Like blood through veins, air and fuel must flow unimpeded through your engine. But when the intake manifold gasket leaks, that vital circulation is disrupted. This sneaky issue causes subtle symptoms initially that signal serious trouble brewing.
Spot and fix gasket leaks early by learning the key symptoms of an intake manifold leak, what caused it, and how much it’ll cost to fix.
What Is an Intake Manifold Gasket?
The intake manifold gasket(s) sits between the cylinder head and the intake manifold. Its main purpose is to prevent coolant, oil, or air leaks.
Because of constant expansion and contraction from temperature changes, coolant and oil contamination, and the constant flow of intake air, the intake manifold gaskets can slowly break down and eventually get to the point where is deteriorates enough to cause a leak.
If a leak occurs, the gasket should be replaced as soon as possible to avoid potential engine damage or possibly getting stranded.
Top 8 Symptoms of Intake Manifold Leak
#1. Engine Coolant Leak.
Engine coolant is sealed by an intake manifold gasket in the engine. If damage were to come to the seal, all the pressurized coolant it is holding back may seep through it.
Often times, the coolant will have debris and dirt inside of it which will create even more problems. If the debris is thick enough, it will cause more wear on the surfaces.
Not only that, leaky coolant will also cause air from the outside to get into the engine through the seal.
Anytime oxygen is present, it will drastically increase the amount of corrosion that forms. This will cause even more damage to the surface.
#2. Overheated Engine.
When coolant continues to leak, it will eventually cause the engine to overheat. But in some circumstances, the engine can still overheat even if the coolant does not appear to be leaking.
Sometimes coolant will leak out of the intake manifold gasket and go right into the intake manifold, causing the engine to overheat.
On the outside, you would not see any signs of this leak. The only way you will know is when the engine starts to overheat and the temperature gauge in your dash rises to a high level.
Then you can investigate and determine if this is the problem. If so, then get it fixed at an auto shop right away.
#3. Engine Misfires.
Engine misfires can be a frustrating issue, since they can be traced back to a variety of causes, and a leaking intake manifold may be one of them.
When an engine misfires due to a leaking intake manifold, it means that the extra air entering the combustion chamber is interfering with the combustion process.
This disruption leads to irregular and incomplete burning of fuel, causing the engine to misfire. These misfires can manifest as sputtering or stumbling sensations while driving.
#4. Rough Idle.
When there is a leak in the intake manifold, unaccounted-for air can enter the system, disrupting the proper ratio of air and fuel needed for smooth engine operation.
As a result, you may experience fluctuations in RPMs (revolutions per minute) and uneven performance at idle speed.
In addition, you may feel vibrations or hear unusual sounds coming from the engine bay when a rough idle exists.
#5. Engine Backfires.
A car engine that backfires is a concerning issue for any car owner. Not only are they embarrassing, they also raise questions about potential underlying problems.
As with misfires and rough idle, a disruption or escape of the air-fuel mixture within the combustion chamber due to an intake manifold leak is to blame.
This disruption can lead to erratic combustion, resulting in a backfire. These noises might manifest as popping or even small explosions coming from the engine area.
#6. Poor Acceleration.
When there is a leak in the intake manifold, air can escape before it reaches the combustion chamber, leading to a decrease in the amount of air available for combustion.
This decrease in air supply can result in a decrease in engine power and acceleration. The engine may struggle to reach higher speeds or may take longer to get up to speed.
Additionally, the engine may feel sluggish or unresponsive when accelerating, even when the gas pedal is pressed down.
#7. Reduction in Gas Mileage.
On the other end of it, if too much air makes its way into the combustion chamber due to an intake manifold leak, the car’s ECM will attempt to compensate by sending more fuel than is necessary.
This will result in the vehicle running rich and you having to spend more money at the pump.
#8. Stalling.
With an air-fuel mixture imbalance, your vehicle may unexpectedly stall while driving. While in most cases you should be able to start the engine back up, it can nonetheless become a dangerous situation and it’s important not to panic if this occurs.
Intake Manifold Gasket Replacement Cost
The intake manifold gasket is maybe the most expensive gaskets in a car due to its durability requirement and unique shape. A new replacement gasket will likely run you somewhere in the range of $50 to $120 which doesn’t sound so bad.
But the expensive portion will be the work required to replace it since it’s not easy to get to.
Because it often takes 2-3 hours to replace, the labor cost to replace an intake manifold gasket will set you back about $250 to $500. This number could even be higher for sports cars and luxury vehicles.
All together, on average you can expect to pay around $300 to $620 for the total cost of an intake manifold gasket replacement.
Causes of Intake Manifold Leaks
Damaged Gasket
The gasket that seals your intake manifold can wear out, crack, or become damaged over time. This can lead to air or coolant leaks, causing various problems such as the one listed above.
Car manufacturers don’t typically have a replacement schedule for intake manifold gaskets so they are usually only replaced after a leak develops.
Cracked Intake Manifold
A cracked intake manifold is another common cause of leaks. When your intake manifold has a crack or a hole, extra air can get into the combustion chamber, resulting in air/fuel ratio related issues like misfires.
Continually driving with a cracked intake manifold can lead to more significant issues, so it’s important to get it fixed as soon as you notice any symptoms.
Loose Components
Loose or disconnected components can also cause intake manifold leaks. If bolts securing the intake manifold become loose or vacuum hoses get disconnected or damaged, air can leak into the system.
Regularly check and tighten any loose components and replace damaged hoses to avoid leaks and ensure proper engine function.
Troubleshooting an Intake Manifold Leak
If engines have aluminum cylinder heads on them, you can expect to have corrosion near the ports of the coolant. The intake manifold gasket’s seal bead has plastic under it that may be eaten away as well.
If you see this, then it means the seal will not hold and will be susceptible to leakage. As a result, the gasket would not be the cause of the leak in this case.
Testing for an intake manifold leak should not be attempted by novice mechanics and in most cases you should let a professional handle it. That said, here are the general processes.
Coolant Leak Testing
If coolant leaks on the outside of the gasket, then you can see it with your own two eyes. But if there are internal leaks which cause the coolant to flow into the oil or combustion chamber, then you won’t be able to spot them that easily.
What you’ll want to do is give your system a complete inspection. Start by checking the oil for signs of foaming or other types of contamination. You should also pull the codes so you know exactly what you’re dealing with.
If the codes relate to the oxygen or efficiency sensor, then it means that coolant has gotten into the combustion chamber. Since phosphates are found in the coolant, along with other chemicals, this will cause damage to the catalytic converter and the oxygen sensor.
If you have a V8 or V6 engine, you can use the codes to figure out which bank has the leak. Any big leaks that are in the runner may give you a misfire code. If you experience this problem for extended periods of time, take out all the spark plugs in your vehicle.
See if the electrodes have any chalky white deposits on them because this is the markings that coolant will leave on them.
By following these techniques, it will help you determine where the leak is coming from and if more tests need to be done, such as leak down checks or compression checks.
Air Leak Testing
A fuel trim problem can occur if the intake manifold has the even the tiniest vacuum leak. If you just use your eyes and ears to find the leak, it will become very time-consuming.
Anytime air leaks through the intake manifold, it will cause air to get sucked in rather than pushed out. Whatever is in the air that’s pulled in will compromise the mixture of the fuel and air, which will impact the emission system and the engine system.
If you have a smoke machine, then multiple leaks can be diagnosed in a shorter amount of time.
This machine does this by allowing the intake manifold to become pressurized while placing vapor and smoke into the system. So, if a leak truly does exist, then smoke will be drawn out.
Find a vacuum port and attach the smoke machine to it just like you would have the brake booster connected to the supply line. Ensure that you have the right sized plug when blocking the throttle body. You’ll also want the PCV system to be blocked off as well.
If the PCV system or oil filter has smoke coming out of it and the engine is not misfiring, then it probably means there is a crack or leak underneath the intake manifold. It may also mean the valve seals or guides are too worn out.
Is It Safe to Drive With a Leaking Intake Manifold?
While it may be possible to drive for a short distance, it is not recommended in the long run. Intake manifold leaks can cause performance issues, such as misfires and reduced power and fuel efficiency.
But more importantly, they can also disrupt the coolant system, potentially leading to overheating and engine damage.
If you notice coolant leaks or compromised gaskets, it’s best to have a professional mechanic inspect and fix the problem as soon as possible.