intake/valley pan renewal - Defender Source
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  #1  
Old November 7th, 2005, 08:01 PM
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intake/valley pan renewal

embarking "potentially" on replacing this gasket in a few weeks. Any suggestions or words of advice before I start. I have an idea of what is involved but was wondering if anyone here that has done this might have a few words of wisdom. thanks dudes

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o yeah should I use RTV or hylomar?
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  #2  
Old November 7th, 2005, 08:06 PM
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I sealed mine with "right stuff". I don't know if that was the best thing to use or not. The only thing I paid particular attention to was that I didn't use so much of it that I might obstruct the flow through the water passages. It seemed pretty straight forward to me and no troubles so far (fingers crossed). Oh yeah, and lots of beer.

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Old November 7th, 2005, 08:08 PM
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cool, how many miles were on you truck when you had to repalce? what were your symptoms
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Old November 7th, 2005, 08:15 PM
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I had 107k on the engine. I pulled the engine and replaced with a 4.6 long engine. It wasn't in bad shape, I just wanted more power. I should clarify, I used right stuff on the valley gasket and hylomar hpf on the intake. It was a lot of fun to do. Great learning experience. I'm no mechanic, so take what I say with a grain of salt(except about the beer of course).
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Old November 7th, 2005, 08:51 PM
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Okay. thats what I have been confused about. The intake has the "3.9" written on it and looks like its held on with allen screws, arent the "trumpets" in there? Does that have to come off seperately when pulling the i_____ to get to the valley gasket? Sorry for my lack of knowledge but yeah.
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Old November 7th, 2005, 09:32 PM
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The thing that says 3.9 is the top of the plenum. The intake is the larger asembly below that. So it comes off first. It's a good idea to change valve cover gaskets when you do the intake seals.
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Old November 7th, 2005, 10:47 PM
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Does this help, Phil?
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  #8  
Old November 8th, 2005, 12:06 PM
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bad ass. thanks a bunch. I dont have my truck with me but it seems like the valve covers had a wierd tyoe of bolt. Is there any particular sort of tools/sockets that I might need ?
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Old November 8th, 2005, 12:16 PM
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A 12 point socket instead of 6 point for those wierd bolt heads. It seems like it was about a 5/16" or 3/8"
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Old November 8th, 2005, 01:11 PM
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did the plenum stacks come out easily, what was your method for removing those items? it seems like the hardest part will be managing all the stuff thats effectivly in the way.
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  #11  
Old November 8th, 2005, 01:17 PM
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The valve cover bolts are a 12 pt 8mm - use a 12-pt 1/4 drive socket on a six inch extension.

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The plenum stacks don't need to be removed - just disconnect the fuel lines, unplug all of the electrical quick disconnect plugs to the fuel injectors and temp sensors and move the heater hoses out of the way. The wiring harness is a little difficult to work the intake manifold out from under but it can be done. I'm right in the middle of putting new head gaskets on my 96 Discovery so it's all very fresh imn my memory. I've got the intake off and the heads come off this evening
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Old November 8th, 2005, 03:50 PM
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will I have drain all the coolant? seems like you would have too

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will the plenum come off with the intake?
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Old November 8th, 2005, 04:52 PM
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Yes you need to drain the coolant, and I would remove the intake and the cover seperate as it will be much easier to remove wiring.
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Old November 8th, 2005, 05:12 PM
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thanks. I might try to get it all out without taking the plenum off, the less stuff I take apart the less stuff I FUBAR.
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Old November 8th, 2005, 05:19 PM
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It is only 8 bolts, you will spend 20 minutes trying to get the connectors off the fuel injectors before you get fed up with it and remvoe the plenum cover in 10. And even if you manage to get the Fuel injector conectors off you will still have to try and get to the bolts holding the intake down that are under the throttel body. So it is WAY easier to just take the cover off. The trick is to unscrew the bolts but leave them in the cover so they go back in the right spot.
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  #16  
Old November 8th, 2005, 05:35 PM
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What do you use to seal the plenum when you put it all back together?
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  #17  
Old November 9th, 2005, 10:00 AM
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I used hylomar hpf to seal the trumpets to the intake manifold and the plenum to the trumpets. I couldn't say that its the best thing for the job, but as they say "so far so good".
I wish I were nearby, I would volunteer to come over and watch (and drink your beer).

Rod
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  #18  
Old November 11th, 2005, 09:56 AM
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genuine or OEM parts? the dude this am @AB said it didnt matter that thier OEM stuff was as good as the genuine. I have always used genuine parts. or does it matter
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  #19  
Old November 11th, 2005, 12:52 PM
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Call Bill at TLR tntlr.com.[since Geo is in HELL] I don't mess with ab anymore. Bill will sell you stuff that works. Most of the aftermarket parts supply Rover so? Go figure!
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  #20  
Old November 11th, 2005, 01:01 PM
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As far as I know, there is really only one company making gaskets for the 3.9 anyways. Mine were stamped with the 'Payen' name, and they are a branch of FederalMogul. I think they make the gaskets used by Rover as well, since they advertise being a big OE supplier. As long as you get the composite style gaskets, instead of the shim steel, you'll be fine. The steel gaskets are a big cause of many of the issues on the 3.9.

Also, as you noticed, you end up needing 12point sockets all over the truck eventually. I had spent a lot of time and money slowly getting all my tools to be 6pt, and now I am forced to buy all 12pt as well. So far I've run into 12pt bolts on the valvecovers, oil pump housing, caliper retaining bolts and looks like the spindle cover as well. Not a bad thing actually, 12pt bolts I've found dont strip out anywhere near as often.

-Hans
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