I'm sorry, I posted briefly about this in response to someone else's dealer problems. I just had to rant!!
So the cold engine rattle (the vibration/rough acceleration when you start the car cold) had started to really bother me. I get the TSB on the cold engine rattle (listed as "01-004/03 2001-2003 PROTEGE/PROTEGE5 - RATTLING NOISE AT 1000-3000 RPM COLD ENGINE") off the net and bring it in to schedule an appointment.
I LEAVE the TSB printout with the service mgr. and tell him to ORDER THE PART NOW so when I come in next week for my appointment I can pick the car up same day. He nods.
Week later, I drop my car off on the way to work. I come by at 4pm when the car is supposed to be ready. I ask the same service mgr if my car is ready. He says "I couldnt find the TSB that you talked about." So he had misplaced the TSB that I gave him, and couldnt find another. Luckily, I know that 99% of dealer mechs are idiots (There are some GREAT ones on this board, though!) and so I brought another copy of the TSB. He blushes. He had already called the mechanic who was working on my car up, and the mechanic (one of the good ones) says "oh yeah, I found that TSB on my own this morning, I had to order a part, it should be in by next week."
Of course, I start fuming, and remind the service mgr that I brought in the TSB last week and told him to order the part. He told me he couldnt order the part without the car there...okay, he STARTED to tell me that, but I cut him off before I could finish, because he's an idiot. So I take their stapler, and staple the TSB to the work order, and write the part # that he needs to order ON the work order FOR HIM, and then watch him order it on the computer.
On the flip side, the engine rattle is gone. The idle is much smoother, and the car is more driveable when it it cold.
BTW, there has been a lot of speculation about the cause of the rattle. Here is Mazda's explanation:
So to sum up (and this has been posted piecemeal before all over the site):
The TSB is:
The TSB is available from:
http://web2.airmail.net/emann/protegefaq/tsb/
under "3rd generation"
Feel free to print this page and take it to your dealer. While you're there, have them sand, prime, and paint the exposed part of your rotors for free:
Sorry for the rant, I hope this helps. Feel free to PM me with any Q's
So the cold engine rattle (the vibration/rough acceleration when you start the car cold) had started to really bother me. I get the TSB on the cold engine rattle (listed as "01-004/03 2001-2003 PROTEGE/PROTEGE5 - RATTLING NOISE AT 1000-3000 RPM COLD ENGINE") off the net and bring it in to schedule an appointment.
I LEAVE the TSB printout with the service mgr. and tell him to ORDER THE PART NOW so when I come in next week for my appointment I can pick the car up same day. He nods.
Week later, I drop my car off on the way to work. I come by at 4pm when the car is supposed to be ready. I ask the same service mgr if my car is ready. He says "I couldnt find the TSB that you talked about." So he had misplaced the TSB that I gave him, and couldnt find another. Luckily, I know that 99% of dealer mechs are idiots (There are some GREAT ones on this board, though!) and so I brought another copy of the TSB. He blushes. He had already called the mechanic who was working on my car up, and the mechanic (one of the good ones) says "oh yeah, I found that TSB on my own this morning, I had to order a part, it should be in by next week."
Of course, I start fuming, and remind the service mgr that I brought in the TSB last week and told him to order the part. He told me he couldnt order the part without the car there...okay, he STARTED to tell me that, but I cut him off before I could finish, because he's an idiot. So I take their stapler, and staple the TSB to the work order, and write the part # that he needs to order ON the work order FOR HIM, and then watch him order it on the computer.
On the flip side, the engine rattle is gone. The idle is much smoother, and the car is more driveable when it it cold.
BTW, there has been a lot of speculation about the cause of the rattle. Here is Mazda's explanation:
As someone else suggested, the rattle is actually the valve rattling against a "screw" (the part that must be replaced in the TSB) because it is getting "bumped" by the swirl.Some customers may experience an engine rattle noise under light to moderate acceleration with engine coolant temperatures below 65 C (149 F) and engine RPMs between 1000 and 2900 RPM.
The noise is the result of the intentional swirl effect that is generated when the Variable Tumble Control System (VTCS) plates in the intake manifold are closed. Swirl accelerates the burn of the air/fuel mixture which reduces emissions when the engine is cold. The noise does not have a negative effect on the engine, and disappears as soon as coolant temperature reaches 65 C (149 F). There is a counter-measure to help reduce the noise in order to improve customer satisfaction.
So to sum up (and this has been posted piecemeal before all over the site):
The TSB is:
01-004/03 2001-2003 PROTEGE/PROTEGE5 - RATTLING NOISE AT 1000-3000 RPM COLD ENGINE
APPLICABLE MODEL(S)/VINS
2001-2003 Protege (2.0L FS only)
2002-2003 Protege5
DESCRIPTION
Some customers may experience an engine rattle noise under light to moderate acceleration with engine coolant temperatures below 65 C (149 F) and engine RPMs between 1000 and 2900 RPM.
The noise is the result of the intentional swirl effect that is generated when the Variable Tumble Control System (VTCS) plates in the intake manifold are closed. Swirl accelerates the burn of the air/fuel mixture which reduces emissions when the engine is cold. The noise does not have a negative effect on the engine, and disappears as soon as coolant temperature reaches 65 C (149 F). There is a counter-measure to help reduce the noise in order to improve customer satisfaction.
Customers having this concern should have their vehicle repaired using one of the following procedures:
REPAIR PROCEDURE
Verify customer concern.
Check vehicle VIN range:
From VIN JM1BJ2***1*400001 to JM1BJ2***2*551281, go to step 3.
From VIN JM1BJ2***2*551282 to JM1BJ2***3*644493, go to step 4.
Replace the VTCS delay valve, then proceed to step 4.
Reprogram the PCM using WDS (Version B22 or later), verify the correct calibration from the table below:
Year/Tranmssion
File Name
New Calibration P/N
2001 MTX
DXAGBT0
1L2U-AA
2001 ATX
DXAGAS0
1L2U-BA
2002 MTX
QKMABB0
2ALU-EA
2002 MTX
QKMABB0
2ALU-EA
2002 ATX
QKAABA0
2ALU-FA
2002 ATX
QKAABA0
2ALU-FA
2002 ATX
QKBA7A0
2ALU-GA
2003 MTX
QOAMCB0
3ALU-JB
2003 ATX
QOAADA0
3ALU-KB
2003 ATX
QOAB8C0
3ALU-LB
Install revised PCM calibration sticker (9999-95-AMDC 97 available through MStore) in appropriate position (next to vehicle emissions label) with the calibration P/N provided in the table above.
Verify repair.
PART(S) INFORMATION
Part Number
Description
Qty.
Notes
N23613980A
Delay Valve
1
Application:
All 2001 Model Year
&
2002 model year built on and before November 5, 2001
WARRANTY INFORMATION
NOTE: This information applies to verified customer complaints on vehicles covered under normal warranty. Refer to the SRT microfiche for warranty term information.
Delay Valve Replacement and PCM Reprogram
Warranty Type
A
Symptom Code
82
Damage Code
9W
Part Number Main Cause
N236 13 980A
Quantity
1
Operation Number / Labor Hours:
XX444XR1 / 0.8
PCM Reprogram
Warranty Type
A
Symptom Code
82
Damage Code
9W
Part Number Main Cause
****18881
Quantity
0
Operation Number / Labor Hours:
XX444XR2 / 0.8
The TSB is available from:
http://web2.airmail.net/emann/protegefaq/tsb/
under "3rd generation"
Feel free to print this page and take it to your dealer. While you're there, have them sand, prime, and paint the exposed part of your rotors for free:
RUST ON BRAKE ROTOR HUBS
Applicable Models
Model Starting S/N Ending S/N
2001 PROTEGE 00000000 ZZZZZZZZ
2002 PROTEGE 00000000 ZZZZZZZZ
1999 MILLENIA 00000000 ZZZZZZZZ
2000 MILLENIA 00000000 ZZZZZZZZ
2001 MILLENIA 00000000 ZZZZZZZZ
0003559 Dealer Repair Information
Rust can be seen on the brake rotor hub area when looking between the wheel spokes. The rust is most visible on vehicles equipped with 17" chrome wheels.
1. Remove rust from hub(s) by sanding.
2. Clean/prep hub surface for primer.
3. Mask off brake rotor area.
4. Apply primer around entire hub area.
5. Once primer dries, apply a heat type silver paint to the affected area to repair the vehicle.
Note: Replace the hub(s) if the affected area cannot be repaired enough to satisfy the customer.
Sorry for the rant, I hope this helps. Feel free to PM me with any Q's
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