Intake manifold leaking - How many bananas and how much $$

[wagon4wd]

Hey Rob,

Coupla pieces of advo,

Investigate and find exactly what's wrong before committing to any heavy lifting. There are ways to determine here an air leak using an external fuel source (propane, carb/choke cleaner), deductive methods of elimination (pinching vacuum hoses) and best of all, communicating DIRECTLY with the dealer mechanic who diagnosed your truck!!! However, I would still verify his diagnosis before continuing.

If you do go after the manifold, clean the compartment and manifold area very well. After that, compare the vacuum routing on your truck to a good, known diagram to assure proper installation before dis-assembly.

There are lotsa details to a paired manifold set up, but those details can be covered when and if you continue.

I'd put the job at bananas if you pay attention to the details and do it right. And it is a job that will give you pride and satisfaction if you properly diagnose and repair the problem.

Best regards,

Rick

X2. Once you've verified that it is the intake manifold, if you can hear the leak, try rocking the intake manifold to see if it us loose - have see this a couple of times. If that's the case, checking the bolts might find a loose one (like someone else said).

 

[Joe_E]

It's not THAT tough to do with the smog stuff. I'm no mechanic and I didn't even label anything on mine. The FSM is actually pretty good for sorting out the spagetti of vacuum lines. Just step your way carefully through it and double check the routing of each line as you go. Carefull with the plastic nipples on those 20 year old vacuum switches! The part I dislike about the job the most has nothing to do with smog equip - that damn manifold bolt next to the firewall.

$35 to have my manifolds milled flat
$45 or so for FelPro gasket and copper coat
$10 for EGR pipe gasket
One afternoon to button it all back together

Anybody can do it if I can!
Butt

I fought with that back manifold bolt for hours it seemed, and mines being completely stripped to pull out for rebuilding.
I fought harder trying to remove that back insulater off the exhaust manifold so I could even get to the bolt. Got the chisel treatment in the end though.

 

[Heartworm]

If indeed it is a warped intake/exhaust manifold, don't...repeat..don't pay a dealer $1800 to fix. First option is to get a machinist to plane them square (they have to be done together). Second option is to order an all new intake/exhause manifold assembly from Cruiser Dan at American Toyota in New Mexico for less than $600. If you do get the new set, be aware that there are some things attached to your old one that you want to transfer..especially a large plug on the back portion at about cylinder 4 or 5 ( ask me how I know). Talk about a huge vacuum leak.

 

[lehiguy]

This would indeed be a great time to do a desmog and add a header. I never had one second of regret. I'm the world's biggest Weber fan too. If you can tune a motorcycle, any dirt bike for example, you can tune a Weber; just main jets and pilot jets, leave the emulsion tubes and air corrector jets alone.

 

[Rob Faucett]

Thanks for so many ideas/opinions. I am out of the country for a few weeks and will start working when I get back.

Mud is phenominal

Best
Rob