2002 Mazda B2300 2.3L EGR Valve removal

PISCES

MEMBER
2002 MAZDA B2300
140,000 MILES

California Mfd (04-02) plane Jane 2WD was still getting 31mpg. The vehicle looks brand new, inside and out. Vehicle developed what in years past used to be known as an off idle stumble and then it just got worse from there. Idles and starts flawlessly. Accelerating from 1500-1800 the engine starts in with a bucking bronco ride, which occasionallys subsides. The tach does not fluctuate during all this and there are NO codes present. It was checked anyway, but nothing came up. CEL is working before start up.

I replaced the fuel filter, plugs and wires (it was time, anyway) along with cleaning the MAF sensor and replacing the TPS. Yesterday I noticed two small cracks emanating from two of the mounting screw holes on the underside of the coil pack. Replaced the pack but it didn't solve the problem. (I kept the coil pack since that was probably going to present a problem in the future.)

One mechanic insists it is the EGR valve, but, again, it idles and starts fine and no codes corroborate that. Oh, and he wants to R&R the transmission to get to the EGR valve. I've worked as a M/C mechanic, as a Saab and GM line mechanic, and was later certified on commercial marine diesels. This whole thing makes no sense.

So far, I've gotten a lot of advice from mechanics that have claimed to have an answer, but when it came out in the wash, really weren't familiar with this engine. I don't mind giving a "contribution", but at this point, I don't want to throw good money after bad. I tried this route with eBay and lost my shirt. Once burnt, twice shy, but I'd gladly contribute for a correct answer. Can that be done after the fact?

Question 1: Could it be an EGR valve issue? If not, what is going on here, and
Question 2: How the $%^#@ do you get at the EGR valve?

Thanks

4 Replies

ASEMASTER6371

MECHANIC
52,797 POSTS

Mitchel does say the trans has to be removed. Engineers designed this and never had to replace one. Go figure.

As far as us giving you a correct diag, we can give you an opinion but without seeing and working with it, it is hard. We assume you did everything correctly but sometimes things are not what they say they are.

Anyway, fuel pressure has to be at factory specs. A little low and you will have issues.
In todays market, cleaning mass air flows does next to nothing. The carbon deposits impregnate themselves on the wire and cannot be removed with conventional cleaners.
Timing is another issue. I know it has a chain but verifying the marks is needed to make sure there no tensioner or guide faults.
And lastly, the throttle body. If the shaft is worn and has a vacuum leak, it will cause a tip in or as you call it a hesitation.

It is not as easy as you think. I know you have had a lot of opinions and replaced a lot of parts but my suggestion is finding a good tech to pinpoint your issue before you spend way too much money throwing parts at it that dont repair it.

Roy

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Wednesday, October 12th, 2011 AT 12:00 AM

PISCES

MEMBER
3 POSTS

Roy,
You sound well informed. I've been reading many of the questions here and wonder how these people ever made it through high school. You must have the patience of a saint.

The problem basically started during the summer. I replaced the plugs and wires and it went away for about two months (go figure). Then, in the last two weeks, it was like I'd gone to the rodeo. So, I will print this info out and head out to find a mechanic who might be able to handle this.

Additionally, about a year ago, I had replaced the air filter with a FRAM but did NOT use the suggested filter that required the oil film. In retrospect, I would think that arrangement might have initiated an oil film on the MAF wire. Your thoughts? When I did clean the MAF sensor, I used the CRC brand of MAF sensor cleaner.

Thanks,
Frank
I tried to send $20 but the Paypal transaction said the 2carpros page no longer existed. I will attempt to pay with a CC. Let me know if it works for you.

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Wednesday, October 12th, 2011 AT 12:22 AM

PISCES

MEMBER
3 POSTS

Roy,
Do you not think it advisable to go after the EGR from the topside by removing the intake plenum, . IF that were to turn out to be the problem?

Frank

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Wednesday, October 12th, 2011 AT 12:30 AM

ASEMASTER6371

MECHANIC
52,797 POSTS

Thank you.

Use a good name brand air filter and you will be ok. As long as you do not use a cold air intake. They alter all kinds of stuff and all they do is look good.

Mass air flow cleaner is a product that will take some of the carbon off but never all of it. The best repair is replacing the mass air flow.

Anyway, I enjoy helping people as I do everyday. I am a trainer in most of automotive systems and have been a tech for 40 years. I know we are in tough economic times and all our guys here go way out of there way to help in these times. It is who we are. Thanks for the comments.

Roy

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Wednesday, October 12th, 2011 AT 12:33 AM