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Home › Mazda › 2003 › Protege5 Automatic › Repair and Diagnosis › Engine Performance › System › Engine Controls - Self-Diagnostics › Diagnostic Tests › DTC P0402: EGR System - Excessive Flow › Diagnostic Procedure

Diagnostic Procedure

  1. Verify Related Repair Information Availability -  Turn ignition off. Connect scan tool to DLC-2. Turn ignition on, engine off. Monitor for FREEZE FRAME DATA and ensure data has been recorded. Check service bulletins for repair information related to this DTC. If repair information is not available, go to next step. If repair information is available, perform diagnosis and repair as necessary. After repair, go to step  5.
  2. Inspect For Other DTCs -  Turn ignition off, then start engine. Using scan tool, check for other DTCs. See RETRIEVING DIAGNOSTIC TROUBLE CODES  under SELF-DIAGNOSTIC SYSTEM. If no other DTCs are present, go to next step. If any other DTCs are present, go to appropriate trouble shooting procedure. See DIAGNOSTIC TROUBLE CODE DEFINITIONS .
  3. Inspect EGR Valve Gasket -  Turn ignition off. Remove EGR valve. If EGR valve gasket is okay, go to next step. If EGR valve gasket is cracked, damaged, incorrectly installed or missing, replace EGR valve gasket. After repair, go to step  5.
  4. Monitor EGR System By Drive Mode -  Reconnect all connectors. Turn ignition on, engine off. Clear DTCs. See CLEARING DIAGNOSTIC TROUBLE CODES  under SELF-DIAGNOSTIC SYSTEM. Start engine. Perform MODE 1 - PCM ADAPTIVE MEMORY PROCEDURE DRIVE MODE  and MODE 2 - EGR SYSTEM REPAIR VERIFICATION DRIVE MODE  under SELF-DIAGNOSTIC SYSTEM. Access ON BOARD SYSTEM READINESS TEST menu of GENERIC OBD II FUNCTION and check EGR System Monitor completion status. If EGR System Monitor is complete, go to next step. If EGR System Monitor is not complete, repeat this step.
  5. Verify Trouble Shooting Of DTC P0402 Complete -  Reconnect all connectors. Turn ignition on, engine off. Clear DTCs. See CLEARING DIAGNOSTIC TROUBLE CODES  under SELF-DIAGNOSTIC SYSTEM. Start engine. Perform MODE 1 - PCM ADAPTIVE MEMORY PROCEDURE DRIVE MODE  and MODE 2 - EGR SYSTEM REPAIR VERIFICATION DRIVE MODE  under SELF-DIAGNOSTIC SYSTEM. Access ON BOARD SYSTEM READINESS TEST menu of GENERIC OBD II FUNCTION and check EGR System Monitor completion status. If EGR System Monitor is complete, go to next step. If EGR System Monitor is not complete, repeat this step.
  6. Verify After Repair Procedure -  Using scan tool, perform After Repair Procedure. See AFTER REPAIR PROCEDURE . If no other DTCs are present, testing is complete. If any other DTC is present, follow appropriate DTC diagnostic procedure. See DIAGNOSTIC TROUBLE CODE DEFINITIONS .
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