Lower Intake Manifold
12-19-2008, 10:31 AM
#1
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Lower Intake Manifold
hey all, went to mazda today with a check engine light on on my 04 rx-8 m/t (54,000 miles), and after two hours of waiting they told me that i needed a lower manifold but i needed to buy the entire manifold because the manifold doesn't come in parts. Also they told me that i needed engine mounts which i have read tend to have problems which i'm not concerned about right now, and a ssv solenoid valve. And there is a grinding noise in second gear that sometimes occurs. Oh an 13 hours of labor to fix the manifold etc. The cost to repair all this is $2,517.85 minus the labor. My question is: is there any place to get this fixed that doesn't charge you twice the price for an item like Mazda does. Or any good places that sell rx-8 parts, that i could look into.
12-19-2008, 11:10 AM
#2
Zoom Zoom....
Hi.
Did they tell you why you need a lower intake? What was the specific code?
If it is just the SSV, then it can usually be repaired/cleaned with the engine still in the car and probably with the upper manifold still on. Look at the shop manual, it is not a difficult job. There are threads on here about testing the SSV actuator in-car. The upper manifold will have to come off to replace the SSV solenoid, though. Again, not a difficult job.
To remove / replace the lower intake, the engine will have to come out. With the LIM out, you could probably de-gunk (de-carbon) the APV instead of replacing the whole thing.
Motor mounts are probably now considered a wear item at your car's age and aren't such a big deal.
New parts can be sourced through Onlinemazdaparts . com; or Rosenthal Mazda. Mazmart sells new parts as well as used parts. Check the parts for sale forum or post a Wanted To Buy thread.
Where are you located? most medium and big cities have good rotary-friendly independent shops.
There is a lot of knowledge on these forums. Chances are good that if you are any good at DIY, assistance can be gained from some of our experienced members!
Good luck to you, and please update your location.
Did they tell you why you need a lower intake? What was the specific code?
If it is just the SSV, then it can usually be repaired/cleaned with the engine still in the car and probably with the upper manifold still on. Look at the shop manual, it is not a difficult job. There are threads on here about testing the SSV actuator in-car. The upper manifold will have to come off to replace the SSV solenoid, though. Again, not a difficult job.
To remove / replace the lower intake, the engine will have to come out. With the LIM out, you could probably de-gunk (de-carbon) the APV instead of replacing the whole thing.
Motor mounts are probably now considered a wear item at your car's age and aren't such a big deal.
New parts can be sourced through Onlinemazdaparts . com; or Rosenthal Mazda. Mazmart sells new parts as well as used parts. Check the parts for sale forum or post a Wanted To Buy thread.
Where are you located? most medium and big cities have good rotary-friendly independent shops.
There is a lot of knowledge on these forums. Chances are good that if you are any good at DIY, assistance can be gained from some of our experienced members!
Good luck to you, and please update your location.
12-19-2008, 02:29 PM
#4
There is nothing in there that they should have to remove to fix unless the APV is so carbonned up it can't be freed up with seafoam. The APV motor, SSV and the VDI actuators and solenoids can all be changed with the manifold in the car.
At worst you will need to remove the UIM to pour the crap straight into the Auxillary runners......
This is a couple of hour job at most. If you need parts...there are lots of fully functioning used ones...ask G3tR3DDY2GR3DDY https://www.rx8club.com/members/g3tr3ddy2gr3ddy-25637/ for some used stuff
At worst you will need to remove the UIM to pour the crap straight into the Auxillary runners......
This is a couple of hour job at most. If you need parts...there are lots of fully functioning used ones...ask G3tR3DDY2GR3DDY https://www.rx8club.com/members/g3tr3ddy2gr3ddy-25637/ for some used stuff
Last edited by dannobre; 12-19-2008 at 02:32 PM.
12-19-2008, 02:52 PM
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I'm located in the northern NJ/NYC area. What the guy basically said was he started talking about the lower intake manifold, and then went into carbon build up in the engine, oil being directly injected into the rotory, all of which i am well aware and i take good care of my 8, and he kinda beat around the bush when it came to telling me why. This is exactly what came up on my car repair quote: P0661 lower intake manifold with tuning valve. Not including Gaskets and SSV solenoid valve. I looked on the service code thread and it said :P0661 SSV solenoid valve control circuit low ON 2 CCM;
12-19-2008, 03:00 PM
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Thanks for the help dannobre, hopefully it's nothing that major. I'm pretty good at DIY, and i don't really mind spending hours on my car. I'll look into those used parts though thanks again
12-19-2008, 03:07 PM
#7
You likely won't need any parts...if that was the code....the SSV is likely stuck..
IT IS EASILY REMOVED WITH THE ENGINE IN. If you want some pictures send me an e-mail address....and you will see how easily it is to get at. You need to remove the alternator and a few wires/hoses...but it is an easy fix.
It is easy to check as well...just turn the little lever by the actuator..
The switch or the solenoid may also be the problem...again an easy fix
The only yhing that you can't fix in the car is a VERY BADLY stuck APV that won't clear up with some seafoam or other cleaner....and that would have to be really stuck!
IT IS EASILY REMOVED WITH THE ENGINE IN. If you want some pictures send me an e-mail address....and you will see how easily it is to get at. You need to remove the alternator and a few wires/hoses...but it is an easy fix.
It is easy to check as well...just turn the little lever by the actuator..
The switch or the solenoid may also be the problem...again an easy fix
The only yhing that you can't fix in the car is a VERY BADLY stuck APV that won't clear up with some seafoam or other cleaner....and that would have to be really stuck!
12-19-2008, 11:08 PM
#9
You likely won't need any parts...if that was the code....the SSV is likely stuck..
IT IS EASILY REMOVED WITH THE ENGINE IN. If you want some pictures send me an e-mail address....and you will see how easily it is to get at. You need to remove the alternator and a few wires/hoses...but it is an easy fix.
It is easy to check as well...just turn the little lever by the actuator..
The switch or the solenoid may also be the problem...again an easy fix
The only yhing that you can't fix in the car is a VERY BADLY stuck APV that won't clear up with some seafoam or other cleaner....and that would have to be really stuck!
IT IS EASILY REMOVED WITH THE ENGINE IN. If you want some pictures send me an e-mail address....and you will see how easily it is to get at. You need to remove the alternator and a few wires/hoses...but it is an easy fix.
It is easy to check as well...just turn the little lever by the actuator..
The switch or the solenoid may also be the problem...again an easy fix
The only yhing that you can't fix in the car is a VERY BADLY stuck APV that won't clear up with some seafoam or other cleaner....and that would have to be really stuck!
and to the op. you car is still under warranty.. for the 04 it was extended to 5 years 60k miles.
let them deal with it..
beers
12-19-2008, 11:14 PM
#10
The APV is the problem....but like I said..it would likely be unstuck with a bit of seafoam or such poured into the aux ports and let sit for a while and then moving the APV either by hand...or by applying a 12V signal switching contacts back and forth to change directions of the actuator. You just have to be careful not to do it too long and fry the actuator motor
12-19-2008, 11:35 PM
#11
ah,
sorry i read the whole thing fast.. i thought somehow you got the lower intake off with out pulling the engine..
i have thought about this. i wonder if you could leave the engine tranny together and pull the ppf. and rotate it to pull the lower manifold?
dont ask me why i wounder about this!
beers
sorry i read the whole thing fast.. i thought somehow you got the lower intake off with out pulling the engine..
i have thought about this. i wonder if you could leave the engine tranny together and pull the ppf. and rotate it to pull the lower manifold?
dont ask me why i wounder about this!
beers
For the OP. i have seen many people "unstick them", but at the same time if you can find a cheap one.... Might be a good project anyway and you can clean everything while the motor is out. Thats how i see projects anyway :P
lmk!
Last edited by G3tR3DDY2GR3DDY; 12-20-2008 at 12:07 AM.
12-20-2008, 06:18 AM
#12
I used a long 1/4" hose so I had plenty of room (not much is needed, but I used about 2' length).
The pump has a trigger to then bleed off the vacuum being applied and the actuator will return.
So simply apply vacuum and then bleed it off to actuate it back and forth.
12-20-2008, 10:51 AM
#13
Then your talking about the SSV for sure...the APV ( the hard to get too one) is not vacuum activated..it is electric like I said.
I can't believe they were going to charge you that much for a stuck SSV
The dealership guys are not mechanics anymore...they just know how to replace parts when "tech" tells them too.........
I can't believe they were going to charge you that much for a stuck SSV
The dealership guys are not mechanics anymore...they just know how to replace parts when "tech" tells them too.........
08-12-2009, 05:40 PM
#15
^Sure... if you remove the drive belt, water pump pulley, alternator bracket, ACV, thermostat, disconnect the SSV position switch, and remove the two bolts securing the valve in the manifold.
After that, the valve will just slide right out.
I also took out my battery housing to have more room to work.
After that, the valve will just slide right out.
I also took out my battery housing to have more room to work.
08-12-2009, 07:27 PM
#17
^ It'll be nice if you can nycgps.
He sent me an email and we've been discussing his problem.
He mentioned that the SSV valve moves smoothly and without resistance.
I also found out that he is receiving a P0661 code, which is for the SSV solenoid.
I told him to focus there first before tearing into the valve.
I explained how to swap the AIR and SSV solenoid wire harnesses and vacuum lines so he didn't have to physically remove the solenoids.
But again, it'll be nice if you can meet with him since you have experience with this setup and could show him (especially with removing the upper intake manifold).
He sent me an email and we've been discussing his problem.
He mentioned that the SSV valve moves smoothly and without resistance.
I also found out that he is receiving a P0661 code, which is for the SSV solenoid.
I told him to focus there first before tearing into the valve.
I explained how to swap the AIR and SSV solenoid wire harnesses and vacuum lines so he didn't have to physically remove the solenoids.
But again, it'll be nice if you can meet with him since you have experience with this setup and could show him (especially with removing the upper intake manifold).
08-12-2009, 07:28 PM
#18
IIRC, the SSV can be removed once the fuel rail is moved out of the way. I don't seem to remember needing to remove the alternator and that the SSV bumps into the part of the fuel line which arcs downward toward the main part of the fuel rail.
On the other hand, maybe I am getting old.......
On the other hand, maybe I am getting old.......
08-12-2009, 07:32 PM
#19
^The alternator doesn't need to be removed, but the bracket does (which is why you need to remove the water pump pulley).
There is a bolt for the thermostat that is behind the alternator bracket and the thermostat needs to be removed so the valve can slide out fully.
I tried sliding the valve out with just the lower half of the thermostat installed and still couldn't do it.
The whole thermostat needs to come out.
I'll see if I have pics of what I'm talking about...
There is a bolt for the thermostat that is behind the alternator bracket and the thermostat needs to be removed so the valve can slide out fully.
I tried sliding the valve out with just the lower half of the thermostat installed and still couldn't do it.
The whole thermostat needs to come out.
I'll see if I have pics of what I'm talking about...
08-12-2009, 07:43 PM
#24
Uuuuummm........a little. 
I really don't get that much time off so I try and take advantage of the moments which come my way. I truly have to make an effort to set aside time for myself these days. I can get about 1-3 days per month off as I work 7 days a week.
I really don't get that much time off so I try and take advantage of the moments which come my way. I truly have to make an effort to set aside time for myself these days. I can get about 1-3 days per month off as I work 7 days a week.
