How to Install an EGR Valve on a 2002 Ford Focus Wagon
- 1). Turn off the engine and allow it to cool. Loosen the two air intake duct-hose clamps that attach the duct to the throttle body and mass airflow sensor, using a screwdriver. Pull the duct off the throttle body and mass airflow sensor and lay it aside.
- 2). Locate the EGR valve on the driver-side of the engine behind the coil pack. Unplug the vacuum line from the top of the EGR valve. Spray the EGR pipe nut on the bottom of the EGR valve with penetrating oil and allow it to soak into the threads for a few minutes. Remove the pipe from the bottom of the EGR valve using an adjustable wrench.
- 3). On 2.3-liter engines, place a drain pan under the driver-side of the radiator. Loosen the drain plug in the bottom of the driver-side coolant tank using a large screwdriver and allow the coolant to drain into the drain pan. Tighten the drain plug when the coolant completely drains from the radiator. The 2.0-liter engines do not have an EGR valve cooled with engine coolant. Skip this step on 2.0-liter engines.
- 4). Loosen and remove the coolant hose attached to the side of the EGR valve, if the car is equipped with a 2.3-liter engine, using a pair of pliers. Remove the two 10 mm bolts that attach the valve to the engine using a 10 mm socket and ratchet. Remove the valve from the engine compartment.
- 5). Push the two 10 mm bolts through the mounting holes in the new EGR valve and slide the new gasket onto the bolts. Bolt the new valve loosely to the engine and start the EGR pipe nut into the bottom of the valve by hand. Torque the mounting bolts to 15 foot-pounds using a torque wrench. Torque the EGR pipe nut to 84 inch-pounds.
- 6). Reinstall the coolant pipe, if equipped, and the vacuum line. Reinstall the air intake duct. Clear the stored trouble codes and test-drive the Focus to verify the symptoms are gone.
