The battery light has been coming off and on for the last couple weeks. Sometimes after stopping, we're unable to start again without a boost. Alternator is fine (confirmed x3 at alternator shop), changed alternator belt, put in new battery and same problem. Cleaned cables around the battery and still same problem. Light comes on after going a few kms. Any ideas?
I'm guessing that you've tested the actual current output of the alternator then. I'm assuming that the output is between 13-14Volts at the battery when the car is running... If it's too low, then it's not charging your battery at all, too high, and it's frying your battery.... Another thing that can cause this is if you have a short in your electrical system.. that, however, will be difficult to narrow down...
I own a 2002 Mazda Protege5 with the FS2.0 Motor. The EGR Valve is located below the throttle-body. You must take off the Intake tube to get a good view of it. To replace it I think you might have to take off the throttle-body, but I'm not sure about that...(yet)
NOTE: Mazda put out a technical note stating that "if your car has sat for a long time, the egr valve could be damaged by moisture (rain) and will need to be replaced". My 2002 Protege sat for 3 weeks and the rain caused this exact issue and had to be replaced. How did I know? The engine light came on (after never coming on) and the car had an extremely rough idle. Total cost was ~$400 (ouch).
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