Find egr valve

1. Install a tachometer on the engine, following the manufacturer's instructions.
2. Detach the engine wiring harness connector from the Idle Air Control (IAC) solenoid.
3. Disconnect and plug the vacuum supply hose from the EGR valve.
4. Start the engine, then apply the parking brake, block the rear wheels and position the transmission in Neutral.
5. Observe and note the idle speed.
   

If the engine will not idle with the IAC solenoid disconnected, provide an air bypass to the engine by slightly opening the throttle plate or by creating an intake vacuum leak. Do not allow the idle speed to exceed typical idle rpm.
Using a hand-held vacuum pump, slowly apply 5-10 in. Hg (17-34 kPa) of vacuum to the EGR valve nipple.

1. If the idle speed drops more than 100 rpm with the vacuum applied and returns to normal after the vacuum is removed, the EGR valve is OK.
2. If the idle speed does not drop more than 100 rpm with the vacuum applied and return to normal after the vacuum is removed, inspect the EGR valve for a blockage; clean it if a blockage is found. Replace the EGR valve if no blockage is found, or if cleaning the valve does not remedy the malfunction.

EGR Valve Removal & Install
3.0L OHV (2 valve) and 3.4L SHO engines



Fig. : EGR mounting-3.0L OHV (2 valve) engine



Fig. : EGR mounting-3.4L (SHO) engine



Fig. : Remove the two retaining bolts and...



Fig.: ... remove the valve from the intake manifold



Fig.: Thoroughly clean the mating surfaces of the manifold and the EGR valve (if being reused)

1. Disconnect the negative battery cable.
2. Remove the vacuum hose from the EGR valve.
3. Using a 22mm wrench or crowfoot, disconnect the EGR valve-to-exhaust manifold tube from the EGR valve.
4. Remove the EGR valve mounting fasteners, then separate the valve from the intake manifold.
5. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold.
   

To install:

1. Install the EGR valve, along with a new gasket, on the upper intake manifold, then install and tighten the mounting bolts to 15-22 ft. lbs. (20-30 Nm).
2. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 26-47 ft. lbs. (35-65 Nm).
3. Connect the vacuum hose to the EGR valve.
4. Connect the negative battery cable.

3.0L OHC (4 valve)



Fig. : EGR mounting-3.0L OHC (4 valve) engine

1. Disconnect the negative battery cable.
2. Remove the vacuum hose from the EGR valve.
3. Remove the two EGR tube-to-EGR valve retaining nuts.
4. Remove the EGR valve mounting fasteners, then separate the valve from the intake manifold.
5. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold.
   

To install:

1. Install the EGR valve, along with a new gasket, on the upper intake manifold, then install and tighten the mounting bolts to 15-22 ft. lbs. (20-30 Nm).
2. Connect the EGR valve-to-EGR tube, then tighten the retaining nuts.
3. Connect the vacuum hose to the EGR valve.
4. Connect the negative battery cable.

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P0401 - Exhaust Gas Recirculation Flow Insufficient Detected

Possible causes - Harness or connectors (EGR volume control valve circuit is open or shorted.)
- EGR volume control valve stuck closed
- EGR volume control solenoid valve
- Dead (Weak) battery
- EGR passage clogged
- Exhaust gas leaks Possible solution - Clean EGR Valve
- Repair EGR harness or connector
- Replaced EGR volume control solenoid valve
- Replaced EGR volume control valve

P0401 - Exhaust Gas Recirculation Flow Insufficient Detected

Possible Causes:
- Harness or connectors (EGR volume control valve circuit is open or shorted.)
- EGR volume control valve stuck closed
- EGR volume control solenoid valve
- Dead (Weak) battery
- EGR passage clogged
- Exhaust gas leaks
- Faulty EGR valve

Possible Solutions:
- Clean EGR Valve
- Replace EGR Valve
- Repair EGR harness or connector
- Replace EGR volume control solenoid valve
- Replace EGR volume control valve

OK, if you replaced the EGR hose, did you go all the way to change the EGR Valve? A stuck open EGR Valve can cause a rough idle and almost make it cut off.
Also, a vacuum leak on the EGR valve can cause a rough idle.

Exhaust Gas Recirculation (EGR) Valve Removal & Installation 2.0L Zetec Engine NOTE: When the EGR tube is disconnected from the EGR valve, it must be discarded and a new EGR tube must be installed. The aluminum threads on the EGR valve must be inspected, and a new EGR valve installed if the threads are damaged.
To Remove:

1. Disconnect the negative battery cable.
2. Remove and discard the exhaust manifold-to-EGR tube. Use the following as a guide:
3. Raise and safely support the vehicle
4. Remove the splash shield
5. Disconnect the EGR tube fitting
6. Lower the vehicle
7. Remove the air cleaner outlet pipe
8. Disconnect the EGR tube from the EGR valve.
9. Detach the vacuum line and remove the two retainer bolts.

NOTE: The EGR valve sealing surfaces are soft metals and easily damaged.
To Install:

1. Installation is a reverse of the removal process. Carefully clean all sealing surfaces and install a new EGR valve gasket.
2. Install a new EGR valve tube.

Detach the vacuum line (#1) and unbolt the EGR valve - 2.0L

3.0L (4v) Engine To Remove:

1. Disconnect the vacuum line.
2. Disconnect the EGR tube.
3. Remove the EGR valve and discard the gasket.

NOTE: The EGR valve sealing surfaces are soft metals and easily damaged.
To Install:

1. Installation is a reverse of the removal process. Carefully clean all sealing surfaces and install a new EGR valve gasket.

Detach the vacuum line (#1), unthread the EGR tube (#2) and remove the EGR valve bolts (#3) - 3.0L (4V)

EGR Valve Testing

1. Install a tachometer on the engine, following the manufacturer's instructions.
2. Detach the engine wiring harness connector from the Idle Air Control (IAC) solenoid.
3. Disconnect and plug the vacuum supply hose from the EGR valve.
4. Start the engine, then apply the parking brake, block the rear wheels and position the transmission in Neutral.
5. Observe and note the idle speed.
   

If the engine will not idle with the IAC solenoid disconnected, provide an air bypass to the engine by slightly opening the throttle plate or by creating an intake vacuum leak. Do not allow the idle speed to exceed typical idle rpm.
Using a hand-held vacuum pump, slowly apply 5-10 in. Hg (17-34 kPa) of vacuum to the EGR valve nipple.

1. If the idle speed drops more than 100 rpm with the vacuum applied and returns to normal after the vacuum is removed, the EGR valve is OK.
2. If the idle speed does not drop more than 100 rpm with the vacuum applied and return to normal after the vacuum is removed, inspect the EGR valve for a blockage; clean it if a blockage is found. Replace the EGR valve if no blockage is found, or if cleaning the valve does not remedy the malfunction.

EGR Valve Removal & Install
3.0L OHV (2 valve) and 3.4L SHO engines



Fig. : EGR mounting-3.0L OHV (2 valve) engine



Fig. : EGR mounting-3.4L (SHO) engine



Fig. : Remove the two retaining bolts and...



Fig.: ... remove the valve from the intake manifold



Fig.: Thoroughly clean the mating surfaces of the manifold and the EGR valve (if being reused)

1. Disconnect the negative battery cable.
2. Remove the vacuum hose from the EGR valve.
3. Using a 22mm wrench or crowfoot, disconnect the EGR valve-to-exhaust manifold tube from the EGR valve.
4. Remove the EGR valve mounting fasteners, then separate the valve from the intake manifold.
5. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold.
   

To install:

1. Install the EGR valve, along with a new gasket, on the upper intake manifold, then install and tighten the mounting bolts to 15-22 ft. lbs. (20-30 Nm).
2. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 26-47 ft. lbs. (35-65 Nm).
3. Connect the vacuum hose to the EGR valve.
4. Connect the negative battery cable.

3.0L OHC (4 valve)



Fig. : EGR mounting-3.0L OHC (4 valve) engine

1. Disconnect the negative battery cable.
2. Remove the vacuum hose from the EGR valve.
3. Remove the two EGR tube-to-EGR valve retaining nuts.
4. Remove the EGR valve mounting fasteners, then separate the valve from the intake manifold.
5. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold.
   

To install:

1. Install the EGR valve, along with a new gasket, on the upper intake manifold, then install and tighten the mounting bolts to 15-22 ft. lbs. (20-30 Nm).
2. Connect the EGR valve-to-EGR tube, then tighten the retaining nuts.
3. Connect the vacuum hose to the EGR valve.
4. Connect the negative battery cable.

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REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the EGR valve electrical connector 3. Remove the bolt retaining the pipe assembly from the EGR valve and carefully pull the pipe assembly back. 4. Remove the EGR valve retaining bolts. 5. Remove EGR valve assembly. 6. Remove the gasket. INSTALLATION PROCEDURE
1.
Install the EGR Valve with a new gasket to the intake manifold. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolts through the EGR valve. Tighten Tighten the bolts to 30 N.m (22 lb ft) 3. Connect the pipe assembly to the EGR valve. 4. Install the bolt. Tighten Tighten the bolts to 30 N.m (22 lb ft) . Connect the EGR valve electrical connector.

EGR VALVE IS #2.

Please wait for second post to answer your second question....comes with a few pictures.

The electronic EGR valve and solenoid assembly is attached to the rear of the left cylinder head ,

1. Remove electrical connector (5) at top of EGR valve solenoid.
2. Remove tube mounting bolt (1) at intake manifold.

1. Remove two bolts (4) connecting EGR tube (1) to valve assembly.
2. Remove gasket located between EGR tube flange and EGR valve assembly.
3. Remove two EGR valve mounting bolts (5).
4. Separate valve assembly (3) from engine.
5. Remove and discard metal gasket located between cylinder head and valve assembly.

INSTALLATION

1. Clean area at rear of left cylinder head where it joins base of EGR valve.
2. Clean EGR tube where it joins EGR valve.
3. Position new gasket between EGR valve and cylinder head.
4. Position EGR valve to cylinder head. Install and tighten two bolts (5). Refer to Torque Specifications.
5. Position new gasket between EGR tube flange and EGR valve assembly.
6. Position EGR tube (1) to side of EGR valve and into intake manifold.
   1. Install EGR tube flange bolt (1) at intake manifold. Tighten bolt. Refer to Torque Specifications.
   2. Connect electrical connector (5) to top of EGR valve solenoid (2).Do a final tightening of two EGR tube bolts (4). Refer to Torque Specifications

REMOVAL - 2.4L The EGR valve and Electrical EGR Transducer are serviced as an assembly.

1. Disconnect vacuum tube from electric EGR transducer. Inspect vacuum tube for damage.
2. Remove electrical connector from solenoid.
3. Remove EGR tube bolts from EGR valve.
4. Remove EGR valve from cylinder head adaptor.
5. Clean gasket surface and discard old gasket. Check for any signs of leakage or cracked surfaces. Repair or replace as necessary

INSTALLATION - 2.4L The EGR valve and Electrical EGR Transducer are serviced as an assembly.

1. Assemble EGR valve with new gasket onto the cylinder head adaptor.
2. Loose assemble the bolts from EGR valve to EGR tube.
3. Loose assemble the bolts from EGR valve to cylinder head.
4. Tighten bolts from EGR valve to cylinder head to 22.8 N·m (200 ±25 in. lbs.) torque.
5. Tighten bolts from EGR valve to EGR tube to 11.9 N·m (105 ±20 in. lbs.) torque.
6. Reconnect vacuum hose and electrical connector to electrical EGR transducer.

REMOVAL PROCEDURE

1. Turn OFF the ignition.
2. Disconnect the EGR valve electrical connector.
3. Remove the bolt retaining the pipe assembly from the EGR valve and carefully pull the pipe assembly back.
4. Remove the EGR valve retaining bolts.
5. Remove EGR valve assembly.
6. Remove the gasket.

INSTALLATION PROCEDURE

1. Install the EGR valve with a new gasket to the intake manifold. NOTE: Refer to Fastener Notice in Service Precautions.
2. Reinstall the bolts through the EGR valve into the intake manifold. Tighten Tighten the EGR bolts to 30 N.m (22 lb ft).
3. Connect the exhaust pipe assembly to the EGR valve.
4. Reinstall the exhaust pipe bolt. Tighten Tighten the nuts to 30 N.m (22 lb ft).
5. Connect the EGR valve electrical connector