My cougar needs new EGR valve. They squeezed the 4.6 litre engine into it. My question is, how hard is it to get out and then back in? I can barely see the top of it behind the intake manifold so don't want to get it off and not be able to get it back in. What size bolts hold it in? I'm sure they are metric. Any help would be greatly appreciated.
I would worry less about the mount bolts and more about getting the pressure fittings off. These can be a real bear if you haven't done a thousand of them. You may have to cut some cheap wrenches in half to gain access to them or use crowfoot wrenches or alot of heat without melting fuel lines, engine parts ect.
Before you do anything, go to your Auto Parts store and buy the manual for your wonderful Cougar. The $20.00 will be the best money spent if you plan on keeping that car for awhile. The instructions and diagrams will tell you how to or not to replace the EGR valve.
How do you know that you have a bad valve? Are you just going by the code,or did you have it checked by a tech.? I have replaced very few valves.If you have a v vacuum pump you can check your egr valve. Apply vacuum an it should hold. Now with engine running apply vacuum does the engine stubble or stall? If the valve holds vacuum its good, an if engine stubble's the ports are not plugged. If all that checks out good the problem is most likely the DPFE sensor. If i were there with a scanner i could tell you exactly what wrong.Its not impossible to change the valve take your time an be patient.
Go to a library that carries the ALLDATA data base. This amazing system has all information you will ever need. Even secret recall campaigns can be found here. Anyways, you are wasting your money to replace the EGR valve. For the most part, they can just be cleaned out with a solvent like Gum-out or butyl cello-solve and returned to service. Usually, these valves get gummed up when the IAC valve is dirty or you are using cheap gas and/or cheap oil. You are right about being metric, but a 13mm is the same as a 1/2 inch. A 14mm is the same as a 9/16 inch. You can even clean this valve by using Amsoil Foaming Cleaner through the intake manifold with the engine running full warm. Eventaully, this cleaner will penetrate the valve and allow it to close. You can tap it lightly with a mallet. Follow with a Gum-out chaser. Good luck!!
