About a year ago a coworker asked me if I would be willing to fix his 03 grand prix for him, he said it was loosing coolant. Without even popping the hood I was pretty sure it needed a new upper intake and lower gaskets. Sure enough you could see coolant puddled up in the pockets of the lower intake and I could see where it was leaking from the throttle body gasket. I told him if he got the part I would do it. A week later he dropped off the car and parts and I fixed it at the house and made a quick 100 bucks. He bought the parts from Napa the gaskets were felpro and the intake was made by dorman. The intake came with the updated EGR stove pipe and I installed it as per instructions. Wiz band threw it together and everything seemed ok. Well about 2 months later he tells me the car runs like crap and the check engine light is on. I couldn't believe what I found, where the EGR pipe expels it had burnt a hole in the plastic intake on the top side. I've replaced hundreds of these intakes at the dealer and never had a problem like this. He went back to napa and got his money back then Went to the dealer and got a GM one. I installed it and its been fine for months now, has anybody else had problems with the aftermarket intakes like this?

thats not my experience. i bought my 98 in 02 and it was shortly there after the first time it needed done, but my wife drives the car and i was on the road so she took it in and im sure they put oem stuff on it. so i guess that one lasted about 8 yrs and i was home to do it this time i bought the felpro and dorman stuff from rockauto. didnt do the egr and blocked the coolant ports to the upper intake. mine has been fine now for i think a year.

https://www.gmforum.com/mechanical-1...2005-a-304071/

Too bad you didn't take pictures, I would like to see this newer style plenum.

And no, I haven't heard of a newer style one do this before.

it seemed to have thicker plastic in those areas

Yeah my coworker took the burnt one back to Napa before I thought about taking pictures.