Recall 2002/2003 GM 3800 V6

03034 ENGINE COOLANT LEAK
JULY 2003 ALL 200 - 2002 AND CERTAIN 2003 CHEVROLET IMPALA, MONTE CARLO; PONTIAC GRAND PRIX, BONNEVILLE; AND BUICK REGAL , LESABRE, PARK AVENUE EQUIPPED WITH 3.8L V6 ENGINE (RPO l36 - VIN CODE K)
CONDITION
General Motors has decided that certain of the vehicles above may have a condition in which engine coolant may leak at the upper intake manifold throttle body gasket, or at the upper intake manifold to lower intake manifold gasket. This condition may result in a low engine coolant level and higher engine operating temperatures.
CORRECTION
Dealers are to replace the three throttle body fastener nuts and add cooling system sealant to the radiator tank.

The ingredient in the coolant supplement is ground up ginger root and walnut shells.

Says a lot for GM Engine QUALITY!!!! This fix should out last the warranty!!

big deal, vw/audi just had a recall on ALL 2001-2002 and some 2003 cars for ignition coils problems.

Is VW repairing the problem or just adding a band aid? Adding trash (crushed nuts and roots) to a cooling system is opposite of the theory of keeping a cooling system flushed and free of debris to aid in the cooling process. GM must have missed those auto classes! The engineers at GM are attempting to avoid the expense of properly fixing a problem caused by lack of quality in the design and manufacturing their product. Something I see as a revamp of the 70's. I think I'll look at an import for a replacement of my 2003 Monte Carlo. I'm just glad they told about the recall prior to purchasing the Silverado I was going to park next to it in the garage. GM needs to revisit the 70's and remember what happened to US auto sales the last time they played these games.

I have a 2001 Pontiac Grand Prix (66,000 miles) and have been having major various intermittent electrical problems.

- Right windown will not roll down ... then it will
- Track light on / off ... changes by itself and can't control
- Tac goes to 0 but car drives
- Car dies at any speed
- brake warning light on / off

Many problems seem like a loose ground to me but I've been charge over $1200 and yesterday it died while my wife / 2 yr old child in it. she had it tolled and this time they said it was a faulty crank sensor and charged me $440.

Now why I posted here. They also did work for a recall 03034 Engine Coolant Leak. (NOTE: It has never leaked coolant) At the bottom of my invoice they said that I have a problem with "Coolant leaking at Upper Intake Manifold" and it would require $692 to fix it. I called the manager and he said there was a hairline crack where they were adding the bolts and I would need to have it fixed.

Does anyone have anymore information about this recall.

Thanks,

i work at a gm dealership

the 3.8-k has a plastic manifold and over time with heat plastic gets brittle and cracks.(problem) egr tube runs right through the manifold and causes heat which eventually cracks the manifold......(and coolant system tabs work) ALL GM VEHICLES LEAVING THE FACTORY HAVE THEM.

Plastic Manifold?? As I have said, Piss Poor Engineering and a 1970s Band-Aid fix. If you put enough garbage into any liquid reservoir you will not have a leak. The question remains is this quality engineering or an attempt to cover a repair through the warranty period. Using your statement, the plastic becomes brittle and cracks over time. This is why I will never own another GM product. I wish I didn’t own this LEMON.

Plastic Manifold?? As I have said, Piss Poor Engineering and a 1970s Band-Aid fix. If you put enough garbage into any liquid reservoir you will not have a leak. The question remains is this quality engineering or an attempt to cover a repair through the warranty period. Using your statement, the plastic becomes brittle and cracks over time. This is why I will never own another GM product. I wish I didn’t own this LEMON.


If you would do you research, You would find out that the plastic that they use for intake mainafolds flows better than a metal one of comparable structure, runs cooler. GM screwed up, big deal they all do. It happens, I'm also sure that there is more to this coolant additive than just a bunch of ground up roots and wall nut shells. There might be some of that stuff in there, but you making it sound like they are going out and digging this stuff up out in some wooded area and then mixing it together and shoving it in the resivor. You would not beleive the ammount of time and money spent in reasearch and devlopment. If they recalled it saying they know how to fix the problem, then they usually do.

I've done some research and the GM cooling system additive pills are just that, roots and nuts, ground ginger root and walnut shells, to be exact. The information on the “additive” was on a Cadillac web site with the same part number. The bottom line was that GM was proud of the fact of the roots and nuts swelling when contacting air to effectively plug a leak. I guess this is the quality fix they usually do.

As far as the better air flow, you are correct. However, I purchased the car for the style and had planned on keeping it for several years. The fact that the plastic parts are not as reliable as the metal is a big deal. This is not a car that I plan on drag racing, placing on a track, or street racing. I can live with a little extra airflow disruption for the quality of durability.

The big deal is the purchase of a new car at a price exceeding $25,000.00 is a big deal to me! I expect engineering and quality in the development and production of an item and feel it should be backed by the warranty and properly fixed. As far as GM screwing up, I agree they did.

This is a major screw up that has been around for several years and models. It is cost prohibitive for them to fix it this far into the game. As long as the public looks at it from your prospective and accepts it as business as usual then it will continue. I felt that the word should be out there as a public service to inform other readers. I know I would have been grateful for the information prior to purchasing my 2003 Monte Carlo SS.

Please do not this personally; it is intended to inform other potential car buyers of the problem. A problem (as I see it) in all 3.8L, V-6, GM engines. Please also note that I have talked with several other people with the same concerns.

So if this is a major engineering flaw ... why are they now saying that it would cost me $700 to fix? It was NOT leaking until they completed the free service work. NOW, there it is leaking on my driveway. I didn't even take my car in for this issue. They totally created this problem when adding the bolts ........ this really sucks!

Put a 180 degree thermostat in your truck to help protect it from excessive heat. OBD2 will still be able to go into closed loop and your truck will also perform better.

DD

If you did not authorize the work they accomplished on the cooling system (changing the bolts) you may have a legal recourse. They can only perform the work (even warranty) after you authorize it. I would approach the service manager and request they resolve the issue. If that fails, contact the manufacture's rep followed by the BBB. I would stand on the facts, they cracked it when replacing the bolts (work over and above the reason it was there) and you DID NOT Authorize work in this area! Another source that may be able to help you in this matter is your states Attorney General’s office, they may have a consumer protection division. Most local TV stations like to also get involved in consumer protection and will help you fight for your rights. One thing is almost a certainty; you will have to fight to get it resolved, GM seems to be taking a 1970s approach to consumer issues and warranty issues, most (NOT ALL) dealers will follow suit. In all cases take notes on who, when, where, and what was said in the conversation. This will help when pleading your case!

plastic plastic plastic..... I cant count on fingers on how many Intake manifold Gaskets i have replace on Chevy's Vortec 350's and 454's same thang plastic ass intake leaks anywheres from 50k to 100k in miles. Gimmie a Oldie from the good ol days and leave the plastic to Matel.. or Hasbro

DSSDOG I think if you look at the intake gaskets you are replacing you will find they are failing from the inside of the coolant passage out. Look at the Dexcool your pouring in those radiators. Give me good old Prestone (cant drink it but I dont ever remeber being that thirsty anyway)
Many of the cars nowdays are coming out with plastic intakes (taurus sable also) Chrysler has been using plastic for its thermostat housings for about 4 yrs. (actually thermoplastic).

Plastic Manifold?? As I have said, Piss Poor Engineering and a 1970s Band-Aid fix. If you put enough garbage into any liquid reservoir you will not have a leak. The question remains is this quality engineering or an attempt to cover a repair through the warranty period. Using your statement, the plastic becomes brittle and cracks over time. This is why I will never own another GM product. I wish I didn’t own this LEMON.


Gm's quality in the last few years is exeptional, and the buick 3.8 is one of the best v-6's made in my opinion. It may interest you to know that JD powers has rated many buick vehicals above toyota for initial quality and reliablity this year (toyota being the highest standard I might add). As for this recall, everyone company makes mistakes should it have happenend no but all in all gm is doing very good work, which is something I cannot say for alot of other companies such as (dodge,vw,many ford products,and mitu) to name but a few

You have stated, GM made a mistake and are trying to correct it. I agree that anyone or any company can make a mistake, and GM is no exception. I agree GM should be afforded an opportunity to correct the problem. I do have a question though, how long is a mistake a mistake? This is an ongoing problem. Look at the recall; it covers 2000 through 2003 cars (Buick, Chevy, and the rest of the line up). I would think that after they found the problem they would have fixed the problem. I also do not consider “STOP LEAK” an engineering fix, just a band aid. You may also find it interesting GM offered to extend my warranty after I complained to the Better Business Bureau. I’m glad you are satisfied with your GM product and feel it is top of the line; I would also like to wish you all the luck in the world with it. My opinion is just that, my opinion. I have already stated it and stand by it.

Prior to posting I would like to ask a couple of questions based on some interesting points I noticed while visiting your profile.
I see you are a mechanic in Canada. Do you feel adding stop leak is a true fix or a band aid fix until you can perform the proper maintenance? Last but not least, are you a GM certified dealer mechanic? If so I understand loyalty!

Hello, I am the webmaster for link removed by moderator. Currently I'm developing a page dealing with 3.8 liter V 6 engines that are exhibiting the following problems due to the intake manifold gasket failing: coolant leak, coolant odor, milky colored oil and/or a milky or whitish substance on either the dipstick or oil fill cap. Typically the problem involves the upper intake manifold/gasket, throttle body nuts and/or throttle body gasket. The cars affected include the 2000 - 2003 Buick LeSabre, Park Avenue and Regal; Chevrolet Impala and Monte Carlo; Pontiac Bonneville and Grand Prix. By raising awareness of the problem with the 3.8 V 6 engine we hope to force GM to remedy the situation, and bring satisfaction to consumers.

If you own an Gm car and have experienced or are currently experiencing any of the above problems we would like to hear from you. We are looking for information from consumers for possible inclusion on the website. By sharing the experiences that you've had with coolant loss or intake manifold gaskert failure, you will assist us in helping the 1000's of consumers who are suffering from problems exactly like yours. Please take some time to visit the website and share your story with us.

My girlfriend has a 99 Pontiac GP with a 3800 V6 and I thought it was one of the best motors (for american anyway) around until the wall between the EGR passage and coolant passage on the upper intake ruptured. Ended up having to get another upper intake for $160. Anyway, her Dad got it all back together while I was at work. Now it won't start. I'm thinking that it maybe fowled sparkplugs but for some reason her Dad doesn't think so. I'm not completely clear as to what all he did to it but I'm going to find out tommorow. If anybody has any suggestions, I'll probably need all the help I can get.

thanks
mrtn82

I have a 2004 Impala with the 3800 engine and it's in the shop today getting this problem fixed at my expense - $700 +. Strangely, I had a transmission problem that an independent shop told me was common on the 2003 model, but not on the newer models. Is there a way I can tell if I might have gotten a 2003 engine/transmssion in my 2004 vehicle? This would suck.

GM's replacement is junk and the Dorman one is the better one.Dorman products already improved the upper intake and GM does not know about it.

Gentlemen this thread is 2 years old start a new one, thanks.