Hello all,

I am a new member with a (apparently fairly common) problem. My 1993 Chevy Lumina APV with 3800 motor did alot of sputtering/cutting off and when taken to my mechanic the Upper Intake Manifold was melted. It was replaced and it did the same thing driving home from the mechanic--I have not driven it since then but it does sputter when I start it in the driveway. I have read alot of posts and this seems common among the Series II motors--is the problem common with my motor also?? I have new(er)plugs, wires, fuel filter, TPS (new), PCV valve, thermostat and Knock Sensor. This is my family vehicle (wife and 3 kids) with 280,000 km (approx 170k miles) and normally drives great with excellent reliability and gas mileage.
I have not yet checked the Catalytic Converter and will do so. Any other thoughts/ suggestions would be greatly appreciated??

Thanks for the help,

Ravi

p.*. On a side note I am a big fan of the Regal/GPrix and Bonneville/Eighty Eight etc cars. I have looked at the pics and there are some very sweet cars here. Both my brothers own 3800 powered Olds Ninety Eights and my Dad owned a 3800 Regal. My other car is also 3800 ( )powered---1987 Grand National.

Well...... i can asy that what you are having problems with is EXTREMELY rare, as your 3800 in the Lumina is a series I engine. It should not melt the intake, as that was only a problem on the Series II.

Gearheads??

The UIM typically does not melt on an L36, rather the area around the hot EGR stovepipe deteriorates from exposure to heat more like a thermosetting plastic pan handle left over a burner, eventually perforating into adjacent cooling passages allowing coolant to be sucked into the combustion chambers. This is only a common problem with the L36 (vin K) engine built starting in 1995. Is your engine original?

I'm wondering the same thing....sounds like failed gaskets to me....

Thanks for the input guys.

I did not see the Intake Manifold myself but my mechanic advised me that I needed one as the "old one had melted". I have been going to this shop for 10 years at least and I trust them completely. I will call tomorrow to see if they have it--I will have a better idea then. Does the cat not also seem like a culprit here?? I have had the van for nearly 2 years--I don't know if the motor is original but I would bet it is. I suppose I should be checking my oil also?? Any thoughts on why this sputtering/cuttiing off continues??

Thanks again,

Ravi

Side question
Were in Canada you located??

The only thing that could POSSIBLY melt it is where the EGR enters the front of the intake. Assuming your EGR could stick open, and the cat were clogged as well, causing extreme exhaust temps.

If that were the case, I gaurantee you that you have cracked exhaust manifolds.

I'd like to see you save that upper manifold.

NOTE:
The EGR in the Series 1 enters the UIM in the same location as the M62 supercharger on the Series 1 L67'*, NOT underneath the inlet from the LIM as on the Series 2'*. I have yet to see a single documented case of a Series 1 L27 UIM failure.

So this is leaning toward being the cat now to solve the problem?? I really need to solve this--this is my daily driver. I called my mechanice and they have it and I will pick it up later.
I am in Toronto.

Thanks for your continued input,

Ravi

Honestly you are having an issue we really aren't very familiar with. Showing us the pictures once you get it will help.