm wrench or a ratchet and crowfoot tool.
Unplug the vacuum hose from the top of the EGR valve by hand.
Unscrew the two EGR valve mounting bolts, using a wrench or ratchet and socket.
Lift the EGR valve off the engine and discard the gasket.
Remove gasket material from the upper intake manifold mating surface, if necessary, using a plastic scraper to avoid damage to the mounting base.
Set the new EGR valve in place, along with a new gasket, and start the two mounting bolts by hand to avoid damage to the threads.
Start threading the EGR valve-to-exhaust manifold nut to the bottom of the new valve by hand to avoid damage to the threads.
Tighten the two EGR mounting bolts and EGR valve-to-exhaust pipe nut.
Plug the vacuum hose to the top of the new EGR valve.
Install the air intake resonator or air cleaner outlet tube.
Connect the black, negative battery terminal to the battery.
