How to fix Mazda Protege P0402 Blocked EGR Passages

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How to fix Mazda Protege P0402 Blocked EGR Passages

[@sixdoubledeuce]

Laughed when I saw this. Started working on a white 2000 Protege a few months ago when it threw a P0171. After cleaning the MAF didn't work, I noticed the same crack in the air intake hose and replaced it. Car ran fine for a few months but then threw a PO171 again. While tracking that down, head gaskets blew. Mechanic took care of that and timing belt, but then a few days later, P0301 misfire. I replaced the fuel pressure regulator, spark plugs, and pcv valve no problem, but when changing the air filter I noticed two of the plastic holding clips on the filter housing box were broken. It's just one thing after another on that car! Guess the good news is I'll know what to do when inevitable EGR codes show up ;-) As always, thanks for your videos!

[@briansmobile1]

John Heyer You're welcome John- good luck! This car was quite the project for sure. I don't remember if this video included pulling the intake and cleaning out all the carbon from the intake manifold passages, but that helped a lot too.

[@007Cornhusker]

Brian i think its great that you do a thorough job and go above and beyond what you are expected to do.

[@logicgyrl9421]

Simple, easy, not expensive, tools on-hand.... thanks for the video. You rock and do dishes too.

[@mosca3]

Best explanation and repair I have seen for this problem on Proteges. I have had several mechanics just yank the EGR and give it a cursory cleaning, then just shrug their shoulders when P0402 pops up a day later.

[@briansmobile1]

The singer? Hells ya I am. No secret there- she's got attitude, she's honest, she's open/expressive, and she's TALENTED. I'm a fan!

[@jdykert]

Thank YOU for this video, after years of having my CEL on, this simple passageway cleaning took care of it. I didn't have to remove the intake manifold either

[@briansmobile1]

I hadn't seen it- I'll have to check it out. Good for you man!

[@shelleywilson3017]

I'm such a chick, . . . although I've learned something about cars, the thing that rings true to me is your comment doing the dishes. Taking out the garbage without being asked, giving her a single rose just for shits and giggles, offering to make dinner, whether it be actually cooking or making the decision of where to order in from and saving the best for last, . . . take the kids without negotiations, without a second thought so she have some down time - now, THAT'S how you can a lot of lovin' cuz to a woman with a husband, kids, a house to maintain, a job outside the home to tend to, what I've described is foreplay; it shows her that you appreciate how hard she works to maintain her humans. After all, couples are supposed to be partners, not leader/subordinate. It goers both ways - I would have mowed the lawn for my hubby, . . . if he ever had done it in the first place. Meeeeow. Anyway, thanks for your vid

[@rushadewright3772]

This is one of your best videos bro respect again *The Mazda Family*

[@bjkarana]

I've had EGR issues on my wife's 99 Protege 1.6 for several years. I cleaned the throttle and EGR apparatus with carb fluid,and that helped with the rough idle for a few months, but I didn't realize that the passage to the EGR might be blocked as well. I'll open up the exhaust manifold this weekend and see if I can't finally fix this.

[@fredeblack]

Thanx for the video..I did the seafoam treatment after I was getting a random misfire po300, and it reeally helped, I need to buy a stubby ratchet to get the egr valve off because the lack of room...I have a complete set of micro tools, scrapers, etc. The throttle body is clean and no buildup after the seafoam, I just want to try an avoid pulling the manifold if at all possible. Thanx again!

[@DJDevon3]

Brian I have an EGR inspection, testing, and cleaning video up for the 626/MX-6/Probe/Protege. Any chance you saw it before doing the repair? I go in depth into explaining the EGR system on my car. The Protege does have a much different EGR system but the way it's routed is similar enough for the FS engine used in other cars to be useful. I'm not a mechanic just a DIY'er. Love your videos. Always excited when I see you working on a Mazda. :)

[@rushadewright3772]

Thanks much for this video bro respect and big up yourself... *The Mazda Family*

[@dnlmachine4287]

Wow - that owner has a dirty car. I have a 2002 Protege - well designed and easy peasy lemon squeazy to work on. I love it, and parts are cheap like borscht. I love taking it apart and cleaning it then feeling the placebo effect of more performance and better operation. But I like to take care of my cars and this one is just great for teaching my niece how to drive and take care of a car so she doesnt wind up like some dumb-dumb with her only tool being a cellphone while stranded. Stay gold.

[@briansmobile1]

Thanks!

[@D4x4Bronc]

love these styles of vids.

[@davidchaisson8888]

Thanks a bunch for posting this I'm sue my 99 Protege has the same trouble.

[@briansmobile1]

Have you done a good thorough throttle/ intake cleaning on it?

[@briansmobile1]

I wish I knew enough about the Wildings to suggest one way or the other. Perhaps you could find out more on the subject from them?

[@FatherEagleSniper]

On our 1998 Mazda Protege, it came up with a P1195 and were pretty sure it's the EGR as well. You think thats right? This is the best video i've seen on the EGR stuff. Good details. thanks for posting this vid!

[@briansmobile1]

Loosen the other end of it and put some wd-40 or the like on the nut. This should help. Always start the threads by hand so they don't cross thread. Best of luck to you!

[@briansmobile1]

That's right!

[@briansmobile1]

There's a rod with plate on it in this vid that the plates were super dirty and then I cleaned them. All you need to do is verify that the linkage on the outside is OK. If it's undone- get it hooked up or braced open.

[@briansmobile1]

Vacuuming is another good one.

[@shepd3]

It's great for carbon, less good for hardened stains. :) I've tried both uses and it also worked wonders on a throttle body and did nothing for the manifold/head mating surface.

[@pcheese1]

Hey Brian, thanks for the video. I also have a 2000 protege 1.6L with a P0402 excessive flow. I'm new to this but want to learn. After some research, this seems to be a common problem. How do u suggest I start? Take apart and clean out egr valve, manifold and throttle body? Do I need to run any tests to check if it's not electronic? Some of the Wildlings to the North have used a Canadian EGR valve with hoses, should i do the same?

[@briansmobile1]

I've seen it, but more common on your red truck is a failed cat that's blocked up and no codes. My white one even did that. Fuel injector cleaning is best done off the car so the cleaner doesn't cement the upper cylinder with white rock.

[@spelunkerd]

Have you ever seen EGR blockage cause problems with no code in a vehicle with OBDII capability? My 98 Ram has a subtle misfire (no code), and I wonder if an EGR/throttle body cleaning would be worth a go. Also, what do you think about fuel injector cleaning?

[@Mail4dalej]

Good marriage advice. It works!

[@allcoupedup]

Had this code on my 2002 Protege5. I exchanged the EGR valve with one from another Protege that I had. Its a pain in the ass to change. Close to the firewall and the bolts are a little recessed into the valve housing so can't turn the bolts much. Thanks for the explanation though.

[@briansmobile1]

You're welcome. It could be this.

[@briansmobile1]

No. She was here today. She got snatched up for another engagement temporarily. She's pretty important/in demand.

[@Micscience]

You go girl!

[@briansmobile1]

Sure.

[@StreetersGarage]

Just did the same process on my son's 98 Avenger (420A). The egr tube into the intake tube was completely plugged up as well. Back of the throttle body was just as bad.

[@ding0925]

Napa use to sell a 5gal bucket of carb cleaner the i would dip every thing great stuff...

[@briansmobile1]

It's probably broken linkage to the manifold butterfly on the passenger side of the intake manifold near the cylinder head.

[@Vacmasterthegreat]

I got a code for the egr valve on my ranger. I wasn't about to deal with it at that moment, but a day or two later the light went off. Did the light go off because maybe the egr was stuck and it freed itself or did the light go off because after a while it goes out, but the problem is still there? It's been about 2 weeks.

[@MrNightpwner]

Could you do a video on P0400? I've cleaned every passage I could on the egr system but the code won't go away. I even changed the gas cap. It's a Suzuki if it matters. All I haven't done is change the hoses, some are a little hard and slightly cracked at the tips but not too bad. My throttle body was cleaned about 1.5 years ago.

[@jaberwocky6669]

Thank you. Thank you. Thank you.

[@briansmobile1]

***** You're welcome!

[@jaberwocky6669]

That's dedication right there.

[@ryansauto93]

Brian, is there a specific reason that the EGR passages got so blocked up on this car and why it had so many repeat offenses for the EGR? Just mileage, poor maintenance, other problem? Great video by the way, as usual!

[@briansmobile1]

I'm professional ASE- and couple decades plus experience.

[@briansmobile1]

The MAF on this car was filthy and that threw off the air/fuel metering. (due to the previous owner running an air filter you could plant a garden in) Also the throttle body had no shortage of dirt/crud to begin the build up. Add 180K miles and it's bound to get blocked.

[@TheStpeteboy]

Hey Brian, I got a 97 Nissan Quest and the removed the Egr valve but I can"t get the reinstall the large flare nut! Is there any tips or special way of installing the egr pipe nut? Thank you!

[@epiphaknee]

I wonder if Napa or AutoZone, sell a screened EGR valve gasket, like they do for some GM and some Ford applications, for this application? These gaskets stop (most of) the carbon at the screen and then only a pick tool is needed to remove the carbon at the gasket.

[@briansmobile1]

You mean the can next to the B12 on my shelf?

[@OminousRooster]

Nice Job on the Vid, I have both of my vehicles with check engine lights. One is for EGR on a diesel truck.Are you interested in to shoot a vid on a Duramax for EGR? I see the power-strokes on YT but not for Duramax.

[@briansmobile1]

Could be slipping clutch/torque converter.

[@dreamer2355]

The dishes and sex comment made me LOL so loud! Great video!

[@edwinpadilla5188]

I have a 03 mazdaspeed n keeps giving me the vtcs code for low voltage....when driving the car only issue I have too is when I'm already at a high speed n I give it more throttle it Boggs n jerks around...couod this be the butterfly in the intake might be sticking....pls help driving me crazy

[@willycwlin]

Brain How do you like seafoam?? and what do you use it on???

[@Electromagnetor]

gonna try it on my protege

[@resaadmahomed8259]

Hi. thanks for the info. Have a bit of a problem with my Mazda etude. south Africa version of protégé. its 1.6L zm motor. with twin coil packs. car has done close to 450 000km and still love it too bits. when I rev it up its sound like a bearing knock. on idle till about 2000rpm its quite. after 2000rpm it makes like metal grinding noise. can anyone offer any advice

[@ritahudson9747]

Redaad, hello, did you find out what the grinding sound was from?I have a 1993 Mazda protege 1.8 lt , trying to get running thanks

[@vtecboy9]

hello, can this be done as preventive maintenance?

[@Micscience]

Brian is a secret fan of Pink \'o'/

[@briansmobile1]

150K

[@sancheztorres35]

Big question i got a 2.0 protege 2003. The engine try to stall sometimes and sometimes shut off completely .code appear p0401 i got the car at many mechanics and no one can find the problem is this same issues linked with the egr? Thanks hope u can help me about

[@aeridyne]

I've had rough idle and wanting to stall multiple times over the years on my 02 with 2.0 engine. Idle Air solenoid, EGR, and the main intake rubber boot have been the culprit every time, having to go through it all again. Used gorilla tape and zip ties on my rubber boot, mine is torn right in half, tape holds it together, hah.

[@all4Hisgloryalone2Tim215]

Are you located in southern California? Id like to have you work on my protege

[@genericusername1365]

I think he's in Arizona.

[@TheTurpin1234]

Thanks, I really dont wanna remove my intake manifold lol

[@christophervoight2684]

I have a code P0300 for multiple misfire. It's been driving me crazy with a rough idle. You think replacing the EGR could fix this whole mess? I've tested the coils, compression, fuel tests, the whole 9 yards.

[@briansmobile1]

I'm blindfolded as to what car it is as you haven't told me, but it could be a vacuum leak or a bad knock sensor or like you say an EGR valve that's stuck open.

[@christophervoight2684]

Sorry about that. It's a 2002 Mazda Protege 5 with 132K. I replaced the EGR so it wasn't the case. The only other thing I could think of is an electrical connection that got wet after detail. It is what it is. Sold it to a mechanic for what I was into it and off it goes.

[@torifan1976]

So did you run Spanky off?

[@tonyabroadwater8869]

i have a 03 mazda protege 5 and when u go to let out on the clutch it jumps through all gears anyone have any idea what it could be

[@YotaFan1]

I see this on honda V6's all the time

[@briansmobile1]

Bad Crank/ cam sensors. Vacuum leaks. Bad MAF sensor.

[@CoolasIce2]

Yea it's easier to remove the manifold and clean it thoroughly, however Scotty Kilmer would have kept it on and done a 1/2 azz cleaning in 1:34.

[@briansmobile1]

That sounds normal.

[@LucaTheSkunk]

my mazda idles really really low and hiccups sometimes and it will not run with the ac on at idle could this fix it?

[@Arz2003]

Pony Rider really late but if you still own the car you should of checked and replaced all the spark plugs, clean the MAF sensor, clean throttle body. It worked for me but i am still getting a small amount of rough idle but if i do this i am almost sure that it will work even better.

[@briansmobile1]

Who isn't?

[@briansmobile1]

Guilty. I did that too. lol

[@edwizard62]

How long did it take you to do all this? How much would you charge? I need it for my 1996 Protege.

[@JohnattanRivera1984]

It's not that expensive I've done in to multiple Mazda 626 as it shares a similar system. I've gone through almost 2 cans of cleaner per intake manifold.

[@killabee623]

These newer OBD II cars are money pits. Soon as you fart the CEL comes on!!! Love ma 94 jeep none of the extra crap sensors.

[@briansmobile1]

It's all true lol.

[@Soldier53flyer]

Drop, a fork lift on it! lol

[@briansmobile1]

lol

[@s.e.hebert7307]

Consider being a decent human being, instead of exchanging shared chores for sex, and your wife and others will love you the most