How To: EGR Removal and Cleaning for Rough Idle Fix

[DeadAir]

Just did this to my '03 P5 (105,600 miles) and it was a b**** to get off (Michigan winters + salt = SUCK)

A couple of notes:
PB Blaster will be your friend. Get Brake-Kleen when you pick up the PB Blaster
Go to Sears and grab a 3/8 or 1/4 drive 12mm universal joint socket (not just the u-joint adapter) to get at the back bolt. It's a tight fit and you'll be working blind from above the engine
Remove the battery
Buy new screws for the solenoid. I got stainless cap-head socket screws. Thread pitch is .70 but I don't remember the type (M7 maybe?)

 

[rmak_14]

Just finished up doing this in the morning. car sounds and runs better now but haven't taken it out for a spin yet. If i took off the neg battery terminal to reset, do i need to reload the supermap if i have the SS AFC? also i tried using a t25 torx bit to take off the IAC but no dice. any other ideas on taking that off?

 

[i like speed]

Did mine a while back and got nothing. It wasn't that dirty though either.

I reinstalled the solenoid backwards but that shouldn't make a difference should it?

Edit:+1 for new screws for the solenoid. I had to use vice grips to get one of them out.

 

[mckernan]

still using it 4 years later TY BRITT

 

[SocialStealth]

Just finished up doing this in the morning. car sounds and runs better now but haven't taken it out for a spin yet. If i took off the neg battery terminal to reset, do i need to reload the supermap if i have the SS AFC? also i tried using a t25 torx bit to take off the IAC but no dice. any other ideas on taking that off?

What is an IAC and how do you clean it?

 

[hbens]

p402

Owner of a Mazda protege 2000, DX, 150000 miles , Manual with a question please:I have been getting p402 however my car runs very well, no rough idling, 32-35 mpg highway....I reset and the code comes back after 400 miles or so..where do you suggest I start first: EGR,Maf....thanks a lot

 

[DeadAir]

hbens- You might try posting this in the Protege5 or All Mazdas sections... you might get more ideas there.

FWIW, I'd start with the MAF. Get some MAF cleaner or electronics cleaner and spray it (remove it first), it's easy and cheap. Move on from there.

Good luck (2thumbs)

 

[mckernan]

Owner of a Mazda protege 2000, DX, 150000 miles , Manual with a question please:I have been getting p402 however my car runs very well, no rough idling, 32-35 mpg highway....I reset and the code comes back after 400 miles or so..where do you suggest I start first: EGR,Maf....thanks a lot

sounds like a bad sensor to me

 

[hbens]

Thanks a lot fellas, I suppose start with MAF, gotta figure what that isht is ...lol .I truly appreciate the suggestion. I am thiking since there is no rough idling that the EGR is ok, ...may be.

 

[mckernan]

Thanks a lot fellas, I suppose start with MAF, gotta figure what that isht is ...lol .I truly appreciate the suggestion. I am thiking since there is no rough idling that the EGR is ok, ...may be.

well im basing this on the fact that my egr is bad officially and my mpg is only 16, so it sounds like something else. but you never know.(well me anyways...lol).

you could still try cleaning since it is on 9/10 proteges a problem.

 

[mckernan]

btw the MAF is easy to locate, lol, if that's what you mean. you can see it as soon as you open the hood. check right next to your air box.

 

[hbens]

Ok, I will do that and report .My mpg is good, so i hope it is the MAF or the valve..

 

[steven giampino]

A lot of people have complained about the eratic idle the Protege sometimes gets when the clutch is pushed in and rpms are allowed to fall quickly. The idle will jump anywhere from around 200-1100. This problem seems to get worse when the car warms up. My car started stalling everytime I pushed in the clutch or allowed it to idle. I had to feather it at stops like I was driving one of my old Vegas. Often people would think I was trying to race them because of the revving at the light. So I decided to do something about it.

1. The EGR is located directly below the throttlebody on the 2.0 engine. First remove the upper intake pipe (from IC on MSPs) and you will see it, it has a black circular cap and a grey six pin plug going into it.

2. The EGR is held on by two 12mm bolts that point up towards the throttlebody. Unplug the EGR and then remove these two bolts. The EGR will come right out. There is a thin metal gasket that may come out with the valve, or it may stay stuck to the mounting pad.

3. This is the valve out of the car. It consists of an electric solenoid attatched to a bypass valve.

4. Remove the four phillips head screws holding the electric solenoid from the valve body. This will come apart easily.

5. Clean the inside of the valve assembly completely with a carbon killer of your choice, I prefer Brake-Kleen. I was suprised at the amount of carbon build-up that came out of the valve.

6. Lube the shaft inside with a drop or two of oil and also lube the outside beneath the spring.

7. Reassembly is the reverse of removal. I suggest resetting the PCM while doing this, so the EGR can readjust after you start it.

8. You may want to follow the Manual's suggestion of measuring the resistance of the pins, but my car runs ten times better now, and I have no stalling issues anymore.

9. Time to complete, 30 minutes at most. Good luck.

Britt

u sed u suggest resetting the pcm while doing this????wat is the pcm??

 

[mckernan]

cleaning the egr didn't help me,
my mpg is still bad and cel came back on a week later shooting the same code.

i think it may just be defective, there really wasn't that much gunked in there anyways.

oh wellz, negative 200$ for me

 

[TheMAN]

yeah, had you searched and known anything about the canadian egr valve, you would've brought your car to the dealership already to get it replaced under warranty without wasting time cleaning it

 

[mckernan]

yeah, had you searched and known anything about the canadian egr valve, you would've brought your car to the dealership already to get it replaced under warranty without wasting time cleaning it

i bought it used with 111000km on it.
there is no warranty

 

[ucMP3]

I believe there is an extended warranty on the canadian EGR valves...

 

[TheMAN]

i bought it used with 111000km on it.
there is no warranty

wait, you're trying to argue with someone who already knows more than you about this subject without even searching and reading to begin with?

just like how you shouldn't talk back to your mother, you shouldn't talk back to someone who is more experienced than you

 

[mckernan]

so even though im not the primary owner i can still take it to mazda?

not to mention the car is now 6 years old

 

[hbens]

I dont know anything bout this warrenty and would like to be enlightened by THE MAN. As of now I just replaced the easiest of all-the pcv- valve, no CEL as of now, we 'll see how it lasts. What is this EGR WARRENTY, i will be happy to take it to the mazda dealer if that is the case...thanks to tHE MAN(headbang)