Please read, intake manifold recall!!

[L0w_N_sl0w]

I have a 03 Mazda Protege5 with the common intake manifold issue. Two VTCS bolts inside the intake manifold had fallen into cylinder 4, bending the spark plug electrode. Im aware of a recall for the 03 model but my car does not apply. My local Mazda dealership Dahl Ford/Mazda wouldnt acknowledge the recall or that it was an issue. After becoming very frustrated I decided to call Mazda (corporate) and discuss this issue. The woman was very nice and recorded all information about my issue. She went on to tell me that recalls are put into effect based off the consumers common issues. If you have had or are having this issue and your car does not fall into the recall dates, call Mazda and tell them about your issue.


1) Have your VIN number ready

2) CALL MAZDA, 1(800)222-5500

3) Select recall, press 0 to talk to a rep.


Lets get are recall!

 

[SoonP5ismine]

I think you are talking about VICS. there was a recall about VICS years ago.

 

[P-Funk!]

Recalls are for safety issues, TSBs are for these kind of maintenance/reliability issues.

Good corporate/customer relations are borne out by how the company handles an issue like this.

 

[Protephile]

It was a TSB, I had this problem and Mazda replaced my intake manifold at about 39k, just before the warranty ran out.
God that was a long time ago! I doubt any manufacturer would replace a manifold on a 10 year old car.

 

[SoonP5ismine]

Mazda warranty is a joke. Mine had 5 years/50000 miles.

 

[L0w_N_sl0w]

Sorry for the confusion I should have clarified it as a TSB. However both recalls and TSB's are still put into effect, my 99 Jeep Cherokee limited just had a recall not that long ago. Not saying that a TSB on are cars is probable but its still worth a shot to those who didn't fall under the recall date. Motors that try to compress bolts once or even multiple times don't last long. Mazda should take responsibility for not correctly installing something regardless if its as simple as a bolt.

 

[SoonP5ismine]

My experience with mazda was that if its under warranty they will try to fix it. If not then you're ******.

 

[L0w_N_sl0w]

Any DIY write-ups on removing the intake manifold? I’ve done some searching but haven’t come across anything. The dealer quoted me 2.5 hours of labor so it’ll probably take me 4-5 hours...

 

[P-Funk!]

search for the 'flat-black' (poster) 'how to'


Yep - 5 hours for first time yourself sounds about right...

Take the manifold off in two sections lower, then upper to acccess the manifold to head bolts (bottom ones).

If you have not replaced your engine motor mounts - srsly consider doing now with the manifold off

 

[SoonP5ismine]

I did take mine apart twice and it was a bit easier the second time around. There really isnt much to it but it is very time consuming as other things need to be removed so you can get better access to the mounting points. I know I had to remove my battery and intake hose from the throttle body and the air filter box as I had to step into the engine bay to get a better position to work. be careful with the injectors and fuel line as those parts can be costly if damaged during removal and install. Also make sure you install everything properly back so your engine wont catch on fire LOL.

Also I highly recommend not doing this alone as sometimes another set of hands was helpful. I did this with a friend and it is a whole day project as you also need to do some cleaning before putting everything back together. Set aside a whole weekend for this so you have time. Make sure you buy the gaskets before you start this. If you will take the 2 halfs of the intake apart then you will need a plenum gasket and you will definitely need the intake manifold gasket. I did not have to take off my valve cover to do this so you will not need that gasket.