Engine Coolant Leak at Intake Manifold Gasket

Some customers may comment about loss of engine coolant, low coolant level, low coolant telltale illuminated and/or engine overheating.

This condition may be caused by a coolant leak at the intake manifold gasket. The leak may occur at the cylinder head-to-intake manifold coolant passage located to the rear of the number four cylinder intake port. The seal may experience a compression set allowing an external coolant leak past the seal during cold engine operating conditions.

Refer to service procedure in this bulletin to replace the intake manifold gasket with the new design 2-piece gasket.

The new design 2-piece gasket is comprised of:

1. Inspect cylinder head-to-intake manifold joint for evidence of coolant leak at location (3) as identified in the illustration. The leak occurs around the coolant four intake port.

•	If a coolant leak or stain is observed at the described above location, install the new 2-piece designed intake manifold gasket. Refer to "Intake Manifold - DOHC (LL0) service procedure in the Induction Section of the 2000/2002 S-Series Engine Service Manual.

•	If a coolant leak or stain is not observed at this location continue to next step.

Important: The cooling system pressure test must be performed on a cold engine. The leak may not be found when engine is warm.

Caution: DO NOT REMOVE THE CAP FROM A HOT SYSTEM. ALLOW THE SYSTEM TO COOL, THEN SLOWLY REMOVE CAP.

2. Remove cap from coolant surge tank.
3. Make sure that all parts of the cap, tester, and adapter are clean.



4. Install Coolant Test Adapter SA9141E-2 to coolant surge tank.

Caution: WEAR SAFETY GOGGLES

Caution: NEVER PUMP THE SYSTEM ABOVE 130 KPA (20 PSI).

Important: During the pressure test the leak observed may be very slight. Allow sufficient time for coolant leak to be identified.

5. Pump coolant tester until gauge needle reaches 103 kPa (15 psi).



6. Inspect the cylinder head-to-intake manifold joint for evidence of coolant leak at location (3) as identified in the illustration. The leak occurs around the coolant passage area to the rear of the number four intake port.

•	If a coolant leak is observed at the described above location, install the new 2-piece designed intake manifold gasket. Refer to "Intake Manifold - DOHC (LL0) service procedure in the Induction Section of the 2000/2002 S-Series Engine Service Manual.

•	If a coolant leak is not observed at the described location, refer to "Cooling System Troubleshooting Chart" in the Cooling Section of the 2000/2002 S-Series Engine Service Manual.

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for J0251 (Gasket, Intake Manifold - Replace), or if another procedure is performed, refer to the appropriate Electronic Labor Time Guide for the correct Labor Operation Code and Time.