Lower Intake Manifold Leak...Help!!

I had my 03 Disco checked for an oil leak today and learned that I have a leak coming from the lower intake manifold.  The import auto shop  that it is at, believe it or not, has not done an 03 disco with this problem...SO...  If anyone knows the parts list or anything else that I can pass on too them please let me know.  I've priced an "intake gasket kit" at Atlantic..and it's about $109 bucks.  Im wondering if there is anything else that should be done to the Disco While its APART.  Thanks.

What mileage is on your truck?  When was your last tune-up?

The Mileage is 58K and the last known service was the 30K service.  It was a lease by a lady with only the 30K service record stamped. 

Perfect.  You are close to 60k, you might as well begin your services.  If you want to keep your truck up like we do, do or have done DiscoMike's 60K services.  Do a search for the 60k services on this website, you'll want to do that or have it done.

While the repairman has your intake off, they can install new ignition wires for you.  It is good to do this every thirty thousand miles, and it is even better if you do it with 8mm Magnecor wires /w Bosch +4 platinum or fusion.  If your valve cover gaskets (AKA Rocker cover gaskets) are leaking, or the screws are constantly coming un-torqued, have them replaced while the plenum is off.  Of course, if you have this done, your coolant will have to be drained.  No prob, it is a part of your services anyway...  So, you can consider replacing your t-stat, and fix any coolant leaks that have been bothering you.  Do you have coolant gathering on your driver's side valve cover, just under the throttle body?  A 15 dollar kit from land rover can fix that.

I just did the following repairs to my '03 two weeks ago, you can consider them if you want.

lifted intake - ignition wire job 8mm mag / +4 fusion
replaced leaking valve cover gaskets, both sides.
replaced serpentine belt
replaced water pump, just to do it (warning, factory gasket is pretty tough to scrape off) they can fail.  Part is 130 bucks
replaced T-stat
Inspected hoses.
replaced the thing under the throttle body because it was leaking.
replaced fan/fan clutch.  you may want to consider just replacing the fan clutch.  Inspect your fan.

Feel free to ask any questions.  Also, we ask this of everyone, have you replaced the u-joints on your front drive shaft?  They commonly fail between 50 - 90k miles, and can cause thousands of dollars of damage.  You can drop the shaft, take it to a drive shaft shop (or have the same mechanic do it if he does drive shaft work regularly) and have them all changed out (3 u-joints, centering kit) for around 225-275 dollars.  Mine started vibrating and whining.  I should have done them when I got the truck and it was running fine.  Anyway, I got it before it failed, its being fixed now.
 
Sorry, you aren't new

Thanks for the info.  I will pass this on to my mechanic. 

Yes, use the Valley pan gasket set from Atlantic British, no after market sets. Also buy a set of Magnacor 8mm wires and have them installed at the same time with some new Bosch Platinum Plus 4's.
When you are all done then clean the t/body, do an induction cleaning and an engine flush. Your truck will run like it has never run before.
You xan order the wires thru Cerrones at 650-365-4145, just ask for Tony.

Thank you.

We just got our D2 back from the Dealer and the estimete for the leaking lower intake manifold gasket is 2400.00.  Is this something that my local mechanic would be able to do?  We just dropped several grand on the 90K, then another couple grand for the timing belt cover, and a couple grand on the ABS box.  Sorry, but running a bit low on disposible income.

You my friend need to stop throw money at your truck like you have no common sense. A 90K, even at a dealer, is less the $500 and you could have done it on your drive way for about $200 and 3 or 4 hours of your time.
Valley pan gaskets cost around $550 give or take a little, or $100 in parts and some of your labor with some help from us.
I am try to tell you to stay away from your dealer, he is a thief.

Upon discussing this with the wife, who picked up the truck from the dealer, she was told that it is not the actual gasket that is leaking, but their is a pinhole in the metal.  What are the chances of that?  We do smell coolant after the truck runs for a bit, and I do need to top it off every 2 weeks or so, so thier is a problem somewhere, I just can't see it.  Also, what the heck is a BG nitrogen tire service?

quote:

ORIGINAL: dragon_avaloch

Also, what the heck is a BG nitrogen tire service?

 
Sounds similar to a muffler bearing service or a blinker fluid flush. 

LOL, sounds like I should give them the 30 bucks to get it done then.  Blinker fluid flush, love it.

I have heard of putting Nitrogen in tires, but I didn't think anybody actually did it. Reminds me of when I was working in a shop/warehouse, we used to "change the tires from summer to winter air" when things were getting slow.

They fill aiplane tires with nitrogen because it isn't affected by temp changes. I used to maintain fuel tank gauging systems that used a pressure gauge and nitrogen in transmission lines. People fill tires with nitrogen so you don't have to change the pressure in winter and summer, and it doesn't get higher when the tires heat up. When I worked on the fuels systems, the Nitrogen was free for me, and I had the tires in my Volvo filled. I never had to adjust pressure again...

You might want to call me.
Don't do the B&G gas in the tires, it is a rip off.
303-862-7680
Colorado before 8 pm

That is way way too much to change the intake. the lower intake is alot like a small block chevy V8. the upper intake is not hard to remove at all. can easily be done in about 25 minutes, 10 if you have done it more than once. lower intake isn't too much harder. once everything is out of the way. just drain the coolant first to minimize the mess. it unbolts just like on an old chevy 350 v8. disconnect the fuel rail and injector wires and other sensors and its pretty easy. I'd try a reputable shop that specializes in european cars. may cost a little bit more than say Firestone and Pep Boys but is definately worth it, because they know wehat other things to look for while performing the repair. these fast food chain versions of mechanic shops usually just blindly perform the repair and don't take the time to really look at your truck while it is apart. Now don't get me wrong there are some pretty good mechanice at some of those shops but hopw do you know who they are, unless you are a mechanic yourself. I hope this helps you some. 

Don''t mean to bump an old post, but my 02 discovery has a leaking intake manifold gasket as well, with a $1400 estimate from the dealer to fix, so I am looking at doing it myself. I read the above post and searched, but couldn''t find the "60k service" things to check while I''m at it. The vehicle is at 85,000 miles.

I was also wondering if anyone has a service manual/parts diagram for the gasket replacement , id anything but the kit is required (ie sealant, etc) and torque values/etc for the bolts.

thanks

You could have a porous block or head, I would get a second opion from a good non dealer shop.
Get nack to us and let us know what you find.

Kavik...here is the 60K service as prescribed by Disco Mike...I would check if your front u-joints are grease-able as well (if not, replace as well with Precision part#344 and #617).

This is the parts list for a 60,000 mile service or a high mileage used truck, the way I do it.
1 Oil filter, K&N 3001 or Mobil 1- 301
1 Air filter
6 Qts of engine oil
12 Qts of ATF
7 Qts of 80/90W synthetic gear oil, 85W/140 for HD use
3 Pints of synthetic Brake fluid
2 Qts of synthetic Power steering fluid
2 Gallons of OAT, orange coolant
1 Bottle of Lucas Power Steering additive
1 Bottle of Lucas Transmission additive
1 Can of Spray Carb. Spray
1 Can Of Brake cleaner
8 Spark Plugs, I use Bosch Platium Plus 4''''''''s
1 Set of Magnacor 8mm plug wires
1 Serpentine belt
2 Bottles of SeaFoam gas additive
1 T/Stat
Hoses and belts, as necessary

60,000 Mile Service or Major Service for High Mileage Used Vehicle just purchased

Bleed the brakes
Flush and change the power steering fluid adding one bottle of additive
Service the tranny adding one bottle of additive
Change the coolant and t/stat
Do an engine flush before changing the oil
Do an induction cleaning
Clean the throttle body
Add fuel additive to full gas tank
Change both of the diffs fluid
Change the t/case oil
Replace the plugs and wires
Replace the air filter
Lube all the drive shaft grease fitting including the 2 slip shafts
Do full inspection of brakes, hoses, bushings etc.
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Do the intake gasket yourself, I did a couple weeks ago and it was a breeze.  I had roughly 13 hours in it and cost me like disco mike says, around 100 bucks.  If you get under the truck and see coolant leaking down around the bell housing onto the cross member bar it''s the same symptoms I had.. I was going through roughly a litre of fluid every few days of constant driving.  Now, I have been checking it every week and she is holding steady now and have not had to add any at all.  I am by no means a mechanic but this was something fun to tackle and allows you to learn about your vehicle in a way that most people don''t... GO FOR IT, and we are always here to help...

quote:

ORIGINAL: jkid

I have heard of putting Nitrogen in tires, but I didn''t think anybody actually did it. Reminds me of when I was working in a shop/warehouse, we used to "change the tires from summer to winter air" when things were getting slow.

A lot of tire stores and dealer do use Nitrogen, much less chance of temp. change leak down.

quote:

ORIGINAL: kavik

Don''''t mean to bump an old post, but my 02 discovery has a leaking intake manifold gasket as well, with a $1400 estimate from the dealer to fix, so I am looking at doing it myself. I read the above post and searched, but couldn''''t find the "60k service" things to check while I''''m at it. The vehicle is at 85,000 miles.

I was also wondering if anyone has a service manual/parts diagram for the gasket replacement , id anything but the kit is required (ie sealant, etc) and torque values/etc for the bolts.

thanks

E-mail me and I will send you the service list.
mikeljacobs@comcast.net