ALUMINUM INTAKE MANIFOLD CORROSION (REPAIR PROCEDURE)

MODELS/YEARS 1985 CUTLASS SUPREME, DELTA 88, CUSTOM CRUISER AND TORONADO MODELS 1986 CUTLASS SUPREME AND CUSTOM CRUISER MODELS EQUIPPED WITH 5.0L (VIN CODE Y) ENGINE

The following information will supplement Dealer Technical Bulletin 86-T-13 dated January 27, 1986.

Intake manifold gasket deterioration as described in Dealer Technical Bulletin 86-T-13 may result in corrosion pitting of the aluminum intake manifold.

It is not necessary to replace the intake manifold for this condition. Use a 80% aluminum epoxy such as Devcon "F" or equivalent to fill the corrosion pits in the aluminum intake manifold. Refer to service procedure below.

SERVICE PROCEDURE:

1. Remove intake manifold.

2. Thoroughly clean corroded area using a wire wheel to remove all aluminum oxide.

3. Remove all remaining grit and dust with compressed air, or thoroughly wash in a solvent.

4. Mix epoxy with hardener according to instructions. Apply with a two inch putty knife or similar flat straight edged tool. A heat gun can be used to shorten curing time.

5. After hardening, smooth surface down to its original machined surface using a single cut flat mill file. Observe the voids and fill if necessary. Surface may be smoothed further using 320 grit sandpaper with a sanding block.

6. IMPORTANT: Before reinstalling the intake manifold, it is essential that sealer, part number 1050026 or equivalent be applied to both sides of the intake manifold gasket where it contacts the cylinder head and intake manifold. Refer to Figure 1.

Parts are currently available through GMSPO.

For warranty purposes use Labor Operation J0200. One (1.0) hour straight time is available without zone authorization, for the above service procedure. This repair does not include R and R of the intake manifold.

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.