I recently was told that the intake manifold for my 2004 Mazda 3i 2.0L engine needs replaced! The car has 47,000 miles on it. Regardless of my dismay and disappointment, I have to get it fixed! The dealer gave me the part number of LF62 13 100J. However, I cannot locate the part on the Internet. If you can help, I would greatly appreciate it!
I have had the same problem at almost exaclty the same milage. 2004 Mazda 3 3 door hatchback (5 door sedan). I was told by the service manager that there is a valve in the manifold that fails and starts flapping, sounded just like a collapsed lifter. I think this should be covered under warranty. If not the mfg warranty the emissions? .. good luck.
As a mazda tech I have encountered this problem and what causes it is a failed vacuum diaphram on the intake and the diaphram is not a replacable part and only comes with the intake. I would have the intake replaced because this "mix" door could cause the car to stall out. The dealer will want to charge you around 3-4.5 hours. It is a difficult job due to the starter having to come off and the " hidden bolts.
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It's exhaust manifold. There are two manifolds, the intake manifold in the valley between the cylinder heads, and the exhaust manifolds, one on each side of a v figured engine.
And, yes, a leak in the exhaust or the intake will make it run lean. If the leak is close to the engine, it can do harm to the valves, too. There is a gasket between the exhaust manifold and the engine block. Likewise, there is an intake manifold gasket between the intake manifold and the block.
I have a Mazda 6 which recently had black smoke / soot coming from the exhaust. On inspection, the inlet manifold was stuck open. I have just had the garage replace the control solenoid for the inlet manifold and so far the car is running ok.
Loosen the vacuum hoses but do not remove the vacuum hoses. Carefully remove the manifold and set it on the side of the engine. If a gasket gets turned in the process, replace it with a new one when you put things back together. These gaskets are hard to find in autoparts stores, so you may have to find them at a Mazda dealership. Use an 8mm socket with extension to completely loosen all 8 bolts. These bolts stay locked in the IM, they do not come out or fall out.
The problem is a faulty solenoid in the vapor recovery system. The solenoid is sticking open and allowing fumes from expansion of fuel in the fuel tank to enter the air intake and smother the engine. This is how the Mazda service tech explained it to me. It is a known problem on the Mazda 3 in various trims which Mazda refuses to acknowledge. Usually the check engine light comes on and the engine diag code reads mass airflow sensor, which is incorrect. I dealt with this for 6 months on my wife's 2005 Mazda 3i before the dealership figured it out. My cousin bought a 2007 Mazda Speed 3 which developed the same problem after a few months and was cured by the same fix.
It is the head gasket. Have that replaced and you will be fine. You have an air leak. I was told by the mechanic at mazda that the anti freeze eats away at the gaskets. CRAZY, but it works. I still have an issue with my 2001 Tribute revving while in park. Its always something.