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Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 2380 (Engine Emission Control System - 2.5L (Hybrid)) >> Removal And Installation >> Exhaust Gas Recirculation (EGR) Valve >> Removal and Installation

Removal and Installation

WARNING: This page is about a different car, the 2010 Mercury Milan and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
  1. Depower the High Voltage Traction Battery (HVTB) system. For additional information, refer to HYBRID SERVICE DISABLE PROCEDURES .
  2. Drain the cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
  3. Remove the Throttle Body (TB). For additional information, refer to THROTTLE BODY .
  4. Release the clamp and separate the upper heater hose.
  5. Release the clamp and remove the bypass hose from the coolant outlet adapter.
  6. Release the clamp and remove the upper radiator hose from the coolant outlet adapter.
  7. Release the clamp and remove the heater hose from the EGR valve.
  8. Remove the bolt and the nut and position the Motor Electronics Cooling System (MECS) coolant expansion tank aside.
    • To install, tighten to 9 Nm (80 lb-in).
  9. Disconnect the EGR valve electrical connector.
  10. Release the engine wire harness retainer from the valve cover stud.
  11. Remove the high-voltage wire harness bolt.
    • To install, tighten to 9 Nm (80 lb-in).
  12. Disconnect the transaxle high-voltage electrical connector.
  13. Carefully position the upper heater hose aside.
  14. Release the clamp and remove the lower heater hose from the coolant outlet adapter.
  15. Remove the 4 bolts and position the coolant outlet adapter aside.
    • To install, tighten to 10 Nm (89 lb-in).
  16. Remove the 2 bolts and the EGR valve.
    • To install, tighten to 20 Nm (177 lb-in).
  17. Remove the coolant outlet adapter and discard the gasket.
    • Clean and inspect the coolant outlet adapter mating surfaces.
    NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the coolant outlet adapter gasket.
  18. Remove and discard the EGR valve gasket.
    • Clean and inspect the EGR gasket mating surfaces.
    NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the Exhaust Gas Recirculation (EGR) valve gasket.
    NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces
    NOTE: Do not reuse the EGR valve gasket.
  19. To install, reverse the removal procedure.
  20. Fill and bleed the cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
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