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How to Replace the EGR Valve in a Villager

by Leonardo R. Grabkowski

The EGR (exhaust gas recirculation) valve is a vital emission-control component on your Mercury Villager. Faulty EGR valves can cause your engine to run rough and decrease fuel efficiency. The most common symptom of a faulty EGR valve is a check engine light with the trouble code "P0401".

Step 1

Let the engine in your Villager cool off for at least 30 minutes prior to beginning the procedure. Engine components can be very hot after the engine has been running.

Step 2

Typical EGR valve

Locate the EGR valve. The Villager's EGR valve is located on the driver's side of the engine bay, next to the intake manifold. Use the photo as a guide.

Step 3

Use your hands to slip off the vacuum hoses. The EGR valve has two hoses, one for intake and one for output. Do not use pliers to help you remove the hoses; they are fragile and easily damaged.

Step 4

Use your socket wrench to remove the mounting bolts for the EGR valve. Most EGR valves have three mounting bolts. Use a standard socket wrench to remove them.

Step 5

Slip the EGR valve away from its mount and set it aside.

Step 6

Remove the old EGR valve gasket; it cannot be reused. Clean the mounting spot with carbon cleaner and a towel.

Step 7

Mount the new EGR valve and gasket. Tighten the bolts by hand to quickly secure the EGR valve, and then tighten them with the socket wrench.

Connect the two vacuum hoses. Start the engine and allow the diagnostic system to cycle for a few minutes. Your check engine light turn off shortly.


  • Use a bolt penetrator, such as Liquid Wrench, if the EGR bolts are difficult to remove. The 1993 to 2003 Nissan Quest is a rebadged Mercury Villager. This procedure is identical for Nissan Quest vans produced during this time.


  • Do not install a new EGR valve without a new gasket.

Items you will need

  • Socket wrench set
  • Liquid Wrench (optional)
  • Replacement EGR valve
  • Replacement EGR gasket

About the Author

Leonardo R. Grabkowski has been writing professionally for more than four years. Grabkowski attended college in Oregon. He builds websites on the side and has a slight obsession with Drupal, Joomla and Wordpress.

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Photo Credits

  • ifcar/, samuraiaz/