Tools You'll Likely Need:
* Socket wrench set (metric)
* Ratchet
* Extensions
* Pliers (possibly needle-nose)
* Vacuum hose
* Shop rags or paper towels
* New EGR valve (ensure it's the correct one for your year and engine)
* Possibly a torque wrench (highly recommended)
* Safety Glasses
* Gloves
Procedure (General Steps - Consult your repair manual for specifics):
1. Safety First: Disconnect the negative battery cable to prevent electrical shorts. Allow the engine to cool completely before starting.
2. Locate the EGR Valve: The EGR valve's location varies slightly depending on the year of your Ford Contour. It's usually found on the intake manifold, near the back of the engine. Consult your repair manual for the precise location.
3. Disconnect Vacuum Hose(s): Carefully disconnect any vacuum hoses connected to the EGR valve. Take note of their routing so you can reconnect them correctly later. Sometimes these are brittle and can break easily.
4. Disconnect Electrical Connector (if applicable): Some EGR valves have an electrical connector. Unplug it gently.
5. Remove the EGR Valve: Use the appropriate socket and wrench to remove the bolts holding the EGR valve in place. These can sometimes be stubborn due to carbon buildup. Penetrating oil may be helpful if they're stuck.
6. Clean the Mounting Surface: Once the EGR valve is removed, thoroughly clean the mounting surface on the intake manifold. Carbon buildup can cause leaks and sealing problems. Use a wire brush, scraper, and appropriate cleaning solvent (check your repair manual for recommendations).
7. Install the New EGR Valve: Carefully install the new EGR valve, ensuring the gasket is properly seated. Tighten the bolts to the manufacturer's specified torque (consult your repair manual). Don't overtighten.
8. Reconnect Everything: Reconnect the vacuum hoses and the electrical connector (if applicable), ensuring everything is properly seated.
9. Reconnect the Battery Cable: Reconnect the negative battery cable.
10. Check for Leaks: Start the engine and check for any vacuum leaks around the EGR valve.
11. Clear OBD Codes (if necessary): After installing the new EGR valve, you may need to use an OBD-II scanner to clear any trouble codes that may have been set.
Important Considerations:
* Carbon Buildup: Significant carbon buildup on the intake manifold is common and can contribute to EGR valve problems. Consider cleaning the entire intake manifold while you're at it.
* Gasket: Always replace the EGR valve gasket with a new one. Reusing an old gasket can lead to leaks.
* Repair Manual: This is crucial! The steps and locations will vary depending on the specific year and engine of your Ford Contour. Do not attempt this repair without a proper manual.
* Professional Help: If you're not comfortable performing this repair yourself, take your vehicle to a qualified mechanic. Improper repair can lead to more serious engine damage.
This is a general guideline. Always prioritize safety and refer to your vehicle's repair manual for detailed instructions and specific torque specifications. Failing to do so could lead to damage to your vehicle or injury to yourself.
