Manifold/header/muffler/tail Pipe problems of the 2003 Mazda Protege

The contact owns a 2003 Mazda Protege. The contact stated that while driving 45 mph, the check engine warning light illuminated. The vehicle was taken to an independent mechanic for diagnosis where it was stated that the intake manifold needed to be replaced. The vehicle was not repaired and the manufacturer was notified. The approximate failure mileage was 114,000.

The contact owns a 2003 Mazda Protege. The contact stated that the vehicle exhibits a no-start condition. The vehicle was taken to the dealer, and a technician concluded that the failure was caused by screws that have fallen from the butterfly shutters inside of the intake manifold and that the repairs would cost $1000. 00. No repairs were made. The manufacturer was notified; however, no assistance was provided. The failure and current mileages were 107,000.

Loud rattling noise at highway speed, engine light came on. Took to Mazda dealership, found problem to be butterfly valve screws backing out and falling into intake manifold. Estimated repair cost ~$900. 00.

Purchased a pre owned 2003 Mazda Protege with approximately 50,000 miles on it. I drove the vehicle for about 4000 miles before there was an engine failure. There were no events that lead up to this incident. The engine began to make a loud knocking noise. I had it towed to the dealer of purchase. A screw on an the intake came loose and went into the engine cylinder. Damage caused the engine to need to be replaced. Mazda has recall 3005c for this problem for the exact year, model, and engine as the one I purchased. However, the VIN number was a few thousand numbers outside of the recall range. Im stuck with a 15,000 piece of junk.

For over two and a half yrs, my car has had a rough idling noise and the engine often hesitates and wants to turn off. On several occasions the engine has hesitated and shut the car off. Very recently a loud noise was coming from my engine. (you could hear a rattling noise) it sounded like a piece of metal rattling around in the engine. A year ago I took my car into the dealership because of a recall (recall 3005c) to get it checked out (this is what the letter from Mazda asked me to do) my car was there only two hours and only looked at maybe about thirty minutes. I received an oil change and then they were to inspect it due to the recall. When I retrieved my car they gave me a certificate of correction, but informed me that nothing had been fixed and that they were only authorized to inspect. That if the part broke that I would be responsible for it even though it was a recall. Here I am one year later and I had my car looked at and it appears that two of the screws must have come loose due to the recall. (they were found in my exhaust) I got no help from the dealer. I found the recall instructions online from Mazda to the dealer which instructs the dealer to replace the parts if they have not been replaced on any previous occasion (which was procedure b). And if it has been previously worked on they are to proceed with procedure a which instructs them to do an air compression inspection for internal damage and give a certificate of correction. They did the wrong procedure on my car and never actually did what needed to be replaced for my car to be legal and ok to drive. They are now avoiding my calls and not returning numerous e-mails or voice mails. I have been trying the dealer and Mazda themselves. On tues . I received nothing but rude mocking from each place telling me that it was my problem. I have been trying everyday since and I have received no response. Updated 2/23/2007 - intake manifold shutter and variable tumble control valves.

: the contact stated while driving 30mph, there was a rattling noise from the engine compartment followed by the engine stalling. The vehicle was towed to an independent repair shop for inspection. The mechanic determined the screws used for mounting the intake manifold shutter valve broke and fell into the catalytic converter as well as the oil pan and pistons. The vehicle is scheduled for replacement of those screws. There is an emission recall, #3005c, regarding the exhaust system. The vehicle has the same problems as indicated in the recall; however it is not included in the recall due to the VIN.

My engine failed causing a sudden loss of power. I was able to pull over safely. My car required about $1,000 worth of repairs, using used parts, and I have permanent engine damage that will ultimately shorten the life of my engine. The root cause of the engine failure was due to loose screws located in the air intake manifold, that allowed for a baffle or butterfly valve to break and enter my engine. This very same problem was recalled by Mazda for vehicles made from March of 2003 to July of 2003, mine was manufactured in February of 2003, and therefore was not recalled. I know of at least three other people who also have experienced this very same issue who have not been included in the recall. I have had two separate Mazda service managers confirm this was the same problem as the recall - loose screws in air intake manifold. I need this investigated to determine if more cars should be recalled.

One of the butterfly valves on the intake manifold fell off completely. This happened when the last of the two screws holding it on came loose and fell-off and was sucked into the engine. When the part was dismantled, there were only five of the original eight screws remaining. Only one of the four valves was completely connected when the unit was opened. I was driving normally down road and luckily this happened as I was parking my car. The event happened on 7/22/05 and the Mazda dealership stated that although they have seen this occur before, there is no TSB or recall. I will need to replace this part of the manifold at a cost of more that $1000 dollars. On a Mazda enthusist website that I frequent, at least ten other members have had the same problem with results varying from complete engine replacement, to the same supposed fix as I need. . Read more...