95 Mercury Cougar headache?

Question

To any experienced auto mechanics out there. I'm trying to replace the EGR valve on a 95 Cougar with the 4.6 V8.... REPLACE IT?!!! I can hardly gain access to it the way it's crammed between the back of the engine and the fire wall. So, is there some little know trick , that I'm not aware of, to getting to it, and acutally removing it?

Answer 1

Are you SURE you need to replace the EGR valve? What are the codes you are getting? P0401 (EGR flow insufficient) or P0402 (EGR flow excessive)? Have you VERIFIED the EGR valve is not working BEFORE you decide to replace it? This is a story I hear ALL the time. To test the EGR valve is working properly, run the engine at idle, remove the vacuum supply hose to the EGR valve. Attach a vacuum pump to the valve, and apply 20Hg of vacuum. If the engine idle quality changes, THE EGR VALVE IS WORKING. The common problem with pre-'96 model year 4.6L SOHC V8s, is for the EGR passages to clog up. To clean it, remove the throttle body 90 degree adaptor to the intake manifold (four 8mm bolts). Once removed, you'll see passages plugged up completely with carbon. Stuff a rag into the intake opening, and scrape out all the carbon. Either clean the carbon off the gasket and reuse, or replace it. This should address the P0401 code, if that's what you're getting. The other common problem is for the DPFE sensor to fail, which will throw the two codes I've listed. This is the sensor with a small and large rubber hose connected to the EGR tube, and a three wire connector. This part can only be purchased from the Ford dealer (part number F77Z-9J460-AB). It is EXTREMELY rare for EGR valves to fail on Fords. Hope this helps.

Answer 2

95 Mercury Cougar

Answer 3

96 Cougar

Answer 4

I have to agree with Dodge Man. The 93 to 96 cougar EGR valves are the hardiest ones to do. There are no secret tricks to replacing them. Just be prepared to lose some skin while doing it because you'll most likely scrape your knuckles more than once.

Answer 5

i own a repair shop,and there's not any hidden secrets on that one i hate doing those,there hard even for any mechanic,all i can say is you must have cruise control and everything on it,because those are the hardest ones to do,you gain access to it the best way you can, i usually start taking loose anything that might get in my way ,and do it that way,i usually run when i see one of those come to the shop,but you,ll get it ,but its not going to be that easy,good luck i hope this helps.