Off topic but why can't I edit my first post to change a few typos?
1/8/2010 Continuing from yesteday
Once the car fired up I let it run for a minute tops and shut it off to check belt and area. I started it back up and it idled a bit rough and I let it run for maybe 2-3 minutes and was so happy and realized the garage started to fill up with a white hazy cloud..... killed engine and coolant came to mind.
I checked reservoir and it was empty, looked into radiator and couldn't see the level of coolant, and I added 1/2 gallon to top off radiator. Before I got the car running I checked the dipstick and oil looked good since I had just had it changed the week of/before car died. After I topped off coolant and tried to start it, she turned over twice and completely locked up! Checked dipstick and from car running it must have sucked coolant into cylinder or something because dipstick was already noticeably different....thicker milky looking.
Pulled all spark plugs and when I came around to cylinder 6 coolant immediately came out when I got plug out. After reading technical service bulletin http://www.tomorrowstechnician.com/A...II_Engine.aspx
on upper intake plenum problems I pulled everything to get it off and look around EGR stove pipe. Once plenum was off we could see there was coolant leaking from somewhere, the entire lower intake areas around the ports leading to the valves was full of coolant. Gasket didn't appear to be sealing around the ports BUT this may have been due to trying to turn car over numerous times with throttle body closed and backfire pressure having nowhere easy to escape other than out through the gasket (who knows at this stage now, there could be a couple reasons why it appeared this way).
Heres what it looked like
Compression test showed cylinder 6 at 195 and the rest of the cylinders between 200-210psi. Lower intake/gasket didn't appear to be bad but since we were there and I don't want to do this again 6 months later I decided to pull that too to replace gaskets.
After inspecting upper plenum I can now see what the service bulletin was talking about and others who have experience with this degradation issue of the plenum. The gasket itself has some degradation on it also but it'* really interesting to see the problem. The coolant passages (1 on each side of EGR stove pipe passage) are so close that the heat melts the EGR passage and mine actually had a hole through the wall and the second picture shows what the wall of the passage all pitted and degraded.
This is where I am at this point, the replacement plenum everyone I have talked to said to get was a Dorman one. I will be getting one tomorrow for $120 and start to put everything back together.
If you have any suggestions or want info/pictures while I have it torn down let me know.