Engine Coolant Consumption or Coolant Leak (Inspect for Material Degradation/Replace Intake Manifolds). Pontiac Bonneville 1996

Subject:

Engine Coolant Consumption or Coolant Leak (Inspect For Material Degradation/Replace Intake Manifolds)

Models:

1995-1997 Buick Riviera

1995-1998 Buick LeSabre, Park Avenue

1996-1998 Buick Regal

1998 Chevrolet Lumina, Monte Carlo

1995-1996 Oldsmobile Ninety-Eight

1995-1998 Oldsmobile Eighty-Eight

1998 Oldsmobile Intrigue

1995-1998 Pontiac Bonneville

1997-1998 Pontiac Grand Prix

with 3.8L Engine (VIN K -- RPO L36)

This bulletin is being revised to update the part numbers. Please discard Corporate Bulletin Number 01-06-01-007A (Section 06 - Engine).

Condition

Some owners may comment on excessive engine coolant consumption, or an engine coolant leak near or under the throttle body area of the upper intake manifold.

Cause

Upper intake manifold composite material may degrade around the EGR stove pipe and could result in an internal or external coolant leak.

Correction

Follow the upper intake manifold removal instructions found in the Engine Unit Repair Section of the Service Information Manual.

Refer to the arrow in the illustration of the upper intake manifold above. Inspect the inner diameter of the EGR passage for signs of material degradation. Degradation will appear as "pitting" of the composite material in the EGR port passage.
If degradation of upper intake manifold composite material is found, replace the lower and upper intake manifolds with the following part numbers:

•	Gasket Kit, Upper Intake Manifold -- 89017554

•	Manifold Kit, Upper Intake -- 89017272

•	Gasket, Lower Intake Manifold -- 89017400

•	Manifold, Lower Intake -- 24508923

Follow the lower and upper intake manifold installation instructions found in the Engine Unit Repair Section of the appropriate Service Manual.
If degradation is not apparent, skip to Step 7.
Verify the repair.
If no degradation is found, evaluate the vehicle for other causes of excessive coolant consumption as noted in the Engine Diagnosis Section of the appropriate Service Manual.

Parts Information

Part Number	Description	Qty
89017554	Gasket Kit, Upper Intake Manifold	1
89017272	Manifold Kit, Upper Intake	1
89017400	Gasket, Lower Intake Manifold	1
24508923	Manifold, Lower Intake	1

Warranty Information

For vehicles repaired under warranty, use:

Labor Operation	Description	Labor Time
J0258*	Manifold, Lower Intake R and R	Use Published Labor Operation Time
J0255**	Manifold, Upper Intake R and R	Use Published Labor Operation Time
* Used for replacement of both the upper and the lower intake manifolds. ** Used for inspection purposes only, where no condition was identified and the upper intake manifold is re-installed on vehicle.

Labor Operation

Description

Labor Time

J0258*

Manifold, Lower Intake R and R

Use Published Labor Operation Time

J0255**

Manifold, Upper Intake R and R

Use Published Labor Operation Time

* Used for replacement of both the upper and the lower intake manifolds.

** Used for inspection purposes only, where no condition was identified and the upper intake manifold is re-installed on vehicle.