Service Procedure

1. Disconnect negative battery cable.

2. Remove cables from junction block. Remove junction block from wheelhouse panel.

3. Inspect wheelhouse panel and junction block for corrosion damage.





See illustrations to determine junction block corrosion category (1, 2, 3 or 4).

4. If junction block has Category 1 or 2 corrosion:

- Clean junction block and wheelhouse panel as needed.

- If needed, coat top of wheelhouse panel with appropriate paint (approximately 2-3 oz. GM P/N 12345321 or equivalent).

- 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:

- Clean wheelhouse panel as needed.

- 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.

- 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.