Replacing intake manifold gasket

[bluerhino99disco]

I have a 99 discovery 1 sd. In February I had some problems with it overheating and the water pump and thermostat were changed as well as the radiator being cleaned. Just recently the problem started again. Now they said the intake manifold gasket is leaking so it needs to be replaced. They also said that the valve cover gasket, thermostat gasket and the inseals must be replaced when changing the intake manifold gasket. For this work they are looking to charge me about $1100. I just want to know if this seems reasonable. I no longer have the warranty I had when I had the other work done and I really can't afford this. I love my disco and I just dont want to be taken advantage of. Thank you in advance for any help or advice.

[p76rangie]

Originally Posted by bluerhino99disco

I have a 99 discovery 1 sd. In February I had some problems with it overheating and the water pump and thermostat were changed as well as the radiator being cleaned. Just recently the problem started again. Now they said the intake manifold gasket is leaking so it needs to be replaced. They also said that the valve cover gasket, thermostat gasket and the inseals must be replaced when changing the intake manifold gasket. For this work they are looking to charge me about $1100. I just want to know if this seems reasonable. I no longer have the warranty I had when I had the other work done and I really can't afford this. I love my disco and I just dont want to be taken advantage of. Thank you in advance for any help or advice.

Sounds way too expensive. The parts are not worth that much, so most of the charge would be labour. It appears that they are charging around 12 hours labour and it does not take anywhere near that long.

[pavel]

Bluerhino:
1 Do you have other tranport if your Disco were sidelined for a weekend or 3 days?
2 Are you handy with some automotive repair experience?
3 Do you have a Haynes shop manual?
4 Have you a set of tools (sockets, wrenches etc.?)
5 Do you have a friend who can lend a hand when necessary and go for parts etc. while you work?
If the answer to the above is yes, then you can do this job yourself - it isn't difficult but will take you many hours if it is the first time. You will need the parts, shop supplies and maybe a few special tools. Total cost for everything including beer should be under $125.
Cheers

[bluerhino99disco]

Thank you for your input fellas. I wish I had the tools to fix it myself because that would probably be the best way to go. One last question... would this intake manifold gasket cause my temperature gauge to fluctuate and my car to overheat? I know if it is leaking it needs to be fixed but could this be a situation where i fix this and then find out it wasn't the cause of my problem.

[p76rangie]

Originally Posted by bluerhino99disco

Thank you for your input fellas. I wish I had the tools to fix it myself because that would probably be the best way to go. One last question... would this intake manifold gasket cause my temperature gauge to fluctuate and my car to overheat? I know if it is leaking it needs to be fixed but could this be a situation where i fix this and then find out it wasn't the cause of my problem.

When it overheats, is your coolant level low?

[bluerhino99disco]

That last question just resulted in a "eureeka" moment for me. When I purchased the car in december it must have already had this leaking problem but it was covered up by a full coolant system. In February I started having problems because the coolant system was getting low due to the slow leak. The repair shop found a faulty water pump and blamed that for the problem and I told them to change the thermostat and flush the rad while they were at it. When they filled the rad up again it covered the problem for another few months until now. Now that they have eliminated their other options they dug a little deeper and must have found the real problem. I told them to check the head gaskets for me to be sure they aren't messed up as well. Other than that I am going to get the rad filled with coolant in order to get it home and park the disco till I have have the time and money to fix it.

Quick question... I don't really have much mechanic experience but I am pretty good with directions. My dad has a little more experience than me and I'm sure with the right tools we can fix the problem for a lot less. My question is that there is no Haynes manual for a 99 series 1. Can I just use the previous years manual for this problem or do I have to look for something else? Thanks everyone for all of your help! I hope this helps anyone else with the same problem as me that can't find an answer.

[Phototone]

I had to replace my intake valley gasket also. This is not rocket science. The gasket, at the most is about $65. Any good independent mechanic should be able to do this for about $150 labor give or take a twenty dollar bill. The flat rate time charges for work like this are online and checkable by most shops. The intake manifold valley gasket will leak over time and will need replacement. You should remember that this is basically a 1963 Buick aluminum v8 engine with modern fuel injection. (Yes I know Rover made many mods over the years, but the basic gasket layout is the same)

If you have a shop do the work, you should take a photo or a few photos of the engine layout showing where all the vacuum hoses go, so you can verify that they are put back correctly after the work is done.

[Phototone]

I had to replace my intake valley gasket also. This is not rocket science. The gasket, at the most is about $65. Any good independent mechanic should be able to do this for about $150 labor give or take a twenty dollar bill. The flat rate time charges for work like this are online and checkable by most shops. The intake manifold valley gasket will leak over time and will need replacement. You should remember that this is basically a 1963 Buick aluminum v8 engine updated with modern fuel injection and electronic engine management. (Yes I know Rover made many mods over the years, but the basic gasket layout is the same)

If you have a shop do the work, you should take a photo or a few photos of the engine layout showing where all the vacuum hoses go, so you can verify that they are put back correctly after the work is done.

[natvboy]

bluerhino. buy the tools necessary for the job and gaskets and spend the weekend doing it yourself (it will still be a lot cheaper and you'll then have tools). I had no mechanic experience and attempted the job myself. You'll feel great for doing so afterwards and you will have learned a little about your vehicle. Take your time and pics and it helped me for room removing the hood. Atlantic British has a kit that will have all the gaskets you need. If you have a shop do it don't use a LR Dealership as they are way overpriced for something so simple. Good Luck to you.

[pavel]

bluerhino: my Haynes manual (#3016) covers the Disco 1 up to 1998. It actually doesn't cover all changes found on my '96 - for example the distributorless ignition is not covered! Nevertheless, most of the info you need is there. As far as I know, the engine is mechanically the same right up to the LR3 but don't quote me.
Be brave, you and your Dad will have fun as long as you aren't in a hurry. As mentioned by Phototone, take lots of pictures first, from all angles and tag every electrical connection so there can be no confusion.

Some thoughts:
1 you will need a 12 point 8mm long socket(1/4" or 3/8" drive) to remove/install the little valve cover bolts - check that you have one.
2 don't buy new bolts for the valve covers (as suggested in the factory manual) they are expensive. Just buy 50 cents worth of clear neoprene tubing from the local hardware store and cut little donuts about 2 mm thick to use as new flexible seals around the old bolt heads. The factory seals will have perished and are thereby easily replaced.
3 clean every machined surface 'lovingly'; get the best RTV sealant available to seal the front and back of the 'valley gasket'.
4 Actually getting the new 'valley gasket' into place without catching and bending it can be tricky but 4 hands can do it efficiently.
5 Do you have a torque wrench? If not, time to buy one (a cheap one-maybe $40?)
6 Phototone says the good shop can do this work for $150. My experience is closer to $400-500 or more for labour($90-100 per hour) and they won't do as good a job as you will...

Cheers and happy wrenching!

[Phototone]

Originally Posted by pavel

6 Phototone says the good shop can do this work for $150. My experience is closer to $400-500 or more for labour($90-100 per hour) and they won't do as good a job as you will...

Cheers and happy wrenching!

I guess this relates to the part of the country you live in. I have a "reasonably" good mechanic/tire shop near me that does various mechanical/alignment/air conditioning/tire stuff at reasonable prices. They look up the "flat rate" time charges on their internet service programs, and I guess they then multiply by the shop labor rates, but here, the labor rates must be less, considerably less.
Either that or they like me. They do call me by my first name.

[pavel]

Phototone: I get the impression everything is better priced once you move away from the coastal cities. Then add in the fact that I live in Canada which seems to cost more again. It's getting really tough for young people to get started up here these days - fewer good jobs (lots of minimum wage opportunities); the 75 year old house across the street from us is renting for $4000 per month (it was $1500 2 years ago). My son is renting a small (but nice) apartment and pays $1375 plus $30 parking per month - he can't afford to own a car (borrows ours when necessary). People are pouring into Vancouver from everywhere - Germany, Iran, India, China, Australia and they all seem to be swimming in money. I was in a Toyota dealership last year where there was a line of immigrant families waiting to pay full list price for Camrys/Corollas. The dealers all charge $105/hour (plus 'shop supplies' and other levies) for service and this is increasing soon.

So, if you can get that valley gasket replaced for $150 labour, you are very fortunate because it is probably a 3-4 hour job!

Cheers and all the best from the mad northwest coast.

[antichrist]

Don't know where you are, but the intake manifold gasket can by purchased at Autozone for $13. Felpro MS96002. I have a Felpro thermostat gasket number around here some place, I'll see if I can find it, about $1.
Another source is Advance Auto Parts online, $29, they'll match RockAuto's price of $22 and if you order enough other stuff to take it over $50 it's free shipping. Like wheel bearings or u-joints.
I agree with those saying just do it yourself. If you have a place to work on it, are careful and can follow directions, you'll come out ahead even with buying tools to do it.

[Phototone]

Originally Posted by pavel

Phototone: I get the impression everything is better priced once you move away from the coastal cities. Then add in the fact that I live in Canada which seems to cost more again. It's getting really tough for young people to get started up here these days - fewer good jobs (lots of minimum wage opportunities); the 75 year old house across the street from us is renting for $4000 per month (it was $1500 2 years ago). My son is renting a small (but nice) apartment and pays $1375 plus $30 parking per month - he can't afford to own a car (borrows ours when necessary). People are pouring into Vancouver from everywhere - Germany, Iran, India, China, Australia and they all seem to be swimming in money. I was in a Toyota dealership last year where there was a line of immigrant families waiting to pay full list price for Camrys/Corollas. The dealers all charge $105/hour (plus 'shop supplies' and other levies) for service and this is increasing soon.

So, if you can get that valley gasket replaced for $150 labour, you are very fortunate because it is probably a 3-4 hour job!

Cheers and all the best from the mad northwest coast.

Thats just crazy prices. Just crazy. I live in a smallish town in Arkansas, USA, right next to a larger town (approx 100,000 pop). I own seven rent houses, of which the largest one I rent for $400. I paid $2800 for my 1994 Disco and I use some local shops because they have a lift, and I can't focus my eyes too well at the distances needed for working underneath a car, when I am laying under it, and I also use shop for other tasks if I like their price quote. As an example of a price quote, I asked one of the shops I use to quote on replacing the valve cover gaskets, drop and clean the pan and oil pick-up and reseal the oil pan, and with me providing the gaskets, their price was just a little over $300.

[pavel]

You are right - the prices are crazy, but still less than other cities like London, Tokyo. For $400 rent in Vancouver you get a cockroach & bedbug infested SRO (single room occupancy) of about 120 square feet. The cheapest LR, mid90s in good condition will cost you over $6karound here - a 5 spd, closer to $10k..it's just a different world out here.
With the high cost of life here, all the more reason to do your own Disco work where possible!