I fix one leak and another one pops up! In the quest for normal O2 sensor readings, I've been hunting down and sealing leaks. I started at the exhaust with new gaskets for the headers and collectors. Then I moved to the intake. I got a new fel pro set of intake gaskets (base, runners, and plenum). Once I got that sealed up I started her up, and now I have a loud whistling/sucking noise coming from somewhere near the EGR. SO I went and tried a new EGR gasket, then a new EGR. Still whistling. Tightened everything that plugs into the plenum. Still whistling.

Could the gaskets be leaking? Here's why: the runners have been taken off I believe 3 times since putting in new gaskets. I screwed up the base gasket so I had to go back in. I also took them off to clean them out. Could all this removal and installation have crushed the gaskets in an improper way? If so, does anyone know of a set of just the runner gaskets?

 

I wouldn't think taking the runners part and putting them back together would hurt anything as long as the gasket didn't rip. Some RTV would probably do the trick, but it'll be a pain to clean off the next time it comes apart.

If you're hunting for a leak in the intake some carb cleaner or starting fluid works. You can spray it around the area you suspect the leak with the motor idling in Park. If you hear the motor rev up a little bit you've found your leak.

 

Yeah I tried doing that, that's what led to the EGR hypothesis. Wherever the leak is, it's CLOSE to the EGR, but it's hard to pin down. It's definitely sucking in, are there any other tricks for pinpointing it?

The only stock gasket set I can find is the whole intake from throttle body to heads. Can I use an set of runner gaskets for bigger aftermarket runners? I'd really like to avoid using RTV in there.

 

You could also go back to the propane torch method and see if you can find the leak that way too.

Bigger runner gaskets might work, but probably won't have as much meat on them as the stock gaskets. Too bad you aren't around here I have an extra set of runner gaskets I would just let you have.