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I have an 03 impala 3.8 that melted a hole in the intake plenum why did this happen and whats the solution

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03 Dodge Intrepid intake manifold torque specs top & bottom is for 3.5 V6

Lower Intake:
  1. Use a skin coat of RTV silicone on both sides of the water passage ports (outer most holes) and put the new lower intake gaskets into place
  2. Hand tighten the 13mm head intake bolts and Torque the bolts , starting from the center and working your way out in a circular pattern
  3. Torque these bolts in a few small increments until they have reached 250 inch pounds of torque.
  4. Upper Intake Plenum:
  5. When installing the intake air plenum , be sure to catch the four center bolts and the two side bolts (stiffener brackets) before tightening , The center bolts should be torqued to 250 inch pounds .The fuel rail bolts should be torqued to 100 inch pounds

Jun 24, 2016 | 2003 Dodge Intrepid

1 Answer

My 03 kia sorento is misfiring at 3 and 4.... is this just my spark plugs or is this the coil pack as well

Could be either, you have 1 coil for each cylinder (6 total). The problem is #3 is the rear middle cylinder. You have to remove intake plenum to gain access to rear bank. #4 is front center. What you can do, is swap #4 coil with the one next to it and see if the misfire migrates to that cylinder, then you know it's a coil problem. If you do have to remove plenum, you should replace rear plugs at the same time.

Oct 16, 2015 | Kia Cars & Trucks

1 Answer

How do you fix a intake plenum switchover valve circuit

Intake plenum swithover valve, that is your whole intake manifold need replaced and all new gaskets on top of motor .

Mar 11, 2012 | 2004 Chevrolet Impala

1 Answer

My 2004 chevy 1500 is running bad ive replaced the oxygen sensors, mas air flow sensor changed the plugs and wires, the check engine light comes on after about 20 milses after i disconect the batery it...

Sounds like you have a bad vacuum leak. Check all hoses and the intake manifold. Not saying this is your problem , but I just replaced a plastic intake plenum because the converter was clogged and when the egr valve kicked in it melted a hole threw the plenum. And ofcourse this car ran like ****.

Jun 26, 2011 | 1999 Chevrolet Silverado 1500

1 Answer

Car keeps running hot. Have added coolant several times. VIN# 2G1WF2E519264894

You have to verify if you have residue from coolant near the EGR below the composite air intake. If you are adding coolant and the car engine still have power then your coolant is vaporizing out and not in into the engine block. Otherwise if the coolant leaks into the engine block the car will act jerky since water is not compressible. Check the oil to see if it looks like coffee color (happens when water and oil mix).
No matter what be prepare to replace the lower/upper plenum gaskets, air intake and the tube that connects from the air intake to the EGR. New air intake comes without the tube. Replace to the lower plenum bolts. All parts available from

Herosbug Performance Co.

May 20, 2011 | 2001 Chevrolet Impala

1 Answer

How serious is an upper plenum leak (found upper

The upper intake has a egr port right next to a coolant port, the egr is exhaust gas that is recyled into the intake for emission control. On a long trip the exhaust burns a hole between the two ports causing your problem. Pretty common on the 3.8. My suggestion is to stop driving it until you have it repaired, reason being is the coolant can travel down the intake and fill up the cylinders. If that happens, worst case you can damage a rod, but you will be stranded.

Apr 05, 2010 | 2001 Buick LeSabre

1 Answer

What causes antifreeze to get under the plenum on a 98 buick 3800 eng ? thank's Luther

the EGR transfer tube melts the upper intake(plenum) it will need to be replaced

Oct 27, 2009 | 1998 Buick Park Avenue

1 Answer

Bogs down at high acceleration

Sounds like a plugged catylic convertor, GM has a Special Policy adjustment that covers the catylic convertors for 10 years or 120,000 miles (190,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. This is for 2001-2002 models with 3.4L or 3.8L engines. If you have a 3.8L engine you want to get this fixed soon, I have seen people drive these things so long with the convertor plugged that they melt a hole in the plastic intake plenum where the EGR port comes into the intake behind the throttle body.

Nov 12, 2008 | 2002 Chevrolet Impala

3 Answers

Code P0507

P0507-- idle speed high

Jun 02, 2008 | 2001 Chevrolet Impala

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