I was at work last night getting out of the SSEi (my mom and I traded cars for the day) and this older gentlemen in a 2002 SE parked right by me. He said nice Bonneville and I said the same for his. anyway, I told him to make sure that he watches the coolant level because of a bad manifold design and he said he definately knew about that because it had already been replaced on his 2002! He said it cracked and let coolant into his engine at only 45,000 miles. I thought this problem was corrected on the 2000+ models but I'm starting to think differently maybe?

Yeah, I thought these 3800'* were bulletproof.. But I have learned that a GM is not a GM unless it leaks coolant at some point. We all need to keep an eye on these things, no matter whether you have the SC or not. You see my story, with only 22K miles!

we have 90k miles on our 2000 and no problems yet(knock on wood). Must be a fluke.

i'd have to agree that i have been hearing more about the 2000+ manifolds doing weird things, especially after my experience....oh well it'll be interesting to see if we get any more posts about it on here.

The GM tech that worked on my SSEi a couple weeks ago mentioned this problem to me. I had him searching bulletins for an overboost issue and he said there was nothing listed but this intake failure. He saw one it happen to about a year ago he said. I guess they will fill the crank case with coolant and can hydraulic the engine when this happens. In my case the oil was clean so we counted it out. I'll be sure to keep an eye open for it now.

Ok, guys.... This is my first post... What a reason to post...

I have a 2002 Bonneville SE and I just had the dreaded intake manifold failure. I will begin replacing tomorrow. I bought the Dorman kit from Advanced Auto for about $145. The kit is very nice. It has the upper and lower gaskets and torque values that should be used on the first, second, and third pass. Also comes with a PCV valve...

I had been reading the many posts and was watching my SE'* coolant level very closely.

The first sign was a small drip of coolant on the transmission housing during a tire rotate/balance. I topped off the coolant and placed a piece of tape on the top off line on the outside of the overflow bottle. That was this morning. This evening after the car had been sitting all day, I moved the car into the garage for a spark plug change. I noticed more coolant on the transmisison housing and some on the garage floor. Dexcool...

My 2002 bonneville has about 89k miles on it. The intake that is in it now has a date of 2001 on it. So, I'm asssuming that it is the original. I can take pictures if anyone is interested. I'll take alot of the Dorman part and compare it to the original.

But, everyone needs to know that the problem has not been fixed for the 3.8L 2002 engine.

I'll keep you posted....

Here are some pictures of the kit.... I hope you get these picts.... first time to post....

The entire kit....


Upper gasket....


Lower gasket....


Additional parts....


Instructions....


Let me know if you guys want more info....

I'm very curious to see the damage you find. I'm personally betting on a crack, unrelated to the EGR erosion. Please keep us updated on this, and good luck! The Dorman kit is a proven performer here so far.

If anyone has any advice on this fix...pipe up...

I'm starting in the morning....

And again....thanks for all of the info...

It'* very straightforward, Silver. The only thing I'd do in addition to being methodical, is to remove the MAF sensor, TPS, and IAC from the Throttle body, and use a liberal amount of intake-safe cleaner and a brush to clean it very well. Pay particular attention to the IAC seat, and the IAC piston that seals it, in addition to the passage area that it controls. Cleaning the TB after 50k miles or so will make enough difference to be felt. This is a very good time to do this.

And make sure to drain the oil immediately. And maybe again in 1000 miles or so.

I knew there was something else I needed to do while I was in there....

Thanks....

I know this info has probably been posted, but its late and I'm kinda' tired...

Any suggestions for a "intake-safe cleaner"?

I had just changed my oil before this event... I don't see any coolant in the oil ( I don't think)...

I guess better safe than sorry... I just hate it that I only will get 200 miles on a full change of Mobil-1 synthetic and a new filter.... $$

I guess this is better than finding it down the road....

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