WTF!?!?! Stalling and I don't know why.

25FConv

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Mazda Protege
Background Info:
My car has gt28rs, MAM mani, AWR MM(95 durometer) and inserts(95 durometer), 626 intake mani, iON 3" TBE, SS FTC, sr motorsport cams( both set at 0*), awr rad, medieval pullies minus the ps pulley, and jdm cams, stock heat range spark plugs, red magnecor wires. So I took my car in about 3 weeks ago for a regular state inspection, but they didnt pass me because my rear endlink broke.....Here is where the problem starts. I took it home and swapped out the awr endlink for a custom endlink another forum member made for me.....I go to start the car up and makes a loud chattering noise like metal is smacking metal, it idles fine and then the idle drops and slowly stalls. I started it up again and it does them same thing. I tried it again and the car would struggle to turn over and eventually turns over but still hearing the lound chattering noise, then slowly stalls. The car does not have CEL, nor have I gotten one since this problem started occurring. The car currently has 57,000 miles on the clock.

The Symptoms:

* The Car struggles to turn over and eventually turns over. However, it when it does startup the a/c is usually on, and when I turn the air off the car slowly stalls.

* It slowly stalls or dies out after finally turning over.

* If I give it gas, the car will move like there is no issue, but when I come to a stop, or idle it stalls out. I had a lightwieght crank pulley on the car and the screws on the timing tooth wheel backed out and started smacking against the crank sensor(which is what the loud chattering noise was)

* As I mentioned be4 the car drives like there is no issue, but i wont hit full boost(7psi) till about 5500rpms....keep in mind it is running a gt28rs with an upgraded compressor wheel....


Diagnosed so far:

* After inspecting the crank sensor I figured the timing tooth wheel that kept chattering against the crank sensor, I figured the crank sensor was ******. So I removed it to compare with a working crank sensor(Thanks mryellerp5).....and visually you can see it was messed up(See pic). I replaced the stock crank pulley, and am using the other crank sensor. After replacing car will start up a bit quicker, but eventually slowly stall out. It will start up and idle fine, but when I turnoff the A/C the slow stall is almost instant. With the A/C off the car struggles to turn over.

* I have sprayed MAF cleaner on all the lines just incase it was a huge vacuum leak....but for the few seconds the car stays on not much could be done but after spraying all the lines it would still stall.

* All intercooler piping are on tight and most connected with t-bolt clamps. Doubled checked to make sure nothing popped off or would pop off.

* Running the stock NGK plugs, checked them and are gapped at .029, just regular black carbon on it. Plugs have about 1,000 miles on them. Changed coil packs, put back stock spark plug wires no change.

* Timing is correct (removed valve cover, accessory belts, and plastic covers to check)

* I have put about 200 miles on the car since the problem has started, using 93 octane from shell gas station.

* EGR is connected to intake mani, but not to MAM mani, I cut EGR pipe and running breather filter on it.

*I have checked the bolts on the MAM mani and the intake mani to see if any of them got loose but all are still tight.

*I can drive the car fine for now until I get to a stop, I have to keep my foot on the brake and partially on the throttle and try to keep the tach needle at or right under the 1K mark.


Please any insight is greatly appreciated. Dont say use the search button because I already have and havent found a solution to this issue.
 

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Also, as of yesterday I swapped out the IAC Valve just incase that was going bad or the o-ring to the valve went bad, but to no correction.
 
cleaned the IAC valve it didn't work, swapped out the IAC valve and still no resolution. Anyone have anything else I can try?
 
what do you mean by out of adjustment? the tps is an enclosed sensor, there isn't anything to adjust.
 
^^^
It didn't lol tried that for s**** and giggles.........honestly, i think the issue lies somewhere with the crank pulley and crank sensor. I mean what are the chances that the IAC or the TPS or I randomly get a huge vacuum leak the same exact time the screws on the timing tooth wheel on the light weight pulley back out and have the timing teeth grind againt the crank sensor......

Eventhough i replaced both the crank sensor and the crank pulley i dont know what else i could do.
 
I've never looked at the MSP tps but have worked on cars with adjustable tps. Just throwing it out there that yours could be bad. Good luck tracking down and solving your issue.
 
I've never looked at the MSP tps but have worked on cars with adjustable tps. Just throwing it out there that yours could be bad. Good luck tracking down and solving your issue.

I hear you. I was just explaining what our tps sensor looks like. Thanks for the input though.
 
Another added symptom i realized today, when I drive for a little bit after the car is warmed up...when it feels like its about to stall, while having my foot on the throttle a bit so it doesn't stall( rpms would be around 1000) it stutters like i am misfiring.
 
Try putting another crank sensor in there. You said you replaced it and noticed a little change. Was it shipped to you or did yeller hand deliver it to you? If it was shipped maybe it was damaged but is still better than the one you pulled but not good enough.
 
Is there maybe a damaged fuel line or sensor or something back around the endlink that was replaced. It might be a dumb suggestion, I don't look back there very often.
 
Try putting another crank sensor in there. You said you replaced it and noticed a little change. Was it shipped to you or did yeller hand deliver it to you? If it was shipped maybe it was damaged but is still better than the one you pulled but not good enough.

I went to Yeller's house to pick it up. He is quite meticulous about the way he takes care of items. I wouldnt think twice about something happening with the sensor while in his care.


Is there maybe a damaged fuel line or sensor or something back around the endlink that was replaced. It might be a dumb suggestion, I don't look back there very often.

IIRC, the endlink area only has the strut, endlink, lateral arm and trailing arm, and brake line. I believe the fuel lines run directly under the car.....I will double check for sensors though, thanks.
 
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Nah no sensors back there,....I went for a drive, I think its my BOV diaphram thats shot. Because when I shift now your here a whistling even when I am not in boost.......I am gonna go rip out the bov diaphram and see what it looks like.
 
So the BOV diaphram was f&cked....I swapped it out for another one I had....It didn't fix nothing. However, I can start the car up now it runs alright till its fully warmed up. But now after its warmed up and I come to a stop or am idling the car just dies out, and still when I turn off the A/C( but it doesn't constantly stall anymore, its more of a random thing) I have no clue what it could be and I out of ideas of a resolution.


Anyone know where else I can check?
So far:
-No Vac leaks that I can find,
-Exhaust Manifold bolts are tight,
-Swapped the Coil packs,
-Swapped wires,
-Cleaned MAF sensor,
-Quadruple checked t-bolt clamps on hard pipes.
-Swapped IAC Valve.
-Checked all wire harness plug to make sure everything is connected.
 
It was sent back to Split Second and they looked it over supposedly get reworked and now its idles and runs like it did right b4 I started having this issue.....so I am a bit hesitant on doing anything with the AFC......so I invested in a MicroTech.
 
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