SB-00-06-01-026G

SB-10059095-6430
File in Section:
Bulletin No.:
Service Bulletin
Date:
06 - Engine
00-06-01-026G
August, 2015
INFORMATION
Subject:
Intake Manifold Inspection/Replacement After Severe Internal Engine Damage
Models:
2016 and Prior GM Passenger Cars and Trucks
Attention: This Bulletin also applies to any of the above models that may be Export vehicles.
This Bulletin has been revised to add graphics and additional information. Please discard
Corporate Bulletin Number 00-06-01-026F.
General Information
•
•
•
When replacing an engine due to internal damage,
extreme care should be taken when transferring
the intake manifold to the new Genuine GM Part
service engine long block. The internal engine
damage may have resulted in the potential
discharge of internal engine component debris
into the intake manifold via broken pistons and/or
bent, broken, or missing intake valves.
After removing the intake manifold from the
engine, the technician MUST carefully inspect all
of the cylinder head intake ports to see if the valve
heads are still present and not bent. Usually when
the valve heads are missing or sufficiently bent,
internal engine component debris will be present
to varying degrees in the intake port of the cylinder
head. If this debris is present in ANY of the
cylinder head intake ports, the intake manifold
should be replaced.
This replacement is required due to the complex
inlet runner and plenum configuration of most of
the intake manifolds, making thorough and
complete component cleaning difficult and nearly
impossible to verify the complete removal of
debris. Reinstallation of an intake manifold
removed from an engine with deposits of internal
engine component debris may result in the
ingestion of any remaining debris into the new
Genuine GM Part service engine. This will cause
damage or potential failure of the new Genuine
GM Part service engine long block.
Copyright 2015 General Motors LLC. All Rights Reserved.
Broken Valves, Broken Pistons and
Piston to Cylinder Head Damage —
Catalytic Converter Failures
Broken Valves, Broken Pistons and Piston to
Cylinder Head Damage
Broken valves, broken pistons and piston to cylinder
head damage all create material debris that scatters
throughout the induction system.
⇒ If ANY of the above were to occur, the intake
manifold MUST be replaced or subsequent severe
engine damage will occur. This replacement is
required due to the complex inlet runner and
plenum configuration of most of the intake
manifolds, making thorough and complete
component cleaning difficult and impossible to
verify the complete removal of all debris.
Catalytic Converter Failures
When catalytic converter failures occur and the inner
brick becomes plugged and breaks apart, the catalytic
converter material can be sucked back into the engine
during valve overlap and transfer throughout the intake
manifold and into the cylinder. Any such material
transfer can cause heavy wear to piston rings and
cylinder walls. Misfires and oil consumption are the by
products of ingested catalytic converter material into
the combustion chamber and cylinder bores.
Page 2
August, 2015
Bulletin No.: 00-06-01-026G
Typical Intake Manifold Debris Views
After Internal Engine Damage
View of Debris in Aluminum Intake Manifold —
Throttle Body Opening
4246245
Bulletin No.: 00-06-01-026G
August, 2015
Page 3
View of Debris in Aluminum Intake Manifold —
Ports to Cylinder Heads
4247214
View of Debris in Plastic Intake Manifold — Throttle
Body Opening
4246791
Page 4
August, 2015
Bulletin No.: 00-06-01-026G
Internal View of Plastic Intake Manifold
Lower Half — Plenum and Runner
Complexity
Notice: The plastic intake manifold CANNOT be
disassembled.
Internal View of Plastic Intake Manifold Lower Half
— Plenum and Runner Complexity
4247259
This internal view shows the plenum and runner
complexity and is the reason why the intake
manifold CANNOT be completely cleaned of debris.
1. Intake port to cylinder head opening.
2. Areas where debris can collect.
3. Areas where debris can collect.
4. Areas where debris can collect.
Ultrasonic welding is an industrial technique whereby
high-frequency ultrasonic acoustic vibrations are locally
applied to workpieces, (in this case the plastic intake
manifold) that are being held together under pressure
to create a solid-state weld. It is commonly used for
plastics and for joining dissimilar materials. In
ultrasonic welding, there are no connective bolts, nails,
soldering materials, or adhesives necessary to bind the
materials together.
GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these
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 your GM dealer for information on whether your vehicle may benefit from the
information.
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