P0402 on Mazda
Exhaust Gas Recirculation Flow Excessive
P0402 on Mazda vehicles indicates exhaust gas recirculation flow excessive. Au7o has documented this code across 7 Mazda models — most commonly on 626, CX-3, CX-30. P0402 means the Exhaust Gas Recirculation (EGR) system is flowing too much exhaust back into the intake. The EGR system intentionally routes a small amount of inert exhaust gas into the engine to lower combustion temperatures and reduce nitrogen-oxide emissions, but the flow must be metered precisely. When the PCM determines the flow is excessive — often because the EGR valve is stuck open or letting gas through when it shouldn't — it sets this code. Too much EGR can cause rough idle, stalling, hesitation, and a check engine light. Typical repair costs on Mazda range from $75 to $3,000, depending on the specific model and root cause.
Common Causes of P0402
- •EGR valve stuck open or not closing fully
- •Failed or sticking EGR valve diaphragm/solenoid
- •Carbon buildup holding the EGR valve open
- •Faulty EGR position or differential pressure (DPFE) sensor
- •Leaking EGR valve gasket or pintle seat
- •Vacuum control or solenoid fault commanding EGR open
- •Wiring or connector problems in the EGR control circuit
P0402 on Mazda by Model
Mazda 626(1 issue)
- EGR Valve and Passage Carbon Buildup1993-2000
EGR valve and intake passages clog with carbon causing rough idle, hesitation, and check engine light. Carbon accumulation in EGR passages restricts flow.
Mazda CX-3(1 issue)
- Rear Brake Noise and Premature Wear2016-2021
CX-3 rear brakes produce excessive grinding, squealing, and scraping noises, often well before pads reach minimum thickness. The rear brake design with integrated parking brake drum-in-hat causes uneven pad contact and noise. Rear pads on the CX-3 also wear faster than expected due to the electronic brake force distribution (EBD) system applying more rear brake bias than typical.
Mazda CX-30(1 issue)
- A/C Condenser Leak2020-2025
The A/C condenser in the CX-30 is prone to developing pinhole leaks from road debris impact and corrosion. The condenser sits exposed behind the front grille with minimal protection. Refrigerant loss causes gradual A/C performance degradation until the system stops cooling entirely.
Mazda CX-5(1 issue)
- Mass Airflow (MAF) Sensor Failure2013-2018
MAF sensor becomes contaminated with dirt or suffers water damage, providing incorrect air intake readings. Causes vehicle to enter "limp mode" with severe performance degradation.
Mazda Mazda3(1 issue)
- Rear Brake Caliper Seizing / Parking Brake Cable Corrosion2010-2025
Rear brake calipers seize due to corroded slide pins and parking brake cable sticking, particularly in northern climates with road salt exposure. The integrated parking brake mechanism within the rear caliper corrodes, causing the caliper to not fully release. Results in uneven pad wear and reduced fuel economy.
Mazda Mazda6(3 issues)
- Subframe and Underbody Rust / Corrosion2003-2015
First and second generation Mazda6 models are prone to severe underbody rust, particularly in the rear subframe, control arm mounting points, and rocker panels. Road salt accelerates corrosion to the point where structural integrity is compromised. Mazda issued TSB 09-007/15 and extended warranty coverage for subframe replacement in some regions.
- Rear Brake Caliper Seizing2009-2021
Rear brake calipers seize due to corrosion of slide pins and the integrated parking brake mechanism. Salt-belt vehicles are especially affected. Causes dragging brakes, uneven pad wear, and premature rotor warping. The parking brake cable can also corrode and prevent full caliper release.
- EGR Valve Carbon Buildup and Coolant Leak (SkyActiv 2.5L)2014-2021
The SkyActiv 2.5L engine in third-generation Mazda6 models uses a cooled EGR system that is prone to carbon buildup and coolant leaks. The EGR valve and cooler accumulate carbon deposits over time, restricting flow and causing rough idle and reduced performance. Additionally, the EGR cooler gaskets can leak coolant into the intake or externally, creating a potential overheating risk.
Mazda MX-6(1 issue)
- EGR Valve Carbon Buildup Causing Rough Idle and P0400 Codes1996-1997
The KL-DE V6 EGR system is highly prone to carbon clogging. Soot accumulates inside the EGR valve diaphragm and inside the EGR passages cast into the throttle body and intake. When the valve sticks open, exhaust gas enters at idle and produces a rough, surging, or stalling idle with a CEL. Owners report that on the MX-6, P0400 (EGR flow insufficient) is the most common emissions code, and approximately 95% of the time it is a clogged valve or completely blocked EGR ports in the throttle body, not a failed component. Access is poor: the upper intake plenum and throttle body must usually come off to clean it properly.
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View P0402 across all makes →Frequently Asked Questions
What does P0402 mean on Mazda?▼
P0402 stands for "Exhaust Gas Recirculation Flow Excessive." P0402 means the Exhaust Gas Recirculation (EGR) system is flowing too much exhaust back into the intake. The EGR system intentionally routes a small amount of inert exhaust gas into the engine to lower combustion temperatures and reduce nitrogen-oxide emissions, but the flow must be metered precisely. When the PCM determines the flow is excessive — often because the EGR valve is stuck open or letting gas through when it shouldn't — it sets this code. Too much EGR can cause rough idle, stalling, hesitation, and a check engine light. On Mazda specifically, this code is documented across 7 models.
What causes P0402 on Mazda vehicles?▼
Common causes on Mazda: EGR valve stuck open or not closing fully, Failed or sticking EGR valve diaphragm/solenoid, Carbon buildup holding the EGR valve open, Faulty EGR position or differential pressure (DPFE) sensor, Leaking EGR valve gasket or pintle seat. Specific causes vary by model and year — see the per-model sections below.
How much does it cost to fix P0402 on a Mazda?▼
Repair costs on Mazda range from $75 to $3,000, depending on the specific model and root cause.
Which Mazda models have P0402 documented?▼
Au7o has documented P0402 on 7 Mazda models: 626, CX-3, CX-30, CX-5, Mazda3, Mazda6, MX-6.