Gas Recirculation Valve (egr Valve) problems of the 1998 Buick Lesabre

Here's what happened, the car started consuming dexcool antifreeze, but none was noticed leaking external to the engine. The upper intake manifold made of plastic apparently warped, and/or a hole burned in near the egr stove pipe, thus dumping antifreeze into the engine and hydrolocking the engine. Major problem, complete engine failure would not start or run. This car had been well maintained with both regular oil and coolant changes, the car has been adult driving . Cost to repair $450. 00 for just upper intake, add another $450 for the lower intake as well.

Vehicle returned for inspection with regard to 04v090 12/13/04 complaints poor performance, fuel economy, hard starting, and use of dexcool anti-freeze since recall performed. Decool anti-freeze entering the intake manifold of engine, and engine oiling system from failure or rupture of upper intake plenum near egr passage. Anti-freeze has filled engine lifters causing noise/failure, filling combustion chamber causing hydro-locking of engine, could cause catastrophic failure of engine resulting in possible fire or accident. Dealer refused to repair under 04v090 manifold over pressure condition stated replacement of upper & lower intake, lifter, plugs, oil, anti-freeze at a cost of $1,150 on vehicle that had 77,827 when the recall was done, and now has 80,407 mi. Which is less then 3,000. This could very well have hydro-locked the engine at freeway speed,or caused catastrophic failure resulting in severe damage, injury, and possible fire from engine oil & fuel hitting the hot catalytic converter!.

This is a engine problem with what I believe was a bad part design. The part is failure of intake plenum. The egr pipe from the engine comes through the plastic intake. There is a lot of heat generated at this point. Over a period of time a hole is burned through the intake. This floods the engine with coolant. I bought the vehicle new. The first time the problem occured at 59,000 miles. I had the vehicle repaired at a cost of $1100. 00. I asked the dealer about this. The reponse was . Yes we know there is a problem with the k engine but the factory has not called for a recall. At 113,577 miles the problem occured again. I again had the engine repaired at a cost of $1140. 93. Again I asked the dealer about this. I was told that a service bulletin was sent out in 1996. This stated that if a owner complained of a coolent leak around the intake. Not only should the plastic intake plenum be replace but also the aluminum intake should be repalced becaused the factory had replaced the egr pipe with a smaller pipe. This would keep the heat from burning a hole in the plastic plenum. The cost of this repair is to be paid by the owner. I checked out the service bulletin and found the problem covered all gm 3800 series engines form 1995 - 1998 my engine VIN # is 1g4hr52k3wh51080. I was told by the gm service tech. That this problem occured so often that any owner of a 3800 series engine and the new design intake has not been installed you are guaranteed the engine will fail. Again I feel this was a design problem.

Intake manifold burned at egr passage adjacent to throttle body coolant passage(all plastic- original design was probably cast aluminum). Subsequent coolant loss into engine air intake causes erratic operation and probable engine damage. Replaced manifold with new one at a cost of $500 parts plus 5 hour. Labor complained to gm but to no avail.

Vehicle had been losing coolant since 1998. Vehicle had been to dealer for repairs at least seven times. The gas recirculation valve (egr) port was made of plastic, and when it melted, coolant seeped into the engine. Consumer received reimbursement of $479. 99 from mc clellon Buick after contacting the original owner.

Intake manifold failed on my 1998 Buick Lesabre at 77,000 miles. Plastic manifold perforated due to exhaust gas impinging from egr tube, flooding engine with coolant and causing engine to stall with subsequent loss of power steering and brakes on interstate highway.

Car backfired and engine caught on fire.

Vehicle stalls continually while driving, replacement of the egr valve, knock sensor and pcm have not rectified problems with stalling. Mjs.

After having t egr valve serviced, miles later without warning, intake manifold began to leak coolant onto engine, causing engine to shutdown and lock up. Mechanic stated intake manifold needed to be replaced when valve was serviced.

While driving egr valve light illuminated on dashboard, causing vehicle to stall. Dealer was notified, mechanic stated sensors were not functioning correctly.

Vehicle had been losing coolant since 1998. Vehicle had been to dealer for repairs at least seven times. The gas recirculation valve (egr) port was made of plastic, and when it melted, coolant seeped into the engine.

Fax fm andrew hunt (NJ) request assistance in getting reimbursed for $561. 24 worth of repairs to fix the upper intake manifold on his 1998 gm Buick Lesabre & recall all cars listed in gm tech. Service bulletin # 01-06-01-007a. The consumer stated the concern was the vehicle did not give warning of a problem as the coolant emitted from the tail pipe unnoticed. If there was too much coolant in the engine the vehicle would stop. The defective plastic intake manifold and the broken starter from the vehicle which clearly showed that the egr stove pipe allowed water to get into the engine.