3100 intake leaks cured?

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Hi

Is there a permanent repair for the 3100 intake leaks?

I have heard of a new gasket and torque procedure, but have no data on if it is successful or not.

The wife is considering a Mailibu with the 3500 V6.

Since it appears to be derived from the 3100, is it cursed as well?
 
No I believe newer designs have been fixed and the intake gasket replacement is supposed to fix the problem as well.
 
Hi

This has me very worried, as we both put tons of miles on a car.

My own car has a 3800 Series II, and although I had to replace the upper plastic manifold, that was 100K miles ago. I swapped dex out for G-05 at that time.

What year did the new gasket/proceedure go into effect?

On other forums, people with cars as late as '03 were still having intake leaks.
 
I think Fel-Pro and GM came out with new gaskets late 2003 to early 2004.

If the car is a 2004 or up I would not be worried. Just keep a eye on it and check it out a couple thousand miles beofre the warrenty goes.
 
I replaced the 3.1 intake gasket on our 99 Cutlass (Malibu clone) some time ago and no problems so far. Other than that the car has been reasonably dependable as a daily driver for my wife.

If you are reasonably handy as a mechanic and have a full day to kill, you can do this yourself and save a ton of labor $$. I used the updated Fel-Pro gasket and also replaced the injector o-rings when I re-installed them back into the intake. Also, in my case, the fuel line attachment to the fuel rail was the original factory attachment that took some muscle to break loose after loosening the attachment note. You MUST use an o-ring to re-connect this or you'll get fuel all over the place. New valve cover and upper plenum gaskets were also installed.

Keep in mind that the pushrods go through the gasket and that you will need to unbolt the rocker assemblies to install the new gasket. These are not hot-lash adjusted so you just have to keep everything in order and then re-install the rockers and torque to specs. Speaking of that, I used some lock-tite on the intake bolts and torqued them to spec - they are kind of puny and I can see why they tend to loosen.

Cost me some time and about $50. I also added some 3M rtv to the corners of the intake and then let the whole thing sit overnight to ensure that everything had cured properly. I refilled with DexCool as well, later will do the G-05, but there were no sludge issues at all with our car, so I just replaced the coolant.

I used the Haynes manual that seemed to cover this repair fairly well. It's silly that this is a known defect on these engines though and that GM turns away if you are out of warranty. For me, the car is generally OK, but the customer support is non-existent, especially for the now-defunct Olds division - that is the reason I will never buy GM again.
 
I have not seen a plastic intake on the 3.1, but don't take my limited view as fact. Our own car has aluminum upper/lower intakes.
 
Hi

For myself, I only drive 3800's, so the L-26 aluminum upper is an option if my dorman replacement ever yields. I ditched dex when I first got the car.

As for the 3500 V6 in question, its a 60 degree conventional pushrod derivative of the 3100 found in cars like the Century, Malibu and Cutlass to name just a few.

I would prefer that she get the Impala with the L-36, but she seems determined to consider the new Malibu.
 
quote:

Originally posted by Drew99GT:
Isn't the 3.5L a DOHC engine from the Intruige?

Sure is, but GM just started putting *brand new* (old school, pushrod, 2 valve) 3.5L's in the new mailbu. My BIL just got one in a malibu maxx. The darn thing looks IDENTICAL to the 3.1/3.4. Made in Mexico to boot
rolleyes.gif
Way to go GM
patriot.gif
!!!!
G/luck
Joel
 
Anyone have any good writeups or sites that show how to fix the intake leak on the 3.8L's? My Mother's 98 Monte Carlo has tested positive for coolant in the oil the last two UOA's. It now has 107K on it and I can see gelled orange dexcool pooling by the injectors on the upper intake manifold. If I could see a writeup and what is involved I will more than likely do it myself. TIA
 
Some 3.8s had a recall due to a manufactoring problem. It's the 60 degrees that have the gasket problems.
 
"Some 3.8s had a recall due to a manufactoring problem. It's the 60 degrees that have the gasket problems."

Had to have the intake gasket replaced in my 02 4.3 truck. It was broken. They must not know how to adjust torque wrenches at the engine plant or how to cross torque a manifold.
 
Ryan,

I think the best place you could possibly go is here:

Online GM Service Manuals

Pick your year, make and model, then click the links for "W Chevrolet", "Engine", "Engine Mechanical 3.8L", and "Repair Instructions". You'll see the intake manifold replacement instructions about halfway down your screen. I'm unsure of exactly which gasket you might need to replace, but the instructions are all right there.

There are also a TSB you might want to read. On the main page of the link above, search for document 812024. Apparently, heat from the EGR can degrade the intake manifold, causing a coolant leak. They recommend replacing the upper and lower intake manifold and the lower intake gasket. Part #s are in the TSB.
 
Hi

Should I ever have another intake leak on any 3800s in the future, I plan on using the new aluminum intake from the L26 Series III engine.

I have been using the Dorman since 11/04 with good success ( 60k mi ) , but it is still plastic.

FWIW, dex has been replaced by G-05.
 
quote:

Originally posted by Marlin:
I think Fel-Pro and GM came out with new gaskets late 2003 to early 2004.

If the car is a 2004 or up I would not be worried. Just keep a eye on it and check it out a couple thousand miles beofre the warrenty goes.


I'm not so sure they totally fixed the problem. I had the gaskets replaced in my 3400 in May 2004 with the "new" gaskets. Everything has been fine until I checked my oil yesterday and found a bunch of white sludge under the oil filler cap. Looks like the problem is back. Problem is this time the warranty is over. Time to spend some big bucks on a problem that isn't my fault!
 
Hi

I wonder if there are several "new, improved" gaskets for these engines?

I have seen a TSB which stressed the importance of using a new gasket that has steel inserts which prevent over torquing and distorting the gasket.

If this gasket is used, and is installed properly, would this fix the issue?
 
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