the warranty company is arguing the cause and effect of the failure. They EGR system which is not covered was teh cause of a failure, therefore they're saying nothing is covered. They're not saying the EGR system failed, it doesn't make a difference. What does matter is that a non-covered item was the direct cause of something that was covered. That really sucks, but I can see their point. I agree though that we all know the cause is an engineering problem, not the EGR'* fault. The upper intake IS the engineering fault, but if the EGR wasn't routed through there to begin with, there wouldn't be a problem.

hi i live in montreal and i know where to get a brand new dorman intake for 150$ canadien and i can help you just dont know if it to late don

It may already be too late for the crank and bearings for a new intake, but there is a cheaper option I believe is better.

Buy a rebuilt upper from Bob Dillon on this Forum for 60 bucks (better than the Dorman IMO), and a reduced diameter stovepipe from Bill Buttermore (custom). Again, better than the alternatives IMO. I've installed both of these on a members car, and believe it to be the closest to a permanent solution. Including ALL GASKETS the total bill is only about 100 bucks.

And GET THAT DEXCOOL out of the car. It'* as much of a problem as the EGR/UIM issue!

It'* not too late for anything really. The car is sitting at the dealer with the UIM/LIM and both heads off. I'm looking at new head gaskets and a LIM gasket too. I really hope the lower end doesn't corrode. I have have been trying to figure out how to get it home, I have nowhere to put it in Montreal. I'm thinking I have to rent a truck and a tow dolly to bring back to my place where it at least can be garaged.

I am no stranger to engine work, but I'm not the one who took it apart and that'* a big minus for me. I have no experience with these 3.8Ls, only GM smallblock V8s and VW fours :p

I'm going to need the best service manual I can get, and really at this point, with the motor half torn down already and sitting in contaminated oil, I'm really considering an L67 swap. What do you guys think? I can get a low mileage L67 near my home for $900. Use my tranny a short while being nice and easy and get the diff update in ohio when I get the chance? I have the time to work out harness issues, and I already see some info out there on the web.

It'* already a fully loaded SSE, I have the HUD, Bose, Leather, I just lack the */C and the boost gauge, and maybe the selectable suspension.

This is exactly why it may be too late already.

Oh no wait! I have rear drum brakes!!! :(

:P

Well that'* that then. I will be Uhauling it one way back my garage in NY. When I get it back I'll take some photos and post them if you guys would like to see a catasrophic uppers failure :/ I'll keep ya posted once I have her garaged. Thanks again for all your help guys.

Don't forget you have many resources here, and locally too if you need it.

To be honest with you, Chilton'* #28200 should be all you need for the repair. But you'll want FSM'* for the swap. At this point, I wouldn't trust the bottom end. Unless you pull the oil pan and a couple rod caps to inspect the crank. NUMBER them if you do that.

Where are you in central NY??