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imjustdave
Regular
Date registered: Feb 2012
Location: Bonney Lake Washington USA
Vehicle(s): 2004 G500, 2014 Audi Q7 TDI, 2006 Ram 3500.
Posts: 77
| Intake gasket - replacement.
I have a 2004 G500 with M113 motor and have a massive air leak between the intake manifold and heads. I had to pull the intake off and now it barley runs, has a massive whistle now and I can cover up the air inlet without killing it.
I assume the gaskets go on dry - can any one confirm this?
Or do I need to use some sort of sealant?
Previous gaskets were dry and had very little debris to clean off.
torque seems to be about 18 ft lbs.
Thx
-David
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J.R.
Elite Veteran
Date registered: Apr 2006
Location: Southern Maryland
Vehicle(s): 00 G500, 09 911 4S, 11 Cayenne S, 86 280GE (sold)
Posts: 828
| Re: Intake gasket - replacement.
David,
no sealants
I suspect that the gasket has slipped out of position during your reinstall. Here is a great tip on how to keep the gasket from slipping https://www.youtube.com/watch?v=v-S5KtPFY-w
You will also want to triple check the orientation. I am guilt of both mistakes.
Lastly, When it comes to engine matting surfaces, I have had much better luck with dealer parts when it comes to engine rubber and metal gaskets than the brands that claim OEM. Sure they might be an OEM, but my experience is that they are using an inferior material when compared to what Mercedes is specifying.
Edited by J.R. 12/20/2020 10:46 AM
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paulunm
Veteran
Date registered: Jan 2015
Location: Los Angeles
Vehicle(s): 2000 G500
Posts: 124
| Re: Intake gasket - replacement.
I've never heard of an intake manifold gasket leak on a m113 (well, hadn't until I googled it just now)...
How did you verify the manifold was leaking? Carb cleaner spray test?
From what I've seen it's much more likely that there's an intake leak at the MAF -> Throttle Body seals- those two dry up really quickly from engine heat. Even the airbox to MAF seal can be an issue if the airbox isn't set correctly. Or one of the EGR hoses that go from the valve cover to the intake...
Then very likely there's a vacuum leak at one of the many vacuum lines up near the air injection pump- and the little vacuum hose that goes into the bottom of the front part of the intake manifold (like you posted a few days ago).
EDIT- sorry, after reading JR's post I realize the intake manifold leak happened after reinstall....
Edited by paulunm 12/20/2020 12:04 PM
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paulunm
Veteran
Date registered: Jan 2015
Location: Los Angeles
Vehicle(s): 2000 G500
Posts: 124
| Re: Intake gasket - replacement.
J.R. - 12/20/2020 7:43 AM
David,
no sealants
I suspect that the gasket has slipped out of position during your reinstall. Here is a great tip on how to keep the gasket from slipping https://www.youtube.com/watch?v=v-S5KtPFY-w
You will also want to triple check the orientation. I am guilt of both mistakes.
Lastly, When it comes to engine matting surfaces, I have had much better luck with dealer parts when it comes to engine rubber and metal gaskets than the brands that claim OEM. Sure they might be an OEM, but my experience is that they are using an inferior material when compared to what Mercedes is specifying.
JR- great video, but a dumb question- if the bolt heads are cut off- how do you get the bolts out of the head/manifold to then replace with new ones? I'd imagine they're going to be pretty flush with the manifold at this point. Or is the fact they're barely screwed in making them stick up enough to unscrew? |
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J.R.
Elite Veteran
Date registered: Apr 2006
Location: Southern Maryland
Vehicle(s): 00 G500, 09 911 4S, 11 Cayenne S, 86 280GE (sold)
Posts: 828
| Re: Intake gasket - replacement.
David,
You will be threading it in only 2 turns. Not much. There should be more than enough sticking out to grab with your fingers and spin it out.
You can also stick an inch of thin walled vacuum line over the end.
Or you can go to the hardware store and buy extra long metric bolts and cut those heads off, still only thread in two turns.
You may want to add a third guide on each side in the middle one. That is a long run.
CAUTION! Have a rag or something stuffed into the head intake ports before you install the guide pins. you do not want to create a new issue with trying to fish a bolt out of a cylinder. Painters tape works well too.
Edited by J.R. 12/20/2020 6:55 PM
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imjustdave
Regular
Date registered: Feb 2012
Location: Bonney Lake Washington USA
Vehicle(s): 2004 G500, 2014 Audi Q7 TDI, 2006 Ram 3500.
Posts: 77
| RE: Intake gasket - replacement.
Ok... Glad I didn't - don't use some sort of sealant.
I did - do use Mercedes parts for items such as this.
Yes I did see those seals and decided to order some new ones 
So little side history I moved recently and well I have to do work on the G outside.. did I mention I live near Seattle WA and it rains a bunch.. and it's December.. So I was outside, under a easy up to stay dry if it rained, very cloudy and it was threaten to rain most of the day and did in the evening.
Well I should have use the cut off bolt option because the left side drivers side on the front moved.  the bolt went in the vent hole and not the bolt hole. I swear I was carful in lining it up but I goofed. So that front hole for .... Actually not sure what that gizmo does. but in any case it had zero seal and 2 -3 maybe all 4 cylinders on that side had also had little seal so yeah not surprised it ran as best it did.
I decided to wait for new seals to show up VS reuse what I have as the ridge on that area is pinched and flat vs slightly raised... and I have zero desire to do this a 3rd time.
So getting the engine to run took about 3 -4 starts I suspect a little heat
helped.. so it ran with maybe 5 hp that's how weak it was. I could hear a Whistle, the air moving into the intake was next to nill.. I ended up using carb cleaner and once I hit the area the engine ran better with every squirt.
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J.R.
Elite Veteran
Date registered: Apr 2006
Location: Southern Maryland
Vehicle(s): 00 G500, 09 911 4S, 11 Cayenne S, 86 280GE (sold)
Posts: 828
| Re: Intake gasket - replacement.
you are on your way to getting this fixed. Please keep us updated!
I lived on Whidbey Island for four years. We really like Seattle. |
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imjustdave
Regular
Date registered: Feb 2012
Location: Bonney Lake Washington USA
Vehicle(s): 2004 G500, 2014 Audi Q7 TDI, 2006 Ram 3500.
Posts: 77
| Re: Intake gasket - replacement.
Well the new parts arrived and the weather was nice so on the Dec 24th I was able to reinstall everything, after doing some last min Christmas shopping my Daughter helped me replace the intake seals. spent a considerable amount of time making sure they were on right. I did notice because it is 1 seal # for the motor that the rib on the seal for the right and left press against either the intake or head depending on which side your on.. you could say I was inspecting everything a bit too much.
Then it came time to hit the key to start... Vroommm oh it purred so nicely, little gas Vroom Vroom I was really happy. The whistle I had was gone, smooth running, the Check engine lights were gone as well. Finished up verifying no leaks and a few zip ties on wires I had cut and Air filter box reinstalled.
shortish test drive and I was all smiles again, daughter says I drive it like a sports car.. lol I sort of feel like it had more power and was running better then ever. I did fix the following things prior to running into this issue.
EGR vac line was rotted in half
Replaced a bunch of other vac lines on the front of the air intake
Fixed the big blue line that I believe is part of the EVAP system, one of the joints was cracked in half.
Took the G on Christmas to the in-laws and all was running great.
So the really best way to verify a repair is Yesterday we went on a snow run up in the snow and was all smiles.
In closing if your doing any work and had the intake manifold off and it wont run .. check the gaskets, it's way too easy to make a mistake.
Thank you everyone for the help. |
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J.R.
Elite Veteran
Date registered: Apr 2006
Location: Southern Maryland
Vehicle(s): 00 G500, 09 911 4S, 11 Cayenne S, 86 280GE (sold)
Posts: 828
| Re: Intake gasket - replacement.
best part of this adventure is involving your daughter. Nicely Done on the repair too! |
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