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JOHN aka Eauto
JOHN aka Eauto, The Car Guy
Category: Chevy
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Experience:  ase tech
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2002 Chevy Malibu: V..oil in the radiator overflow / fill reservoir

Resolved Question:

I have a 2002 Chevy Malibu V-6 with 116000 miles. It is getting oil in the radiator overflow / fill reservoir.
There is no sign of water in the oil. I see a TSB # XXXXX about oil/coolant leak. Is tis TSB about this problem, is this common in these models, and what might be the fix. The value on the car is @ 3600.00 and a local shop informed my girlfriend ( her Car) that replacing head gaskets will be 1500.00 to 3000.00 depending on whether heads need replacing.
Submitted: 8 years ago.
Category: Chevy
Expert:  JOHN aka Eauto replied 8 years ago.

I would say its the lower intake gasket which is about 7 hours labor and 200 in parts and fluids

Engine/Cooling System - Oil or Coolant Leaks


Bulletin No.: 03-06-01-010C

Date: April 08, 2008

Engine Oil or Coolant Leak (Install New Lower Intake Manifold Gasket)


2000-2003 Buick Century
2002-2003 Buick Rendezvous
1996 Chevrolet Lumina APV
1997-2003 Chevrolet Venture
1999-2001 Chevrolet Lumina
1999-2003 Chevrolet Malibu, Monte Carlo
2000-2003 Chevrolet Impala
1996-2003 Oldsmobile Silhouette
1999 Oldsmobile Cutlass
1999-2003 Oldsmobile Alero
1996-1999 Pontiac Trans Sport
1999-2003 Pontiac Grand Am, Montana
2000-2003 Pontiac Grand Prix
2001-2003 Pontiac Aztek


with 3.1L or 3.4L V-6 Engine (VINs J, E - RPOs LG8, LA1)


This bulletin is being revised to update the Parts Information and add an Important statement. Please discard Corporate Bulletin Number 03-06-01-010B (Section 06 - Engine).


Some owners may comment on an apparent oil or coolant leak. Additionally the comments may range from spots on the driveway to having to add fluids.


Lower Intake manifold may be leaking allowing coolant oil or both to leak from the engine.


Install a new design lower intake manifold gasket. The material used in the gasket has been changed in order to improve the sealing qualities of the gasket. When replacing the gasket the lower intake manifold bolts must also be replaced and torqued in sequence to a specification.

Important: The gasket kit part number listed below now includes the new bolts (4 long bolts and 4 short bolts) with the pre-applied threadlocker on them. It is no longer necessary to order the bolts separately when ordering gaskets.


Notice: An oil leak may result if the vertical bolts are not tightened before the diagonal bolts.


Diagonal bolts may require a crows foot to tighten.


1.Tighten the vertical lower intake manifold bolts (1) to 7 N.m (62 lb in).


2.Tighten the diagonal lower intake manifold bolts (2) to 7 N.m (62 lb in).


3.Tighten the vertical lower intake manifold bolts (1)to 13 N.m (115 lb in).


4.Tighten the diagonal lower intake manifold bolts (2) to 25 N.m (18 lb ft).


Parts Information

Warranty Information

For vehicles repaired under warranty, use the table.

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