head gasket in 2002 chevy malibu ... plus other

The reddish stuff is probably concentrated dex cool. Trans fluid is closer to motor oil in color unless it is new. The oil in the overflow could be trans fluid. Since you mentioned "lower intake" I assume it is a 60 degree 3.x engine. I'm sure you are aware of the intake manifold problems with this engine. Make sure you mark the push rods. Head gasket leaks are fairly rare nowadays. If more than a few drops of water were getting into the trans, the trans would be dead by now.

I had a problem much like yours with my 3.1 buick. Leak from cooling system from lower right side and front , I took it to the dealer as soon as I noticed the leak. I did not see any oil in coolant but I found it early and had it repaired. Dexcool looks pretty cruddy after a few years. I think a compression check will tell you if it is is intake gasket or the head gasket. My problem was intake gasket. Dealer reported head gasket was fine. Good luck Ernie

Thanks so far for the help. I have researched and found out about the lower intake manifold gasket problems. Most people report getting water in the oil if it gets that far. Mine has oil (nearly positive it is not xmission fluid), and quite a lot of it. No water in oil that I can see. Would the lower intake gasket cause this. I am now sure coolant is leaking externally from lower intake to block (as reddish fluid mentioned before was concentrated dexcool and see where it is leaking). It would be great to save taking off the heads, but still contemplating doing so while I am that far (and parts are on the way). How worried should I be about thougoughally flushing the coolant (I will do so to some extent). What about new coolant. They do not make dexcool anymore from what I have heard. The good old green stuff or the new Prestone? (yellow bottle, mixes with anything). At any rate, plan on tearing into it soon. Thanks, Chris

No pressurized oil galleries in the intake manifold. Oil in the water is probably from a blown head gasket. It sounds like the engine may been overheated once. I would go ahead and do the head gaskets. I hope you ordered new head bolts.

Dexcool is still readily available from what I've seen on the shelves in Advance and Wal-Mart.

Some of those Iron Duke POS's were very susceptible to cracking of the block. The crack occurs at the water jacket above the lifter gallery. You can access that gallery by taking off the stamped sheet metal plate on the side of the engine. The traditional crack will be an inch or two above the floor of the lifter gallery and will run horizontally IF THIS IS YOUR PROBLEM.

GM told me my series was not at risk for this cracking, but it cracked nevertheless. And when I went to the junkyard to find cores to rebuild, 4 out of 5 I found were cracked.

Yours may be something totally different. Just relating my experience with the Iron Puke and lying GM.

Most likely failure on these motors is the intake manifold gasket. It seems that almost every GM 3.1/3.4l engine of that era is destined for intake manifold gasket failure.

The big problem is if the coolant has gotten into the oil enough to cause additional damage!

John

If you are going to replace the upper and lower intake gaskets why not replace the head gaskets as well. I wish I did soon after replacing the intake gaskets a oil leak started. Also the service manual suggest putting sealer tablets in after the repair. I did not and hope I do not regret that as well. Greg

Well, I got the Malibu apart. On most Army bases they have an Auto Skills Shop where you can "rent" a bay ($4 per hour for flat bay, $6 per hour for a lift) , use any tool you can think of free (air tools, hand tools, special tools, etc... welders, tire machines, lathes, etc. are an additional small fee), and have a competent mechanic to answer questions as necessary. One of the best services I think. Wonder if it would work as a buisness. Anyway, one of the mechanics was doing the same thing on a 3.4l chevy Venture (they will work on your vehicle for $36 per hour), and another

2001 malibu was outside ready for, again, same problem. Mine and the Venture both had quite bad lower intake gaskets. I also found that there was water in the oil as well as oil in the water in mine. ended up taking off heads too, just in case. Head gaskets looked fine. Have taken heads in for checking, etc. Figured while this far, might as well ensure all is ok and not have to do this job twice. I like my malibu and hope to get another 100,000 miles out of it once fixed. However, I think I will be looking at toyota or honda products next. So, all is going well. Three 3.1 or 3.4 chevy's with same problem in on same day on small army post in Germany seems like there is a problem. I am just glad I know enough to do the job for $6 per hour (my fees) plus parts ($204 plus fluids and filters when done) and head servicing (here about $150 for both to check for cracks, level, grind valves, and replace valve seals, though I will be doing valve seals just for experience). Thanks again. I will post again when done. Chris

Greetings again, After over 3 weeks, I finally got the heads back (not as convinient or cheap in Germany). Had heads checked for cracks, new valve seals, valve seats ground, and planed. Cost about $350 here. Got the car together today (fired up first try). Seems to be doing great. I am going to drive it carefully and short trips for about a week, then change fluids again (coolant and oil). Question is, GM reccomends in a service letter putting coolant sealer (stop leak) in in conjunction with replacing lower intake gasket, and I have never cared for any of the "stop leak" products. Any suggestions. Should I do it? Thanks again. Chris

Got a '02 in the driveway ready for intake gaskets and no I will not use sealer in the cooling system. Didn't put it in my sister's '01 when I did her intake gaskets. Just keep an eye on the coolant level and a quick oil analysis test will confirm if no visible leaks are found and your losing coolant. Stop leak was a stop gap to prolong the inevitable gasket replacement. I myself don't want to chance plugging a heater or rad. core.