i just bought a 19995 lesaber with 80000 miles on it and have heard from a few people around work about their problems with 3.8 engines melting and leaking coolant into the engines . mine is the L vin # model . from what ive read on this site it seems that the K-vin 3.8s are the ones that have the problem of the egr valve melting the intake . does the 1995 lesaber L-vin engine do this as well ? if not what is the difference between the two models ? thanks david moon in ohio

The plastic intake on the 3.8 is known for that problem. It's not the EGR valve, it's a cooloant inlet passage on the drivers side. The factory plenem is faulty but the aftermarket one that is out is strenghened and will run you about $160.00

Although both VIN L and VIN K 3800 (A.K.A. "3800 Series II") engines both have a composite intake plenum, only the VIN K engine has proven to be problematic. The hot E.G.R. gases warp the plenum over time. Coolant from nearby water jackets begin to seep into the engine when this occurs. An aftermarket replacement intake plenum (not from dealership) for the VIN K engine with reinforced passages has been available for a few years already. The same part for the VIN L engine has just recently been released within the last 6 months. The VIN L engines with the composite intake plenums were only used from 1993-1995. The VIN K engines were first installed in 1995 and are still being installed in some cars to this day.

The EGR Valve is mounted right by the intake plenum on the back of the engine just behind the throttlebody on the VIN K engine. The EGR gases go directly from the EGR valve through the intake plenum *near a couple water jackets*..........On the older VIN L engine, the EGR valve is mounted remotely from the intake plenum and has a pipe that goes from the EGR valve mounting bracket to the front of the intake plenum away from all water passages. Any harmful warpage is nearly impossible because of its design.

If it makes you feel any better, your '95 LeSabre has the exact same engine as my '95 Regal GS. I have 158K miles on my car and my plenum is just fine and has never been touched.

What's the difference between the two engines? - pretty much everything. A VIN K 3800 is essentially a re-engineered 3800 altogether and it has nothing in common with its predecessors except they use the same valve covers. To my knowledge no parts are interchangable between the VIN K engine and its predecessors (other than the valve covers of course).

In case anyone needs to know, Dorman makes the replacement intake plenums for both engines and they are available at any AutoZone. The VIN L (1993-1995 ONLY) intake plenum is Dorman Part number 615-179 and usually sells for around $180. The VIN K (1995-present) intake plenum is Dorman part number 615-180 and usually sells for around $135.

See Thread for Ken-Co replacement EGR nipple to eliminate repeated intake manifold replacement.
You replace this part when replacing the intake. The reduced size nipple does not contact the intake.