Mazda Protege/Protege 5 Air intake Hose
The adventure, The Process, and The How-To Video
A couple of weeks ago I took the car to get an oil change at Brake Masters. They did their usual awesome job of getting me in and out quickly; changing the oil, rotating the tires and making recommendations as to other maintenance issues. Along with the oil change, I had them replace the air filter and was on my way in less than 1/2 hour.
A few days later I noticed that my Mazda Protege was starting to lug off the line. At first, I assumed it was because it’s the time of year here in Arizona that we switch from shoes to flip-flops and I was having trouble adjusting to the lack of a heel when shifting. A couple of more days later and it was getting really bad lurching as I shifted from 1st to 2nd and the check engine light came on. So I popped the Mazda’s hood and took a look.
I checked that everything was tightly connected, no loose hoses or wires. Based on past experience with 80’s and 90’s model cars and the owners manual I was convinced I had an emissions issue with a faulty EGR Valve. As it turned out with the hood up and the engine idling, I could hear a hiss. Closer inspection revealed the problem – a cracked hose leading from the air filter to the intake manifold.
Now the fun really starts! I went online and pulled up the phone numbers for Checker, Auto Zone and Pep Boys – then started calling.
Trying to find the part for my Protege turned out to be a royal pain as I didn’t know what Mazda called the part, nor did the clerks.
After finding out that none of the stores carried the part, I called the local Mazda dealer and found out the hose is called an air induction hose (air intake hose for normal people). I found out that the rubber degrading and cracking was par for the course with these hoses on the Protege in hotter climates like Southern Arizona; they, of course, carried the part in stock for $119.97.
Armed with the Mazda name, part number and not wanting to spend that much for a part that wears out so quickly I called the parts stores back. Again no luck finding the part, but one of the stores Auto Zone referred me to a local parts chain Merle’s Automotive Supply (Merle’s gets the plug for giving me an aftermarket part number). With a brand name and model number in hand again I called the local shops. Unfortunately, no one stocked the aftermarket air intake hose even though it’s used on 1999-2003 Mazda Protege and the Mazda Protege 5 2.0L and as the dealer told me the rubber cracks with heat and age. I found out I could special order the part for $44.99 but it would take at least 5 days, so…
Being a computer geek I looked online and found the aftermarket air intake hose on Amazon for $27.97!
Great deal huh? Well maybe not.
I went ahead and ordered the Dorman 696-601 (for Mazda Protege / Protege 5 2.0L) from Amazon and since it was so cheap I paid the $19.97 for overnight shipping; what a long night that turned out to be. Once the part was ordered, I still had the issue of a seriously cracked air intake hose – Duct Tape to the rescue!
With the hose taped up, I could drive short distances and prevent debris from getting into the intake manifold. The check engine light even went out after a couple of miles (melted into place forming a seal of sorts with the hose).
Since the duct tape I used had a max temperature range of 200° F driving any distance was out of the questions, But it didn’t matter as it would only be a couple of days… or would it.
Amazon emailed me the next day saying the part had shipped, so I was pretty excited – I’d expected it to take a few days to be picked and packed. Unfortunately the part didn’t arrive overnight, in fact FedEx never received the part from Amazon. So I went online to Amazon, struggled to find a way to contact them and finally got ahold of a support rep.
To give them credit, they issued a credit on the next day shipping – but that didn’t do me much good. The next day I get in touch with Amazon again and after a very frustrating conversation end up with a new part to be shipped next day on Monday (it was Thursday).
Frustrated but unable to do anything, I waited. It was shipped on Friday; delivered on Monday.
Dorman air intake hose in hand, I pop the hood, struggle to remove the old part and get the new hose installed in about an hour.
Changing the hose should have taken less than 10 minutes, but I ran into a problem with an odd metal piece which slips into a slot on the hose. It had become wedged with age and I was afraid to use too much force, which might have broken something else. After trying several methods to separate the bracket, I was finally able to pry it loose with a flat head screwdriver.
Once installed a quick jaunt around the block and all was well.
Update! – I Just came across this great video on YouTube that shows step by step how to replace your Mazda Air Intake Hose with the aftermarket Dorman Air Intake Hose.
Yo Jack – you really rock. Your post saved me half the price, and a 1/3rd if I went by what you could get it locally for. I really appreciate brother.
2003 – Protege 2.0L
I read that that Dorman 696-601 is only for 1.8L and 2.0L engine.If the engine is 1.6L does’t fit. What engine is yours?
Jason Saeler says
2.0L engine – if you get the dealer part number, you may be able to find what you need by going to the Dorman site and using their OE search number function. TryDorman 696-604 Air Intake Hose, it fits the 1.6L on the 2000 Protege’.
thanks for posting this man!! started having a rough idle in my ’03 P5 last week and got a check engine light…everything I read online pointed towards a dirty EGR valve, but when I got the CEL code checked at auto zone it threw this code: P0171..Which means a lean air/fuel ratio cue to vacuum leak or dirty MAF sensor…I took apart my intake to check for cracks and clean the MAF and immediately saw the crack underneath the Intake Hose (just like yours)..have been looking around online for this part for a bit to no avail til I came across your post..gonna order tonight, hopefully I’ll get it quicker than you did..haha..thanks again
Jason Saeler says
Thanks for posting Bdon.. Hopefully that code “P0171? will help other avoid the dealer shaft 🙂
same problem – same code – same duct tape – even the same place where I bought the same hose !!
I tried to pick out the metal thingy with my fingers but its too tight – shall try the ‘safe screwdriver method’ tomorrow and replace the hose.
I owe you one Jay!!
Tore apart the engine tonight with the intent of cleaning out my egr only to discover the previous owner had upgraded to the newer Canadian “non-fouling” one. As soon as I touched the hose, the REAL culprit for my poor idling was clear…
I went to my local junkyard to find a car that had already his hose replaced and in good shape,
the hose total cost 10$
Good deal, wonder why i didn’t think of that!
I bought a new 2004 RX-8 in July 2004. It has been my daily derivr for 4 years and I have not had any problems with it.Some things to keep in mind.1)The car consumes oil. It is not very much. About a quart every 2000-3000 miles. I have seen some people say more, some say less. I would check it at least every thousand miles. It does not take too long, and it can be done in the time it takes to fill up with gas.2)The stock tires cannot be driven on the snow. Get snow tires if you plan to drive in the snow. With snow tires it works great in the snow.3)I have always warmed up my car. I will let it warm up for 3-5 minutes in the winter, and about a minute in the summer. I don’t know if this prevents problems but the engine will idle high when it is cold which makes shifting difficult with a manual transmission.
Janine K. Dickson says
So, my 02 Protege was pinging slightly at low RPMs under load and sometimes suffered some hesitation just off idle when pulling away from a stop. Put in premium fuel and the pinging stopped, but I knew it was a band-aid solution. After doing some research on forums, I was 90% sure the air hose was my problem. Many were experiencing similar problems along with rough idle and the occasional CEL (check engine light). Sometimes more expensive/complicated solutions were suggested initially which didn’t fix the underlying problem of course.Sure enough, when I took out my OEM hose, it had a giant crack in it (you couldn’t tell just by feeling it). Replacing it took me about 45 minutes (taking my time and also cleaning up the engine bay) and fixed 100% of my car’s issues. So I’d say if your Protege is experiencing similar problems and you’ve never replace the air hose, REPLACE THE HOSE FIRST. It’s easy and cheap to replace and is very likely what’s causing problems.
Thank you all for the great information!
The large crack on the hose was hard to spot if you were not looking for it.
Duck tape helped until I received my new Dorman hose from Amazon.
The cost was like $26. Installation was not difficult at all.