How to fix Mazda Protege P0402 Blocked EGR Passages

How to fix Mazda Protege P0402 Blocked EGR Passages

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bjkarana says:

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. 

allcoupedup says:

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.

Colon Cavitys says:

ok ive been trying to fix my code 71 egr system my egr valve is fine but im
gonna try cleaning my egr passages anything else it could be tho

Pony Rider says:

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

hammerofjezabel says:

I bought a 2000 Mazda Protege with 130,000 miles in 2011. I found out that
the EGR port was plugged (intentionally) and the sensor was cut but left
plugged in. Everything runs normal.

Vacmasterthegreat says:

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.

briansmobile1 says:

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

Soldier53flyer says:

Drop, a fork lift on it! lol

Usernameinvalid16 says:

Hey Brian i am Glad you made this video. My friend has a 1988 Mercadys Benz
Gas Engine Inline 6, it will not pass emmisions ONLY AT IDLE though. I’m
guessing its Dirty mass Air Flow Sensor Is that a possibility? I will look
for Cracks in the intake Manifold and stuff too.

briansmobile1 says:

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

shepd3 says:

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.

vtecboy9 says:

hello, can this be done as preventive maintenance?

CoolasIce2 says:

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 says:

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!

007Cornhusker says:

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

briansmobile1 says:

Vacuuming is another good one.

ryansauto93 says:

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 says:

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.

torifan1976 says:

So did you run Spanky off?

jvp367 says:

How many miles do you think it took for the EGR passages to get all blocked
up like that ?

Roly Wiener says:

why not use that seafoam stuff?

DJDevon3 says:

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.
🙂

trevorlee164 says:

Is this what could be happening with my forester 2.5l BC on extreeeemmly
cold mornings it will stall and on regular driving it will jerk the engine
right out the gate

briansmobile1 says:

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

MrNightpwner says:

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.

epiphaknee says:

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.

Micscience says:

Brian is a secret fan of Pink ‘o’/

briansmobile1 says:

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.

briansmobile1 says:

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

briansmobile1 says:

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

briansmobile1 says:

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

moparmania74 says:

brian i see you talking up the chemtool alot so i decided to buy some when
i needed to clean my intake manifold/head surfaces off before putting it
back on a 318. well i was very disapointed with the stuff! i almost think
hot water would have worked better…

briansmobile1 says:

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!

playstation2bigs says:

brian just a sideline car mechanic?

briansmobile1 says:

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?

briansmobile1 says:

You’re welcome. It could be this.

Yod S says:

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!

WillyLin says:

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

Dirk Diggler says:

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.

briansmobile1 says:

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

briansmobile1 says:

That’s right!

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