Engine - Oil Leak By High Pressure Fuel Pump

TECHNICAL

Bulletin No.: 09-06-01-014

Date: December 03, 2009

Subject: Oil Leak by High Pressure Fuel Pump (Reseal Camshaft Cap)

Models:
2007-2009 Chevrolet Cobalt SS, HHR SS
2007-2009 Pontiac Solstice GXP
2007-2009 Saturn SKY Redline
2008-2009 Opel GT
2008 Daewoo G2X
Equipped with a RPO LNF Engine
Please Refer to GMVIS

Condition

Some customers may comment on an oil leak.

Upon further investigation, a technician may find oil leaking from the high pressure fuel pump area.

Cause

This condition may be caused by a camshaft cap that is not sealed correctly to the cylinder head, causing oil to leak out.

Correction

1. Verify the customer's concern.
2. Remove the fuel pump. Refer to Fuel Pump Removal in SI.
3. Remove the camshaft cover. Refer to Camshaft Cover Removal in SI.





4. Remove the camshaft cap (1). Remove all excess sealing material from both surfaces.





Note
It is critical during installation to ensure the bearing rear cap and cylinder head alignment is correct and the mating surfaces are flush.
- Ensure that all sealing material has been removed from the components and the sealing surfaces are clean and free of contamination prior to applying the sealer.
- Install and align the rear cap within 20 minutes of applying the sealer.

5. Apply a 2.5 mm (0.1 in) bead of sealer, GM P/N 12378521 (in Canada, use P/N 88901148) to the cylinder head at the number 6 intake camshaft rear cap mating surface.

Note
Apply the sealer to all locations centrally locating the bead on the rail.
- Run the bead to 5 mm (0.2 in), dimension "a", as shown.
- Where the cap ends on the perimeter rail, extend bead approximately 4 mm (0.2 in) beyond edge of cap.
- Run bead, dimension "c", 32 mm (1.3 in) from the edge of the cylinder head as shown.
- Run bead, dimension "b", 20 mm (0.8 in) from edge of cylinder head as shown.

6. Install the number 6 intake camshaft rear cap.

1. Tighten the cap bolts evenly to 5 Nm(44 lb in).
2. Tighten the cap bolts evenly to 10 Nm(89 lb in).
3. Back the cap bolts out 120 degrees.
4. Tighten the cap bolts evenly a final pass to 10 Nm(89 lb in).

7. Install the camshaft cover and gasket, GM P/N 12609291. Refer to Camshaft Cover Installation in SI.
8. Install the fuel pump. Refer to Fuel Pump Installation in SI.

Important
When installing the fuel pump, install a NEW high pressure fuel pump O-ring (GM P/N 12600313), high pressure fuel pump gasket-to-cylinder head (GM P/N12595951) and high pressure fuel pipe (GM P/N12615401).

Parts Information





Warranty Information





For vehicles repaired under warranty, use the table above.





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