Intake manifold deteoriating gaskets problem - GM Service Bulletins

[Peter Solarik]

Sample of General Motors service bulletins
Updated Thu. Apr. 6 2006 8:28 PM ET

CTV.ca News Staff

FIRST SAMPLE BULLETIN

File In Section: 06 - Engine/Propulsion System

Bulletin No.: 01-06-01-007A

Date: July, 2001

TECHNICAL

Subject:

Engine Coolant Consumption or Coolant Leak

(Inspect For Material Degradation/Replace Intake Manifolds)

Models:

1995-1997 Buick Riviera
1995-1998 Buick LeSabre, Park Avenue
1996-1998 Buick Regal
1998 Chevrolet Lumina, Monte Carlo
1995-1996 Oldsmobile Ninety-Eight
1995-1998 Oldsmobile Eighty-Eight
1998 Oldsmobile Intrigue
1995-1998 Pontiac Bonneville
1997-1998 Pontiac Grand Prix
with 3.8L Engine (VIN K - RPO L36)

This bulletin is being revised to correct parts and labor operation usage. Please discard Corporate Bulletin Number 01-06-01-007 (Section 6 - Engine/Propulsion System).

Condition

Some owners may comment on excessive engine coolant consumption, or an engine coolant leak near or under the throttle body area of the upper intake manifold.

Cause

Upper intake manifold composite material may degrade around the EGR stove pipe and could result in an internal or external coolant leak.

Correction

1. Follow the upper intake manifold removal instructions found in the Engine Unit Repair Section of the Service Information Manual.


2. Refer to the arrow in the illustration of the upper intake manifold above. Inspect the inner diameter of the EGR passage for signs of material degradation. Degradation will appear as "pitting" of the composite material in the EGR port passage.


3. If degradation of upper intake manifold composite material is found, replace the lower and upper intake manifolds with the following part numbers:

^Lower Intake - 24508923


^Upper Intake - 17113136 (includes necessary upper intake plenum gaskets)

^Lower Intake Gasket - 12537197



4. Follow the lower and upper intake manifold installation instructions found in the Engine Unit Repair Section of the appropriate Service Manual.


5. If degradation is not apparent, skip to Step 7.


6. Verify the repair.


7. If no degradation is found, evaluate the vehicle for other causes of excessive coolant consumption as noted in the Engine Diagnosis Section of the appropriate Service Manual.

Parts Information

Parts are currently available from GMSPO.

SECOND SAMPLE BULLETIN

Engine Oil or Coolant Leak (Install New Intake
Manifold Gasket) # 03-06-01-010B - (10/24/2003)


Engine Oil or Coolant Leak (Install New Intake Manifold Gasket)

2000-2003 Buick Century

2002-2003 Buick Rendezvous

1996 Chevrolet Lumina APV

1997-2003 Chevrolet Venture

1999-2001 Chevrolet Lumina

1999-2003 Chevrolet Malibu, Monte Carlo

2000-2003 Chevrolet Impala

1996-2003 Oldsmobile Silhouette

1999 Oldsmobile Cutlass

1999-2003 Oldsmobile Alero

1996-1999 Pontiac Trans Sport

1999-2003 Pontiac Grand Am, Montana

2000-2003 Pontiac Grand Prix

2001-2003 Pontiac Aztek

with 3.1L or 3.4L V-6 Engine (VINs J, E - RPOs LG8, LA1)

This bulletin is being revised to change the model Information. Please discard Corporate Bulletin Number 03-06-01-O10A (Section 06 - Engine).


Condition

Some owners may comment on an apparent oil or coolant leak. Additionally, the comments may range from spots on the driveway to having to add fluids.

Cause

Intake manifold may be leaking allowing coolant, oil or both to leak from the engine.

Correction

Install a new design intake manifold gasket. The material used in the gasket has been changed in order to improve the sealing qualities of the gasket. When replacing the gasket, the intake manifold bolts must also be replaced and torqued to a revised specification. The new bolts will come with a pre-applied threadlocker on them.

Notice

An oil leak may result if the vertical bolts are not tightened before the diagonal bolts.


Diagonal bolts may require a crows foot to tighten.

Tighten

1. Tighten the vertical lower intake manifold bolts (1) to 7 N.m (62 lb in).

2. Tighten the diagonal lower intake manifold bolts (2) to 7 N.m (62 lb in).

3. Tighten the vertical lower intake manifold bolts (1) to 13 N.m (115 lb in).

4. Tighten the diagonal lower intake manifold bolts (2) to 25 N.m (18 lb ft).

Parts Information

Parts are currently available from GMSPO.

THIRD SAMPLE BULLETIN

File In Section: 06 - Engine/Propulsion System

Bulletin No.: 03-06-01-016

Date: May, 2003

TECHNICAL

Subject:
Loss of Coolant, Milky Colored Oil
(Replace Intermediate Intake Gasket)


Models:

2000-2003 Buick LeSabre, Park Avenue, Regal
2000-2003 Chevrolet Impala, Monte Carlo
2000-2003 Pontiac Bonneville
2000-2003 Pontiac Grand Prix
with 3.8L V6 Engine (VIN K - RPO L36)

Built Prior to the VIN Breakpoints shown.

Condition

Some owners may comment on a loss of coolant, coolant odor, having to add coolant or a milky substance on either the oil dipstick or oil fill cap. Additionally, owners may indicate that there are signs of coolant loss left on the ground where the vehicle is normally parked.

Cause

Condition may be due to coolant leaking past intermediate intake or throttle body gaskets.

Correction

Important: The upper intake manifold should not be replaced for a coolant leak condition, unless a rare instance of physical damage is found. Even if the throttle body surface shows a slight warpage, the upper intake should not be replaced unless a drivability concern is noted or a relevant engine DTC, such as a code for an unmetered air leak, is set and the upper intake manifold can clearly be shown as the cause of the concern.


Thoroughly check for any external leaks. If no external leaks are found, then replace the intermediate intake manifold gasket and the throttle body gasket. When changing the throttle body gasket, the nuts that retain the throttle body should be replaced with a new design that improves torque retention. Medium strength thread locker should be applied to the studs before installing the new nuts.

Parts Information

Parts are currently available from GMSPO.

FOURTH SAMPLE BULLETIN

Bulletin No.: 04-06-01-017

Date: May 26, 2004

INFORMATION

Subject:
New Upper Intake Manifold and Gasket Kits


Models:
1995-1997 Buick Riviera
1995-2004 Buick Park Avenue
1996-2004 Buick Regal
1997-2004 Buick LeSabre
1998-1999 Chevrolet Lumina
1998-2004 Chevrolet Monte Carlo
2000-2004 Chevrolet Impala
1995-1996 Oldsmobile Ninety-Eight
1995-1999 Oldsmobile Eighty-Eight
1998-1999 Oldsmobile Intrigue
1995-2004 Pontiac Bonneville
1997-2003 Pontiac Grand Prix
with 3.8L V6 Engine (VIN K - RPO L36)


New upper intake manifold and gasket kits have been released. These new kits will provide the dealer with the ability to get exactly what is necessary for a correct repair. In addition some of the gaskets have been updated to a more robust design. Please reference the part numbers when ordering from GMSPO.

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[BNaylor]

Good info Peter.

[Peter Solarik]

Originally Posted by bnaylor3400

Good info Peter.

Thanks Bnaylor:
From their service bulletins I understand that the procedure og changing the gaskets is not simple affair.
I keep now a close watch on the level of the coolant in that plastic white container (in engine compartment). I will also bombard the 'Buick Customer Relations Center' with requsts/demands to have the work done by GM. Perhaps our forum members who are affected would like and should do the same.
Thank you Bnaylor for keeping us informed. I am sure that everybody here agrees.

[slischyn]

Anyone know how long it would take to change out these gaskets as DIY with the right tools and kits on hand?
Steve L.

[BNaylor]

Originally Posted by slischyn

Anyone know how long it would take to change out these gaskets as DIY with the right tools and kits on hand?
Steve L.

For a typical DIY type person about 2 - 3 hours worse case which includes draining radiator, refilling, bleeding air out and final check out.

Good luck!

[Flatrater]

It would depend on the engine and what parts you are replacing. The 3.8K engine intake job is about 4 hours for an experienced tech and the 3.1, 3.4 engines are about 5 hours depending on if the engine has A.I.R. system.

I can do all of these under 3 hours if I try hard and use air tools.

[BNaylor]

Originally Posted by Flatrater

It would depend on the engine and what parts you are replacing. The 3.8K engine intake job is about 4 hours for an experienced tech and the 3.1, 3.4 engines are about 5 hours depending on if the engine has A.I.R. system.

I can do all of these under 3 hours if I try hard and use air tools.

I did a complete UIM/LIM job to include throttle body on a 3.4L in 3 hours. I installed polished and ported UIM and LIM from APoC and a RSM Racing 62mm throttle body. That included pulling the fuel injectors due to the LIM swapout and putting in new o-rings. BTW - I'm not an automotive tech.

[Peter Solarik]

Originally Posted by bnaylor3400

I did a complete UIM/LIM job to include throttle body on a 3.4L in 3 hours. I installed polished and ported UIM and LIM from APoC and a RSM Racing 62mm throttle body. That included pulling the fuel injectors due to the LIM swapout and putting in new o-rings. BTW - I'm not an automotive tech.

CTV lifts hood on potential problem in some GM cars
Kathy Tomlinson, CTV News

Update, April 24, 2006: General Motors has been slapped with a class action lawsuit in Canada. The suit comes after this CTV Whistleblower report that revealed problems with a small engine part in millions of GM vehicles. The lawsuit alleges GM is at fault for the failure of intake manifold gaskets in several of its vehicles.

It's a simple component buried deep under the hood -- in some one million General Motors vehicles sold in Canada alone. It has the potential to cause huge headaches though, for the GM vehicle owners.

It's an intake manifold gasket, put in at the GM factories, in some makes and models between 1995 and 2003. According to GM's own internal service bulletin, the part can "degrade" -- causing coolant to leak -- sometimes into the engine. Several vehicle repair mechanics told CTV that in the worst case scenario, the coolant mixes with engine oil -- making the oil ineffective -- and damaging the engine.

They say in extreme cases, the engines overheat and seize completely -- which means the vehicles need complete engine replacements. Some GM customers have been hit with repair bills of up to $5000 -- after their warranties have expired.

"I started to cry," said Ontario resident Lisa Slatter, whose 2002 GM Montana needs at least $1700 worth of repairs. "I cried and I cried because I thought I don't know how I'm going to pay for this."

Slatter's problems started when her vehicle had less than 100,000 kilometres on the odometer. It was leaking coolant, she said, and her warning light was on. An independent mechanic diagnosed a leaking intake manifold gasket -- and told her she should get it replaced.

Eventually, her GM Montana broke down completely. Now, she needs a new head gasket -- a significant repair.

"I didn't know (how serious that problem was) until my thermostat was over in the red," Slatter said. "It totally overheated. Because the coolant was gone."

"This is absolutely not normal wear and tear," said Kirk Robinson, an independent mechanic who worked as a GM service technician several years ago. He also hosts a call-in cable TV show in Toronto, called "Auto Talk".

Robinson agrees with several other mechanics, who told CTV they see and hear from GM customers with the same problem almost every day. Kirk told us he does repairs associated with GM intake manifold gaskets at least once a week -- and says it's the number one complaint he hears during his call-in show.

"It's very well known in our industry that this is a fault," he said. "It's definitely a manufacturing defect."

It turns out that GM has known about the problem for years. CTV obtained copies of four GM internal service bulletins -- from 2001 to 2004 -- warning General Motors dealers about the potential problem. For example, in 2001, GM wrote:

"Some owners may comment on excessive engine coolant consumption, or an engine coolant leak near or under the throttle body area of the upper intake manifold." "Upper intake manifold composite material may degrade...and could result in an internal or external coolant leak."

GM's service bulletins list several vehicles potentially affected -- 23 makes and models manufactured between 1995 and 2003. Since then, GM has come out with a new, improved intake manifold gasket. Still, mechanics say, the old part continues to break down in vehicles that haven't had it replaced.

Robinson, for one, thinks GM should have called all the potentially affected vehicles in for full repairs, when they first identified the problem.

"I think they should have brought (the affected vehicles) back and fixed it a lot sooner," he said.

"I think this is the biggest problem that I've ever seen with automobile manufacturers," said Phil Edmonston, who writes the consumer car guide Lemon Aid. "I really believe it's the biggest problem GM has ever had."

There's an on-line consumer petition -- with 11,000 signatures from GM customers -- calling for a voluntary "goodwill" recall by GM. In Canada, The Automobile Protection Association has logged 800 complaints. There are class-action lawsuits brewing in the U.S., where Edmonston now lives.

"The way to fight is just simply send a registered letter or an e-mail (to GM)," Edmonston told CTV, during an interview in West Palm Beach, Florida. "If your vehicle is not reasonably durable and has a mechanical defect, any judge on any bench -- small claims up to the Supreme Court of Canada -- can make that company pay."

Edmonston said he knows of several cases where GM has paid for intake manifold gasket repairs -- beyond the warranty period -- when customers have made a big fuss. He believes GM should now cover all related repairs, on all its affected vehicles.

CTV asked General Motors several times for an on-camera interview. The company sent a statement instead, which says, in part:

"An intake manifold gasket concern can arise from a variety of causes. It is for this reason that any concern a customer may have beyond the warranty period is handled on a case by case basis," wrote Stew Low, director of communications for GM Canada.

He also indicated there will be no voluntary recall of affected vehicles.

"GM does not plan to issue any type of goodwill action regarding the intake manifold gasket situation."

GM vehicles potentially affected (source: GM Technical Service Bulletins):

1995-1997 Buick Riviera
1995-1998/2000-2003 Buick LeSabre
1995-1998/2000-2003 Buick Park Avenue
1996-1998/2000-2003 Buick Regal
2000-2003 Buck Century
2002-2003 Buick Rendezvous
1996/1998-2001 Chevrolet Lumina
1998-2003 Chevrolet Monte Carlo
1997-2003 Chevrolet Venture
1999-2003 Chevrolet Malibu
2000-2003 Chevrolet Impala
1995-1998 Oldsmobile Ninety Eight
1995-1998 Oldsmobile Eighty Eight
1998 Oldsmobile Intrigue
1996-2003 Oldsmobile Silhouette
1999 Oldsmobile Cutlass
1999-2003 Oldsmobile Alero
1995-1998/2000-2003 Pontiac Bonneville
1997-1998/2000-2003 Pontiac Grand Prix
1996-1999 Pontiac Trans Sport
1999-2003 Pontiac Grand Am
1999-2003 Pontiac Montana
2001-2003 Pontiac Aztec
General Motors Canada encourages any of their customers to contact their Customer Communications Centre at 1-800-263-3777 if they have questions regarding their vehicle or service needs.

Send us your tips, stories and ideas to CTV Whistleblower:


Email address: [email protected]
Phone number: 416-313-2494

Mailing address:
Whistleblower
c/o CTV News Toronto Bureau
444 Front Street W.
Toronto, Ont. M5V 2S9

[Flatrater]

"I started to cry," said Ontario resident Lisa Slatter, whose 2002 GM Montana needs at least $1700 worth of repairs. "I cried and I cried because I thought I don't know how I'm going to pay for this."

Slatter's problems started when her vehicle had less than 100,000 kilometres on the odometer. It was leaking coolant, she said, and her warning light was on. An independent mechanic diagnosed a leaking intake manifold gasket -- and told her she should get it replaced.

Don't feel the slightest bit bad for her! She was told and decided to play stupid. I don't feel GM needs to warrranty a repair because the car owner played dumb after being told to get something fixed.

[BNaylor]

"I started to cry," said Ontario resident Lisa Slatter, whose 2002 GM Montana needs at least $1700 worth of repairs. "I cried and I cried because I thought I don't know how I'm going to pay for this."

Slatter's problems started when her vehicle had less than 100,000 kilometres on the odometer. It was leaking coolant, she said, and her warning light was on. An independent mechanic diagnosed a leaking intake manifold gasket -- and told her she should get it replaced.

Eventually, her GM Montana broke down completely. Now, she needs a new head gasket -- a significant repair.

Originally Posted by Flatrater

Don't feel the slightest bit bad for her! She was told and decided to play stupid. I don't feel GM needs to warrranty a repair because the car owner played dumb after being told to get something fixed.

lol. Yeah it makes you wonder about her. Just what part of "leaking intake manifold and get it replaced" did she not understand.

[troy1]

Originally Posted by bnaylor3400

lol. Yeah it makes you wonder about her. Just what part of "leaking intake manifold and get it replaced" did she not understand.

X2.

[Hapynzap]

Well there's no help for Buick owners in the States. We are on our own nickel.

[skijet]

I've replaced entire engine on a 98 Buick Lesabre due to this defect($3,500). I got the engine at cost and paid $850 labor. I won't ever buy another GM product!!!! I've saved my receipts just in case.
Skijet

[allisonbays]

I have a 1999 Buick Century Custom 3.1 about 3yrs ago I had to put a new/used motor in my car. This was all due to the intake gaskets! It cost me $500 for the motor (w/64,000miles) and $500 for labor and parts. Well now 3yrs after all this my car started over heating on my husband and right then I told him I know what it is. I was actually gonna not let him drive home and I was actually going to have it towed home to have my mechanic father whom is now living w/us fix it. When this happened the last time on my way home my motor blew up and everything locked up on me going around a curve and I almost went off a cliff!!. He made it home with the car though and we are hoping for the best now hoping it's not to late. It cost me a lil over $100 to get all the parts and new oil and stuff. I was told by another mechanic that those gaskets should be changed every 60,000 miles. My car should be back together and running today hopefully! Good luck to anyone with this horrible problem.