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2002 Mazda Protege SE EGR Valve Replacement

Is your car having a hard time holding idle...

iFixit Library 2002 Mazda Protege SE Moderate 30 minutes - 1 hour Guide 130524

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This attributed iFixit guide is displayed through Fixonic's recorded commercial API permission. iFixit remains the independent source and author of the procedure.

Guide overview

Before you begin

Is your car having a hard time holding idle RPM? Is it stalling out? The problem could very well be your exhaust gas regulator (or EGR) valve. A common issue occurs when the valve becomes extremely dirty and it either sticks open or closed. This guide will help walk you through the steps to remove your old valve, and replace it with a new one.

Step 1

Repair step

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Pull the latch to open the hood of the car.

Step 2

Repair step

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Once you have opened your hood, use your 10 mm wrench (or 10mm socket) to disconnect the negative lead from your battery terminal. This will ensure that no electrical damage will occur during the removal and replacement of your valve.
If you forget to remove the lead from your battery terminal, there is a chance of electrical damage to the car and to you!

Step 3

Repair step

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TOOL USED ON THIS STEP Phillips #00 Screwdriver Referenced by the iFixit guide

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Remove the intake line by loosening the screw in the clamp that holds the intake line near the air-box.
Remove the fuel solenoid from the bracket in the top of the intake line and set it aside. This is so that you can fully remove the intake line and have enough room to pull the old EGR valve out.
On the side of the intake line you will find another small hose. Gently remove it and set it aside.
Be careful! When removing the hose from the side of your intake line, you could easily crack or damage the hole it fits into. Make sure to be extremely gentle during removal!

Step 4

Repair step

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TOOL USED ON THIS STEP Phillips #00 Screwdriver Referenced by the iFixit guide

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Fully remove the intake line and set it aside.
Make sure to keep track of your clamps! It is easy to drop them if you loosened the screw far enough for the clamp to slide off.

Step 5

Repair step

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Carefully disconnect the electrical connecter and lay it to the side.
When replacing the valve, be sure to reconnect the electrical connector firmly until you hear/feel a subtle click.

Step 6

Repair step

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There are 2, 12 mm bolts located on the bottom of the valve. You can loosen them using either your 12mm wrench or socket depending on what is easier for you. Once you have completely loosened the bolts set them aside and pull your old valve out.
There should be a gasket located between the valve seat and valve face and it is very easy to drop! Make sure you have a hold of it when pulling out your valve.

Step 7

Repair step

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TOOL USED ON THIS STEP Phillips #00 Screwdriver Referenced by the iFixit guide

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Once you've removed your old valve completely, you can begin replacing it with your new valve in the exact reverse order of removal. Be sure to check for tightness on all bolts, screws, and hoses.
Don't forget to place your new gasket between the valve seat and face before tightening down your new valve.