New member from Toronto

[gblunt99]

With a 2002 Protege 5 that has an apparently undiagnosable and unfixable problem.

[FE3-323]

Welcome. whats the seeming issue with the p5?

[gblunt99]

2002 P5 Gasping, Stuttering, and Occasional Stall

Hi,

I have a 2002 Protege 5, 2.0L that I bought new. It stays in the driveway winter and summer, no garage. Mileage is now 86,000 km, or about 53,000 miles. So it's 90% city driving, about 4500 miles per year. It had all the warranty maintenance as scheduled, and I've continued to take it in to a trusted garage for regular oil changes/checkups.

Only major repair aside from wear and tear was a leaky fuel pump that caused the gas tank to corrode so had to replace both in 2011.

The Problem Started about two years ago. It began to stutter and choke and gasp as you roll to a stop. Also when you're going up to 40-50 km/hr (25 or 30 mph). Sometimes it'll stall outright when idling.

It's intermittent, not consistent. Sometimes it'll go for 4 or 5 months without doing it. Other times it happens multiple times a day.

Happens with full tank or emptier tank.

It has never shown an engine light.

So Far I Have Taken it to Mazda Dealer for diagnosis. Didn't find anything. All they did was set the idle a little higher, which didn't help/hurt.

Replaced the EGR valve. Didn't help.

Replaced the catalytic converter. Didn't help.

I have tried using "water-remover fluid" when I fill the tank. Thought it helped at first, but it doesn't.

Two days ago I replaced the MAF sensor. Car seemed to be peppier, but it's still gagging.

Today I replaced the spark plugs and the PCV valve. Also put in a new battery (unrelated; the old one--the original, I believe--was corroded). Just drove it a couple of miles, no problem, but as I say, it may be two months before it happens again (or maybe it was the plugs. They certainly looked ugly.

Last week I asked an online "Mazda mechanic" about it (cost $28) and he suggested either the fuel filter (although there are actually two) or the MAF sensor.)

My trusted garage says very unlikely to be the fuel filters because a) they replaced the pump (which contains the filters) in 2011 and b) if it was fuel filters the problem would be consistent, not intermittent.

So, if the spark plugs don't cure it, what do you think it could be?

Could it be they installed a faulty fuel pump? Could it be an O2 sensor (I hope not.)

I'm out of ideas. Any help much appreciated.

Giles

[gblunt99]

To Continue It's not the spark plugs. Today I drove out to the airport and it started stumbling and gasping at 60 mph. When I got back into town it actually quit while I was driving along at 25 mph.

I noticed since I filled the tank three days ago the fuel gauge heading south rather quickly, and today I could smell gas as we were driving. Although not in the driveway. That says fuel pump, no? This problem did start a few months after the pump and tank were installed in 2011. The fuel pump was constantly ruled out because it was new and I suppose because there was never any engine light and the diagnostics couldn't find it. If it is the pump, I hope to god it hasn't corroded the tank again.

If it is the pump, do I have any hope of getting some recognition that this installed problem has already cost me a cat con, an egr valve, a MAF sensor, a diagnostics test? Or am I just gonna have to pay the full cost all over again?

I guess I better move this discussion to another forum--rather lengthy for a New Member intro.

Giles

[me109]

Does this ever happen with a full tank?

I had a similar issue once. There was sedement in the tank that would block the in-tank filter when I turned left with < half a tank of fuel.

Do you have a fuel pump access panel under your backseat? If you do, open it up when the tank is near empty and look inside with a flashlight.

[gblunt99]

Thanks me109,

Yes, it does happen with a full tank.

I don't think I have a fuel pump access panel, but I'll check the online manual when I get a chance. I'd be surprised if it was sediment, what with the two-filter system, but who knows?

[me109]

Well, I mean sediment in the tank. The filter was doing its job keeping the sediment out of the lines and engine, it just couldn't pass fuel at the same time. You may not have the same issue. I fixed mine with a POR 15 fuel tank restoration kit.

[gblunt99]

Thanks for the info. I thought, with a two-filter setup, that some of the unused fuel went back into the tank--or is that crazy? (I'm about as far from a gear-head as you can get.) Removing a gas tank is way beyond my level--plus I have no way to get under the car. I felt positively heroic changing the MAF, battery and spark plugs!

[me109]

Two filters and fuel return are unrelated. You should not have to get under the car or remove the tank. See if you can remove the backseat bottom cushion. Or ask how to do that in the BJ chasis forum.

[gblunt99]

Oh. I watched a POR 15 video and it showed them sloshing a series of fluids around a detached tank--and the sloshing was crucial. But perhaps that was a different kit. Tank is 3/4 full at the moment.

[me109]

No, that's what I did. But I confirmed the diagnosis long before I dropped the tank.

[FE3-323]

Mazda put too much "FORD" into these cars & thus the fuel system design sucks.
The fuel filter system is just silly. Either way i would start with "both" filters.

Have you changed the coil on plugs? apparently the upgrade is to change from the coil on plug system to a coil pack setup from any other Protege/626.

[gblunt99]

No, haven't changed the coils and wires yet. Have to order them. I'm waiting until I get a verdict from the mechanic on what needs doing. And under the category of All Sh*t Happens At Once, I have to replace a brake light and the CD holder under my aftermarket radio/CD player just fell apart and is rattling under the radio. The front part came off and I can see where it had been glued back together after someone broke it (someone at one of the two car radio shops I went to).

[scort4life]

It sounds like the problem I was having with my escort. It turned out it was the throttle position sensor if that car has one.
I did the same thing as you, trying to chase the problem, and the garage couldnt find the issue as it wouldnt happen for them.
Then a buddy suggested swaping the throttle position out. I havent had the issue since! Good luck.

[gblunt99]

Thanks, scort - Yes, I think it has a TPS. I'm taking it for Mazda diagnostics on Friday. I'll ask them to check for that. Cheers.