How do you install a EGR valve on 1999 Mercury Villager?

Answer 1

This is a difficult installation if you are not an experienced dexterous mechanic. The EGR valve is mounted to the rear of the throttle body/upper intake manifold assembly. You will need to loosen the EGR tube that attaches to the rear exhaust manifold. This is best done from under the vehicle. The valve itself is held on by three screws which go in from the back and attach it to the throttle body. One of these screws will be very difficult to reach and invisible, you'll be working by feel. The other two are merely tricky. You won't really be able to see what you are doing. You'll need a small 10mm socket and long extensions to reach from the back and will have to curl you arm around the part to reach the far screw. You'll have to remove various wire harnesses and perhaps some hoses to get if off. It is actually easier to remove the entire upper manifold with the valve attached, just watch out for the small vacuum hoses that attach underneath it. The manifold is plastic so be careful not to break it, and always use new gaskets to put it back on.