1. Gather Necessary Tools and Parts:
* New EGR Valve: Ensure you purchase the correct part number for your specific engine.
* Socket Set: Various sizes, including metric and potentially SAE.
* Wrench Set: Similar to above.
* Screwdrivers: Phillips and flathead.
* Pliers: Needle-nose and possibly regular pliers.
* Rags or Shop Towels: To clean up potential spills.
* Penetrating Oil (PB Blaster or similar): To help loosen rusted bolts.
* Repair Manual: Essential for detailed instructions and torque specifications.
* Jack and Jack Stands (Highly Recommended): For safer access and working conditions.
* Wheel Chocks: For added safety.
2. Preparation:
* Disconnect the Battery: This prevents accidental short circuits.
* Locate the EGR Valve: Generally located on the intake manifold, near the back of the engine. Your repair manual will show the exact location. It's usually a rectangular or square-shaped component with vacuum lines and an electrical connector attached.
* Safety First: Work in a well-ventilated area. Exhaust fumes are dangerous.
3. Removal Process (General Steps):
* Disconnect Vacuum Lines: Carefully disconnect any vacuum lines attached to the EGR valve. Take note of their routing for reassembly.
* Disconnect Electrical Connector: Unplug the electrical connector if present.
* Remove Mounting Bolts: Use the appropriate sockets and wrenches to remove the bolts holding the EGR valve to the intake manifold. Penetrating oil may be necessary if bolts are stuck. Be prepared for some resistance. The bolts can be difficult to reach.
* Remove EGR Valve: Carefully remove the EGR valve. Be mindful of any gaskets or seals.
* Clean the Mounting Surface: Clean the mounting surface on the intake manifold of any debris or old gasket material.
4. Installation Process (General Steps):
* Install New Gasket (if necessary): A new gasket is usually included with the replacement EGR valve. If not, purchase one separately. Apply a thin bead of high-temperature sealant (if recommended in your manual) to the new gasket before installation.
* Install New EGR Valve: Carefully install the new EGR valve onto the intake manifold, aligning it with the mounting holes.
* Tighten Mounting Bolts: Tighten the mounting bolts to the torque specifications listed in your repair manual. Over-tightening can damage the valve or manifold.
* Reconnect Electrical Connector: Reconnect the electrical connector if applicable.
* Reconnect Vacuum Lines: Reconnect the vacuum lines, ensuring they are properly routed.
* Reconnecting the Battery: Reconnect the negative battery cable.
5. Post-Installation:
* Clear the OBD-II Trouble Codes (if applicable): If a check engine light was on due to the faulty EGR valve, you might need to use an OBD-II scanner to clear the code(s) after the replacement.
* Test Drive: Take your Contour for a test drive to ensure the problem is resolved.
Important Considerations:
* This is a general guide. Consult your repair manual for specific instructions and torque specifications for your vehicle. The location and access to the EGR valve might be different based on your specific engine and transmission.
* Exhaust manifold temperatures can be extremely high. Allow the engine to cool completely before working on it.
* If you are not comfortable performing this repair yourself, take your vehicle to a qualified mechanic. Improper repair can lead to further engine damage.
This information is for guidance only. Always prioritize safety and consult your repair manual for specific details related to your 1996 Ford Contour. Incorrect procedures can cause damage to your vehicle.
