How do you remove the EGR valve on a Mazda 626?

Answer 1

On a 1996 Mazda 626 thr EGR valve is very hard to remove, if you simply want to clean it you can do so from the inside the Intake Manifold. Before you do this job you will need to get a new Throttle Body Gasket from your local Mazda dealer or auto parts store. the old one will not be reusable.

1 Remove the air intake and put aside.

2 Remove and connectors and hoses on the throttle body (some coolant will leak out of the throttle body once the hoses are disconnected so be prepared to handle that)

3 Remove 2 nuts and 2 bolts that hold throttle body in place. (You may need to give it a light tap with a rubber mallet or something to loosen it).

4 Remove throttle body from Intake Manifold.

5 use an old credit card or plastic scraper and scrap off old gasket (if using a flat utility knife blade to do this use extreme caution so as not to gouge the mating surface) Do this to both Throttle body and Intake Manifold mating surfaces.

6 Spray seafoam (available at NAPA) or throttle body cleaner into manifold and scrub with an old tooth brush or cloth. Some people use a coat hanger to free clogged EGR hole. (You will see this hole leading down and underneath the intake manifold)

7 Once its cleaned, wipe off excess seafoam or cleaner, place new gasket onto intake manifold and replace throttle body. (You may use high temp gasket maker to help ensure a good seal)

8 Reverse removal order and put everything back together.

*NOTE* Make sure throttle body bolts are tightened down very well. If unusually high idle occurs after reassembly, it is most likely a proper seal was not achieved where Throttle body meets intake manifold. Remove, re-clean, use high heat gasket maker and tighten everything down properly.