Intake Manifold Gasket May Leak Coolant or Engine Oil on Chevrolet Malibu

The intake manifold gasket may develop and external engine oil or coolant leak. In some cases, an internal coolant leak may occur causing coolant to mix with the engine oil. Our technicians tell us that operating the engine  with a coolant/oil mix can result in internal engine damage. Replacing the intake manifold gasket should correct these leaks.

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Average mileage: 106,278 (22,000–298,000)
Engines affected: 2.2L 4 Cylinder, 2.4L 4 Cylinder, 3.1L V6, 3.5L V6, V6
11 model years affected: 1997, 1998, 1999, 2000, more2001, 2002, 2003, 2004, 2005, 2006, 2007
122 people reported this problem
62 people shared problem details
Mechanic said intake manifold gasket leak and cracked manifold-$1500 10,000 miles later, leaking in the same place, behind power steering pump. I took pump loose and laid to the side-antifreeze leaking around two manifold bolts. These bolts come new with a coating on the threads to seal and keep them tight I guess, its not enough. I took out the two leaking bolts, cleaned them up on a wire wheel, coated them very well with sensor safe Hi-Temperature Silicone, put some in manifold holes also and tightened up, put rest back together and let sit 4 hours for silicone to dry and now have 150,000 miles on car with no leaks. An old mechanic told me 30 years ago to silicone your intake manifolds for trouble free future, no matter who luaghes at you for doing it. I think it could be the bolts causing the problem, not sure. It couldn't hurt to use gasket sealer when replacing, but of course your mechanic would lose business that way. Car won't start half the time-theft system or what? When it runs I love it-LOL
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Oily gunk appearing in the coolant
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2004 Chevrolet Malibu- 3.5L V6135,000
Internal coolant leaking past intake manifold gaskets. Damn GM!
Garbage can on wheels.
Coolant began leaking around 70K miles. Added stop leak to engine, which has been sufficient with little leaking since (mileage now at 90K).
Intake manifold gasket needed to be replaced. Went to get oil changed and tech advised there was oil in anti freeze. Seems to be a common problem.
2001 Chevrolet Malibu- 3.1L V670,000
I'm on my 3rd replacement of this same part! I am told each time that it is a known problem and they have totally redesigned the part to rectify the problem...each time costing me over $650.
1999 Chevrolet Malibu- 2.4L 4 Cylinder102,000
The repair cost me about $2000.00 at the local dealership. I had them change the water pump also since they had the engine dismantled. Now the car has a kicking problem when I stop for a light or driving very slow. Seems like the trans.
Intake manifold leaked coolant for the second time. The first time was at about 60000 miles and was serviced by the dealer.
2006 Chevrolet Malibu- 2.2L 4 Cylinder167,965
Just realized what it was today...currently seeking solutions.
Oil entered coolant overflow & engine repeatedly overheated. Head gasket replacement fixed this problem
2003 Chevrolet Malibu160,000
The engine always leaked coolant. After having the entire coolant system replaced twice the engine finally overheated. The car is not drivable. The coolant light did not come on or beep before it overheated. It's also had issues with the thermostat and sensors. The problem could not be fixed even after smaller repairs to the coolant system.
2003 Chevrolet Malibu128,000
Oil in coolant resivoir tank. Had to replace upper and lower intake gaskets. six months later the upper gasket was leaking externally. Stopped leak only by installing two gaskets. One year later seems ok.
Engine light continues to come on, when I put more coolant in goes off happens every couple days.
Bought the car with a blown gasket. Can only imagine that the previous owner let this happen and blew it out. Replace the head to fix it
2001 Chevrolet Malibu172,600
Always oily substance in my coolant reservoir, although I never see any discoloration in the oil itself...
2006 Chevrolet Malibu- 2.2L 4 Cylinder145,000
Was slowly loosing coolant but didn't ever see any on drive under car or anywhere on engine. Took it to dealer and was told the water pump was leaking. Had dealer replace water pump but slow leak continued. Took it back to dealer and this time was told leak is going internal and head is bad and it will cost $2500 to fix in addition to the almost $1000 already paid to Baum Chevy for them to NOT fix the problem.
Intake leaked coolant could lead to mixing of engine oil and coolant and damage engine. Diagnosed during an oil change.
2002 Chevrolet Malibu120,000
Symptoms of blown head gasket, most prominent being exhaust from combustion chamber pushing coolant back into and out of the over flow tank, causing engine to over heat. have yet to fix the problem, Malibu has simply been un drivable. Hope to replace gaskets soon.
I noticed my 2002 Malibu LS was over heating and I could smell burning antifreeze. Took it to a mechanic was told the intake gasket manifold was leaking. Paid $700 for the car to be "fixed" not even a week later and its still running hot. I can still smell burning antifreeze and my car is blowing out cool air NO HEAT! This is ridiculous.
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