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Old 05-19-2017, 10:10 AM   #1
floridasl22002
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2003 L-Series 3.0L Sedan
2002 SL2
Default 2003 L300 V6 Upper Manifold Intake Runner issue

Earlier this week my youngest son (HS Senior) contacted me to say the car was shuddering and was quite lumpy at stop. Off the top of my head I said it could be a fuel injector or possibly a coil. We had a look at it in the evening and I also noticed it was making a metallic clickety clack right around the center of the intake manifold on the right hand side (looking toward the driver). Although the CEL was not lit we took it for a scan to the local O'Reilly's. He confirmed codes P0300 and P0305. The former is general misfire is misfire cylinder # 5 which is top right hand of the engine. So we all reckoned fuel injector.

I took it into mi die mechanic who checked out the fuel injectors (all of them) and they were fine. He found out the rear coil cassette was a culprit on the misfire and that was replaced. He also replaced the spark plug under warranty as it had discolored after the misfire.

The clickety clack noise turned out to be a jammed upper manifold intake runner. If you look on top of the manifold, the casting in the middle of the grey pipework has a connection on the RH side and a solenoid valve. This Intake Runner is opened and closed by the vacuum action of the solenoid and has a spring return. It's function is to stay closed normally as the cpm considers the airflow adequate up to that point for combustion then opens up to create more airflow above that point. Despite the indie garage cleaning it up the best they could the runner is still notchy in operation and in time will stick again.

The biggest problem is that being an orphan car this part is no longer manufactured!! My guy tried the bulk of GM Dealers but got the same answer - no stocks available.

So my only course of action now is to take a trip to the JY and see if I can get an intake runner that rotates and springs back normally.

It's one of those parts you tend to overlook and never think about, but if it goes squirrally like my son's has, then lack of parts availability can cause major headaches.

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Old 05-19-2017, 02:05 PM   #2
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2004 L-Series 2.2L Wagon
2004 L-Series 3.0L Wagon
Default Re: 2003 L300 V6 Upper Manifold Intake Runner issue

Sorry to hear about that. That's a new problem on the 3.0 that I have never heard of. Any pictures that you could provide would be helpful to better understand the situation you are dealing with.

FWIW, I think the 2000-2003 3.0's are the same. Something changed in 04/05 as I always see interchanges listed for those year groupings. Not sure what changed but hopefully you will find a 2000-2003 in your JY search.

If anyone knows what changed, please chime in!

Keep us updated.

...
2004 L-Series Wagon 2.2 218K Miles
2004 L Series Wagon 2.2 68K Miles
2004 L-Series Wagon 3.0 48K Miles

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Old 05-19-2017, 03:55 PM   #3
floridasl22002
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2003 L-Series 3.0L Sedan
2002 SL2
Default Re: 2003 L300 V6 Upper Manifold Intake Runner issue

At them moment the car has that component disconnected, so my lad is running around with the CEL on. I am hoping to get to the JY soon as I don't want that CEL on any longer than is necessary. My own car (Suburban) is off to the garage on the 30th to have it's evaporator replaced involving dismantling the whole of the dash!! So my lad is loaning Dad the Satty to keep me mobile. I'm planning on getting to the JY then so I can hopefully get a decent part and swap it out.
I will try and get some pics when I have his car.

If you have a V6, if you look at the gray manifold castings, it's the biggest part in the center. That's the UPPER Manifold. There is a LOWER Manifold underneath. If you then look to the right of the top manifold you will see the exterior of the runner. it has a vacuum valve attached to it and attached to that via a rod is the solenoid valve which is controlled by the cpm. If you look at the runner exterior you see a coiled return spring. The runner itself is bolted into the manifold casting by 2 torx bolts.

You can buy that casting with the runner for anywhere between $50 to $100 off Ebay, but I only want the runner, not the casting. I'm hoping the JY checkout will see the runner as a mystery part and charge me maybe $5 or $10 tops.

As I said earlier, it's one of those parts that just gets on with it and does its job and we pay it no heed. When it gets faulty, that's when we have issues on its repair or replacement as the part is no longer available new.

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Old 05-20-2017, 04:23 PM   #4
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2004 L-Series 2.2L Wagon
2004 L-Series 3.0L Wagon
Default Re: 2003 L300 V6 Upper Manifold Intake Runner issue

Quote:
Originally Posted by floridasl22002 View Post
My own car (Suburban) is off to the garage on the 30th to have it's evaporator replaced involving dismantling the whole of the dash!! .
Just shoot me!!!! Be glad someone else is doing this.

Back to your Saturn situation, I looked at my 3.0 and see what the issue is.

Looks very doable once you find the right part.

Thanks for the information.

...
2004 L-Series Wagon 2.2 218K Miles
2004 L Series Wagon 2.2 68K Miles
2004 L-Series Wagon 3.0 48K Miles

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