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EGR Valve Cleaning on 2014 Sport Nav 2.2D

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#41 ·
Okay Viper we believe we have maybe finally resolved the problem.Firstly after cleaning the cooler we test drove and at about 80 miles lights came just as before at about 80 miles motorway.Then we got really angry and took an EGR cooler out of a perfectly good car and tested that.Well 120 miles later no lights.Tomorrow night were going test it again to 174 miles.I believe it was the EGR COOLER as Mazda had said!
It makes sense as a blockage will throw all the air values out.All the sensors are giving information to the ECU and it’s trying to it’s hardest to compensate by making adjustments to EGR valve etc etc
What doesn’t help is fake codes.The ECU sensed a blockage which normally would be the DPF and your supposed to drive for 15 minutes once blue light came on.The sensors in the exhaust system are designed to detect reduced gas flow which is what happens when the gases are restricted at the cooler.On a long run it senses this restricted flow and warns of DPF soot accumulation,we had already changed the DPF previously.
Tomorrow we will know for sure but I am 99%
Now let’s sort you out Viper.Firstly you can post your EGR cooler to Pontefract and they will clean it within 24 hours (01977 600630) and return.Their website explains everything and we are sending our bad cooler to them next week and testing driving it.The video site I posted shows you exactly how to remove it and our mechanic did ours in half hour as it was his second go.If you want to go that route there a couple of things I think will help.
However it’s late now so allow me the weekend to get my head around your p0401 gremlin 👍
 
Discussion starter · #42 ·
Excellent! Fingers crossed you've got to the bottom of it. It's so difficult to troubleshoot these things.

I wonder is the EGR cooler the cause of my woes too? I had the engine hydrogen cleaned for the same price but I am still seeing a lot of carbon in it.
 
Discussion starter · #43 · (Edited)
@Jay at Would you happen to have the part number handy for the EGR Cooler? I think it's the same engine as yours. There's a few on Ebay for around 60 quid so I'm thinking maybe it's worth a shot rather than sending off the EGR Cooler in the post. Thanks.
 
#44 ·
Our part number SHO1 20 30Y MARAYASU INDUSTRIES CO.LTD
Viper what is your car exactly,age,mileage,service history.I used to be a domestic gas engineer and familiar with combustion and flues which is similar to what we are dealing with.Where ever we have a carbon restriction be it in the EGR cooler,EGR valve,manifold,DPF it will be sensed by the car.Your code p0401 is insufficient air flow.Ideally the cooler and manifold should be cleaned and the EGR BYPASS pipe inspected and cleaned as well.It could well be accumulative effect of all these items.The manifold clean is a bit more difficult.The problem with a used part is you can’t tell how much clogagge you have,how many miles did the vehicle do.You can visually inspect it at one end and try and clean it as we did but we were not able to clean it properly so it was all done in vain and now have opted to send it it to the Egr cleaner company as we do not want to sell a problem car to a customer.Unknowingly we purchased this car from a main dealer part exchange and it presented the problem on the motorway.As we cleaned the manifold first we can only speculate whether just cleaning the cooler would of worked.
However a used cooler most probably didn’t have a fault showing but will to some degree have sootage.Spending £60 when proffessional clean is £89+vat and postage is for us the better option.The EGR cooler is the first place the gases go to and the channels small and I imagine prone to blocking.Mazda will not clean them,just replace.A cleaner cooler may increase the air flow enough to get rid of p0401.We don’t know until we try.Older cars did not have coolers as emissions were not as strict but the AA is reporting this problem across the board for diesel and petrol.
I think you got a chance but by cleaning the used one increase your odds of success.No waiting for postage etc
If it fails your next step is the manifold.
Done slowly it is not difficult especially with video which is looking to remove the manifold as well so certain stages can be skipped.
Were going to take it for a longer run for peace of mind.Update pending 😀
 
Discussion starter · #45 ·
Thanks for the part number @Jay at :)

Mine is a 2014 2.2D Skyactive GJ engine code.

I've been seriously considering buying an ultrasonic cleaner. 6l ones on ebay for around £90. I imagine this place in Pontefract do something similar. I could use this to clean vaeious EGR parta amongst other things. I've watched a few videos on it and most people seem to think they do an excellent job. I'm not sure if the 6l version is big enough for the EGR Cooler but a 10l one is only a few pounds more.
 
#46 ·
Interesting I will have a look too.I will measure the cooler tomorrow tomorrow and send you a measurement.Your engine is the exact same.I saw some one use a suspended glass jar with a wood sander strapped to it do a good job. 👍
 
Discussion starter · #48 ·
I think I'm going to order the 10l one. It is virtually the same price as the 6l version and the question is always going to be in my mind that I should have go the bigger size. It looks like it's going to take a week or so to deliver. There was another version on Ebay which I could have got quicker but they don't deliver to Northern Ireland. Hopefully the EGR cooler isn't too difficult to remove! :)
 
#49 ·
It’s about 15” long as I had to measure the gap on the engine due to the part being already packaged.I am not sure if it will fit lengthwise or you can tip up it side ways.I can send you photos of taking the cooler off and you look at the video as well. 👍 The air box,battey and battery box are only 7 bolts,the rest is straight forward as video,but I can tell what to skip.If you do it on a Sunday I can help on a live chat.
 
Discussion starter · #50 ·
Wow that's really helpful of you Jay. Much appreciated! I had the airbox and battery etc off already and it was straightforward. It was when I contemplated swapping out the vacuum pump. I've thought about it and I've decided to give it another go. I hate the hose clips and removing the hoses but I've ordered a couple of tools that should make it a lot easier. I may as well have another go seeing as I have to remove the battery /airbox etc anyway (to get at the EGR cooler).

I ordered the 10l ultrasonic cleaner and it's been dispatched already. Hopefully it will arrive later this week. If it all works out and does the job, I'd be more than happy to throw your EGR cooler into it at no cost (other than postage obviously). Its the least i can do considering all the help you've given me so far!

I wonder is there anything else other than the EGR valve and cooler l could easily throw in to the cleaner? I was thinking the MAP sensor as it's still a bit dirty but not sure if the water will damge it.
 
#51 ·
Thanks Viper I will consider your offer.But firstly back to the cooler,will it fit into your ultrasonic cleaner?
It is recommended that you either drop the coolant level in your car or catch it when you take the hoses off,our mechanics just dropped onto the splash guard underneath (Or a bit of both).You lose a kettle and a half as reservoir also drops.
The black bracket will be in the way of everything firstly.The hose on the bracket disconnect at connection on radiator.
Under the cooler are two sneaky nuts hiding behind the cable,they support two silver pipes running under the cooler.Remove those and then nuts to cooler and turn cooler over and you access plastic clips to get cable off.You can’t get to them otherwise without breaking them.
There is a little splash guard as well.You only need I think 8mm,10mm and twelve sockets.Note your gaskets,one of them on the cooler is silver colour and sticks to the the inlet pipe.
I looked at the vacuum pump and it seems to have stuff going to other parts.Get a video if you can,I understand why you have hesitated.
The cooler cleaning company won’t touch anything electrical.I filled a spray can lid with just enough carburettor cleaner spray to soak the dirty part of the MAP sensor for 15 mins and cleaned lightly twice.Just pick at with a pin and then everything dry out for 20 mins.
I will investigate the vacuum pump tomorrow.We don’t want to overreach unnecessarily and will speak to one our mechanic mates.Remember Viper if I mess up our mechanics are also mates and will sort us out in an emergency.
Do not want your car sitting on your driveway 😀
 
Discussion starter · #54 ·
Thanks Jay! Yes, I wouldn't want it sitting in the driveway either ;)

I actually have the proper service manual which has a guide on how to remove the cooler. I'll going to follow it as best I can. I'm not great at reading car manuals to be honest.

I don't know if the cooler will fit the ultrasonic cleaner yet until i try. If it doesn't I'll just have to do each end separately. Trial and error really!
 
#59 ·
If you compare to the video certain things can just be placed to one side without compromising access.Use a clear ziplock bag to collect coolant and you can put it back in.Your vacuum pump is fully exposed 👍
 
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