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2005 4.7L DC Intake Manifold screw loose
Here's a good one for you, will be interested to hear if anyone else has experienced this!
About a week ago my 2005 4.7L DC (172K miles) developed a slight hiccup,
Brought it right to the dealership the next day, no warning lights were on so they didn't hook it up to diagnostics, but suggested I get the throttle body and injectors cleaned (it was a bit overdue anyway),
Did that, still didn't fix the problem, and the only other thing they could think of was that the EVAP cylinder (I think that's what it's called), the charcoal cylinder in the gas tank had become over saturated and was sending confusing signals to the engine, so they told me to drive it till it was below half a tank and see if it gets better,
Well...it definitely didn't get better, in fact it got alot worse, I practically didn't make it back to the dealer the next morning, it was running very rough, stalling out at stoplights, and the engine warning light had turned on,
This time since the engine light had turned on they hooked it up to diagnostics to find all the even cylinders had misfired, and after further diagnostics they narrowed the issue down to a loss of compression in #8,
Then they tore down the head on that side and discovered that a bolt had come loose from the baffle on the intake manifold and made it's way down to the intake valve in #8 and gotten lodged in there, luckily, they're saying there's no damage to the cylinder itself and they've quoted me ~2,200 to fix (labor and parts), which includes a new intake manifold, which they recommend because they're a bit nervous there could be other loose screws in mine,
First off, they say they've never seen this before and I was wondering if anyone's heard of this ever happening to the 4.7L engines?
Also, I'm wondering if people think they're recommendation on a new intake manifold is prudent?
And lastly, while the truck is obviously out of warranty, I'm wondering if anyone thinks I might have some recourse with Toyota in terms of getting reimbursed? FYI, the dealer has put in what they call a "story" with Toyota to raise visibility but that's as far as it's gone.
Thanks in advance for any feedback!