(didnt want to hijack Crunkgringo's thread)

1998 Disco1 - V8 4.0 122k

its high time the valve cover and valley pan gaskets get replaced -
going with:
MAHLE MS19611 - valley pan gasket
MAHLE VS50513 - valve or rocker cover gaskets
FEL-PRO MS97221 - plenum gasket

I have a few questions
The RTV mentioned for the intake: Is permatex ultra black a good choice? and is it just in the front or rear too?
Gasket adhesive Bostik 1775 and cleaner Bostik 6001 - whats a alternate? (was figuring alcohol for cleaner)
Is 4hrs a reasonable estimate for down time?

Any other thoughts - advice?

 

The D1 doesn't have a plenum gasket, the Bosch motors in the D2s do. The lower manifold to middle manifold and then middle to intake plenum takes hylomar sealant. It is a very thin and sticky very flexible sealant.. I think ultra black for those very tight joints might be to thick but I haven't tried it.
The ultra black or even better "the right stuff" can be used for the rubber end gaskets front and rear.
For cleaning I used solvent because your trying to get rid of oil on the surface before you place the sealant. You can use brake cleaner, carb cleaner or solvents.
I think 4 hours is reasonable. It took me 45 minutes to pull my manifold but I just finished a rebuild so I new exactly what I needed to do. It will take me twice that to put it back in.
Be sure to follow the rave the end gaskets are a little tricky/annoying. Pull the valve covers before you try pulling the manifold off.
YOU DON"T NEED TO TAKE OFF THE MIDDLE INTAKE TO DO THIS JOB. Only if you need to pull the fuel rail and injectors off would you need to remove the middle manifold from the lower. You will also be in for a cleaning project if you do. Those surfaces are hard to clean and you have to be gentle cause the seal is metal on metal.

 

And if you do split the lower manifold from the middle (intake runners) then you might as well change the fuel injector orings if it hasn't been done either.

 

Place the intake manifold on the valley gasket and screw in a few bolts (don't tighten them, just screw in a bit) to make certain you have the gasket aligned properly BEFORE you tighten the end bolts/clamps.

 

Great info guys thank you very much.

Now a stupid question - I assumed I should just do the valley pan gasket too. With all the oil leaking from the Valve / rocker covers I cant tell if I actually need to do the valley pan. Is this a part known to leak or need replacing after xxx miles/years?

Crunkgringo -
I cant source hylomar easily - looks like

Permatex 85249

is the closest permatex equal - would you agree?


Walt - thanks you confirmed my suspicion as I saw a post where some one was having issues with gasket alignment

 

I give credit to ihscouts for that tidbit.

 

Yes that looks like it will be just fine. And it is true about getting it aligned. It is not easy and I put mine on with the motor out of the truck on the motor stand. The valley pan end gaskets can leak after so many miles so I don't think its a bad idea.