How To Replace a Ford Coutour EGR Valve

The valve that is responsible for allowing an amount of exhaust or emission gasses to re-enter or circulate back to the combustion chamber of your Ford Contour is known as the Exhaust Gas Recirculation or EGR valve. If your car fails an emission test, it could mean that your vehicle has a bad EGR valve. The malfunction could be caused by either a damaged diaphragm or a mechanical problem. This means that the valve gets stuck in the closed or open position. Either way, you will need to replace that valve as soon as possible. How do you tell if your vehicle’s EGR valve is malfunctioning? You will notice that the car has a very rough idle or that it bucks upon acceleration. Luckily, replacing this component is fairly easy. This article will guide you in removing the defective valve and installing a brand new one onto your Ford Contour.

  • Prepare the tools and equipment that you will need. For this do-it-yourself project, you should have a 22mm wrench and a crowfoot wrench by your side. You will also need a set of ratchet and socket and a plastic scraper. Purchase a new EGR valve and have it ready for installation. Call your local auto supplies shop and inquire if they carry replacement valves for your specific car model. It is also highly recommended that you replace the valve gasket, so ask the salesperson if they have that in stock as well. If the auto supply is having a hard time finding the parts that you need, inform them that the part is also known as a secondary gas injection valve or a Kombi-valve.
  • Turn the car off and disconnect the power before doing any work. To avoid getting shocked during the installation, switch off the power of the vehicle by disengaging the cable from the negative terminal of your car’s battery.
  • Remove the defective EGR valve. For 2.0l engine models, you will need to take out the Ford Contour’s intake resonator. This is a small, rectangular pipe made from plastic that is located at the top and back of the car’s engine. This is a part of your vehicle’s gas intake system. For 2.5L engine models, you will need to take out the tube of the air cleaner outlet. You will be able to see the EGR valve once you remove this tube. If you are still having a hard time locating the valve, look for it on the engine’s side. It looks like a metal mushroom that has been flattened. It has a diameter of about 3 inches and has the hose attached to its top. Detach the nut of the intake manifold found at the bottom of your old EGR valve. You can use the 22mm wrench or the crowfoot one. You can also disconnect this using a ratchet. With your hand, unplug the car’s vacuum hose from the lid of the valve. With a screwdriver, unscrew the mounting bolts attaching the old EGR valve. Lift out the freed EGR valve, including the gasket. Take off the gasket material. You can find this at the upper part of the intake manifold surface. Do this carefully to prevent damaging your mounting base. If you are having a problem lifting it out, use a plastic scraper.
  • Put in the replacement EGR valve. Position the brand new valve where the old one used to be. Include the new gasket if you opted to change it as well. Screw in the mounting bolts gently with your hands in order to prevent damaging the screw threads. Attach the nut of the intake manifold to the bottom of the replacement EGR valve. You can do this by hand as well. Gently tighten all the connections then plug in your vacuum hose. Put in the tubes for your air cleaner or intake resonator. Restore the electricity to your car by attaching the cables to its battery.

Failing to replace a defective EGR valve will not result to any life threatening circumstances; however, it will diminish the life of the vehicle and will impair its performance. Periodic cleaning is also necessary to prolong the life of your valve. You can do this by pulling out the EGR valve and scrubbing the bottom passage using a scratch awl. This will help you remove any carbon deposits.


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