Did the job on Friday and Saturday
Here is what the whole thing started for...







I found some blockage in the water channels..YUCK!!





And some pitting in the metal in one side of the LIM




Got it all cleaned and rebuilt it


Then, I went to put my tensioned back on and found the bolt hole threads were stripped completely out so I got a new on of those and took it back apart and put it all back together..then i tried to start it and it SPEWED fuel out of the connection from the fuel rail to the injector. Somewhere along the way that got broken..but just on one.....ODD. Oh well dealer and Junk yards are closed till monday so I am down until then...



**SIGH**

Holy crap, that'* a major leak.

That is quite a lot of work. I'm impressed. Sorry about the fuel rail, but you can probably pay far too much at RiceZone for oversized rails and get it all done sooner. Your way is probably a whole lot better, though.

LKQ should be open, but these fuel lines can't be repaired that easily. From the looks of things, you may be a newbie here, but you've held a wrench or two for quite a while

Thanks for the encouraging words. I was worried about the pitting in the LIM, but i probed it and it didnt go very deep. I cleaned it up really good and put it all back together. Before i did though, I put the new gassket on the LIM to make sure that the pitting didnt go all the way out to the new gasket surface...and it didnt so i sighed and put it back together. I only need this car to last 12K more miles and then it is time for a new Bonneville anyway..I cant wait for a newer 04..

Yeah this isnt my first intake manifold, but its my first bonneville intake.

Look at my Intercooler topic in Performance to see how to repair the pits.

That'* gotta be one of the worst I've seen. Maybe THE worst.

So you just filled the pitting with JB weld and ground it flush? I was going to try that..i did put the new gasket over that spot and the pitting was all inside the gasketed area so i thought it would be alright for the ammount of time that I am planning on keeping this old bonny....since i have read all your posts I am having second thoughts...sigh

That little bit of pitting is just a little worse than mine was.

I just cleaned it up as best I could and put it back together with the new gaskets and APN upper. Good as gols so far 11000 miles in, with 163000 on the car!!!

Bob

Yeegh!!! That'* NASTY! Yeah,you oughtta fill that....if you do it with the head on the block, make sure to mask the valley and slap some duct tape across all the exposed ports...

I'd rather replace the lower with a JY unit. Shouldn't cost much and thats what the GM bulletin says, replace.
Whatever caused it to pit like that is bound to happen in other area'*.
If you plan on selling after 12k miles thats another thing.