Protege 1999-2000

Exhaust Gas Recirculation System

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EGR Valve



Operation

Specific to:

Mazda Protege 1998-2003

Mazda Protege5 2002-2003

The EGR system controls the oxides of nitrogen (NOx) emissions. Small amounts of exhaust gases are recirculated to the combustion chamber. The combustion chamber temperature is reduced and NOx emissions are lowered. The EGR control is enabled when the vehicle is running after warm up. The EGR valve is a stepping motor type. The PCM controls the EGR valve to increase or decrease the EGR amount.

Removal & Installation

Specific to:

Mazda Protege 1998-2003

Mazda Protege5 2002-2003

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the EGR valve connector (1).
  4.  
  5. Remove the mounting bolts and remove the EGR valve (2).
  6.  
  7. Remove the gasket.
  8.  
  9. Install in the reverse order of removal.
  10.  
  11. Use a new gasket.
  12.  
  13. Tighten the EGR mounting bolts to 14-18 ft. lbs. (19-25 Nm).

    Click image to see an enlarged view

    Fig. Removing the EGR valve

  14.  

Testing

Specific to:

Mazda Protege 1998-2003

Mazda Protege5 2002-2003



Click image to see an enlarged view

Fig. Related Diagnostic Trouble Codes

Circuit Open/Short Inspection

Specific to:

Mazda Protege 1998-2003

Mazda Protege5 2002-2003

  1. Remove the PCM. See -Powertrain Control Module (PCM)- in this section.
  2.  
  3. Connect the 104-Pin Breakout Box to the PCM using the engine harness connector.
  4.  
  5. Tighten the connector attaching screw.
  6.  
  7. Inspect for an open or short circuit in the following wiring harnesses by probing the applicable sensor and 104-Pin Breakout Box terminals with ohmmeter leads.
  8.  
  9. To check for open circuit:

    Control circuit (EGR valve connector terminal E and PCM connector terminal 68)
     
    Control circuit (EGR valve connector terminal A and PCM connector terminal 72)
     
    Control circuit (EGR valve connector terminal B and PCM connector terminal 46)
     
    Control circuit (EGR valve connector terminal F and PCM connector terminal 56)
     
    Power circuit (EGR valve connector terminal C or D and main relay connector terminal D through common connector)
     

  10.  
  11. To check for short circuit:

    Control circuit (EGR valve connector terminal E and PCM connector terminal 68 to GND)
     
    Control circuit (EGR valve connector terminal A and PCM connector terminal 72 to GND)
     
    Control circuit (EGR valve connector terminal B and PCM connector terminal 46 to GND)
     
    Control circuit (EGR valve connector terminal F and PCM connector terminal 56 to GND)
     
    Power circuit (EGR valve connector terminal C or D and main relay connector terminal D through common connector to GND)
     

  12.  
  13. Remove the EGR valve, and inspect for any damage or clogging. Replace the EGR valve if not as specified.
  14.  
  15. Connect the negative battery cable.
  16.  

Resistance Inspection

Specific to:

Mazda Protege 1998-2003

Mazda Protege5 2002-2003

  1. Disconnect the negative battery cable.
  2.  
  3. Inspect resistance of the EGR valve coils.
    1. If not as specified, replace the EGR valve.

      Resistance should be 20-24 ohms when probed between terminals C-E, C-A, D-B, and D-F.
       

    2.  
    3. If as specified, inspect the vacuum hoses for improper routing, kinks or leakage, and carry out the -Circuit Open/Short Inspection- and repair or replace the parts if necessary.
    4.  

  4.  

 
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