NHTSA Complaint #10025956 — 1995 PONTIAC BONNEVILLE

GM TECHNICAL SERVICE BULLETIN 01-06-01-007A IDENTIFIES AN INHERENT DESIGN FLAW ON THE 3.8 L ENGINE (VIN K - RPO L36) AVAILABLE IN THE FOLLOWING VEHICLES:995-1997 BUICK RIVIERA995-1998 BUICK LESABRE, PARK AVENUE. *AK 1996-1998 BUICK REGAL 1998 CHEVROLET LUMINA, MONTE CARLO 1995-1996 OLDSMOBILE NINETY-EIGHT 1995-1998 OLDSMOBILE EIGHTY-EIGHT 1998 OLDSMOBILE INTRIGUE 1995-1998 PONTIAC BONNEVILLE 1997-1998 PONTIAC GRAND PRIX GM MINIMIZES THE IMPACT OF THE PROBLEM BY IDENTIFYING ONE OF THE SYMPTOMS AS OWNER COMPLAINING OF A SMALL COOLANT LEAK. THE FACT IS THAT IN MOST CASES THE LEAK IS NOT VISIBLE. THE COOLANT TYPICALLY LEAKS INTERNALLY BY THE EGR STOVE PIPE INTO THE ENGINE'S INTAKE MANIFOLD WHERE IT BUILDS UP. EVENTUALLY THE COOLANT LEVEL IN THE INTAKE MANIFOLD RISES TO THE POINT WHERE THE COOLANT WILL GET SUCKED INTO ONE OF THE CYLINDERS. IN LESS SEVERE CASES, WHEN IT HAPPENS AT IDLE OR LOW RPM, THIS CAUSES THE ENGINE TO SEIZE AND STALL. IN THE MOST SEVERE CASES, WHEN IT HAPPENS AT HIGH RPM, THE HAMMERING EFFECT OF THE ENGINE TRYING TO COMPRESS A LIQUID, CAUSES THE AFFECTED PISTON TO SHATTER (MY CASE). THIS IS A CATASTROPHIC ENGINE FAILURE CAUSED BY A DESIGN FLAW. WHEN THIS HAPPENS ON A HIGHWAY AT 75 MPH (MY CASE) THERE IS GREAT POTENTIAL FOR AN ACCIDENT AND INJURY TO PASSENGERS. I WAS LUCKY, BUT I STILL HAD TO REPLACE MY ENGINE WITH A REMANUFACTURED ONE AT MY EXPENSE. GM IS FULLY AWARE OF THE PROBLEM. GM REPAIR CENTERS ARE ATTRIBUTING THE FAILURE TO NORMAL WEAR AND TEAR AND ARE CHARGING OWNERS TO REPLACE THE FLAWED PARTS WITH THE NEW DESIGN. I SPOKE WITH A SERVICE MANAGER AT A LOCAL DEALERSHIP AND HE STATED THAT HE HAS SEEN A LOT OF VEHICLES COMING IN WITH THE SAME FAILURE, THE LESS SEVERE CASE BEING THE MOST COMMON. THEY COMMONLY JUST DRAIN THE AFFECTED CYLINDERS AND REPLACE THE FLAWED PARTS WITH THE NEW DESIGN. I ASKED HIM HOW DID HE KNOW IF THE AFFECTED PISTON HAD BEEN DAMAGED CAUSING A CATASTROPHIC FAILURE LATER ON. HE DID NOT HAVE AN ANSWER.