Caprice RWD V8-305 5.0L (1992)
See illustrations to determine junction block corrosion category (1, 2, 3 or 4).
4.
If junction block has Category 1 or 2 corrosion:
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Clean junction block and wheelhouse panel as needed.
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If needed, coat top of wheelhouse panel with appropriate paint (approximately 2-3 oz. GM P/N 12345321 or equivalent).
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Add insulator, P/N 10239854 (when reinstalling the original junction block in step 5).
4.
(Con't)
If junction block has Category 3 and 4 corrosion:
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Clean wheelhouse panel as needed.
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Thoroughly remove all visible corrosion, then coat top of panel with an appropriate paint as required (approximately 2-3 oz. GM P/N
12345321 or equivalent).
NOTICE:
In the event that perforation/corrosion extends beyond junction block mounting holes (unable to bolt on new junction block), replace wheelhouse panel
referring to 1991-92 Chevrolet Caprice Service Manual Section 10-5 for procedure.
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Obtain a new junction block for installation in step 5. This new junction block has a heavy material on back, and does not require the insulator.
5.
Install junction block (and add insulator if old junction block is being reused - Category 1 or 2). Be certain to use new junction block if inspection
revealed category 3 or 4 corrosion.
Torque mounting screws to 2.0 N-m (17 lb.in.). If mounting screws require replacement, use GM P/N 11509645. If mounting clips require
replacement, use GM P/N 10215577.
6.
If corrosion perforated wheelhouse panel (and panel did not require replacement in step 4), hoist vehicle, thoroughly clean bottom of panel (tire
side), and coat with body undercoating (3M P/N 08883 Rubberized Undercoating or equivalent).
7.
Attach cables to posts of junction block, and torque nuts to 34 N-m (24 lb.ft.). If nuts require replacement, use GM P/N 11502812.
8.
Reconnect negative battery cable.
9.
Install Campaign Identification Label.