10/30/2023 0 Comments Egr valve 2002 mazda protege 5![]() Many have misdiagnosed the early symptoms of a bad EGR valve or like me just simply disbelieve the EGR valve has failed. The only way for the ECU to monitor the EGR functionality is with the boost (MAP) sensor but because it takes a lot of pressure change to cause a failure to be detected, the ECU misreports a P0300 code. The Protege's EGR valve does not have a pintle position sensor so it does not know that it is stuck unlike other cars such as some GMs with electric EGR valves out there (despite the fact that our cars also use electric EGR valves). A P0401 is not as common and usually no driveability issues are experienced. A P0300 code is a more common occurrence with stuck open EGR valves. Later on as the problem progresses, a P0300 random misfire or P0401 EGR flow insufficient codes along with a "Check Engine" light occurs. Early occurrences of this problem usually includes any or combination of the following: rough idle, cruise surge, low idle, or stalling. ![]() When combined with carbon build up (which is normal for all EGR systems) this is a perfect recipe for the EGR valve to seize. The TSBs state that the problem is with water condensation built up in the EGR valve which causes the motor to rust. Mazda USA and Canada has released TSBs on this common issue and also released an updated EGR valve which has a metal shield to seal the stepper motor from the valve/pintle assembly from the elements in order to "correct" the problem. Many have resorted to disassembling their EGR valve and cleaning off the carbon build up in the pintle and housing, but this is only a temporary solution as the problem comes back at a later time. This problem is extremely common on our cars and usually occurs on higher mileage vehicles and especially during cold weather (especially if humid). Many of you have either experienced or know someone who have experienced engine performance or driveability issues with their Protege.
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