Engine - Upper Engine Oil Leak Diagnostic Guidelines
Group: 15Number: 05-01
Date: Nov. 2, 2005
Subject:
Oil Leaks From Upper Engine Areas, Diagnosis Guidelines
Model(s):
All Models with Engines 1998 > 2006
Listed in Table Below
Condition
Misdiagnosis of oil leaks from upper engine areas may result in unnecessary replacement of camshaft adjusters and/or camshaft adjuster gaskets.
Models Effected
^ Use the table to categorize oil leaks and properly determine their root cause.
Service
- Visually inspect area of suspected oil leak.
- Classify suspected oil leak (Category 1, 2, or 3) according to the "Categorization of Leaks" table (see excerpt previously shown) included in Warranty Service Circular VWA-05-31 dated Nov. 2, 2005.
A. If suspected oil leak is classified as category 1 or category 2 WITH a customer complaint:
- Clean oil stained area.
Explain to customer that oil residue on engine (suspected oil leaks classified as category 1 or 2) may be the result of spilling during engine oil top-off or normal gaskets "sweating" and this is not an indication of technical malfunction.
B. If suspected oil leak is classified as category 1 or category 2 WITHOUT a customer complaint:
- No repair necessary.
Oil reside on engine (suspected oil leaks classified as category 1 or category 2) may be the result of spilling during engine oil top-off or normal gaskets "sweating" and is not an indication of a technical malfunction.
C. If suspected engine oil leak is classified as category 3 only WITH a customer complaint:
- Start diagnostic procedure by replacing cylinder head cover gasket(s) only on cylinder bank(s) where suspected oil leak of category 3 is identified.
- Add oil dye to engine oil.
- Clean oil stained area(s).
- Perform test drive.
- Following test drive, inspect engine to verify oil leak is eliminated.
Tip:
When installing cylinder head cover gasket(s) always apply sealant in critical areas as further described in the Technical Bulletin.
If, after a test drive, the engine is still leaking:
- Locate source of oil leak.
^ If oil leak is traced to camshaft adjuster or camshaft adjuster gaskets, service manager authorization is required before any other repair is performed.
^ If oil leak is traced to any component other than camshaft adjuster or camshaft adjuster gasket, perform repairs as necessary.
^ If cylinder head cover must be removed again WHILE performing this Technical Bulletin, same cylinder head cover gasket can be reinstalled.
Tip:
When installing cylinder head cover gasket(s) always apply sealant in critical areas as further described in the Technical Bulletin.
D. If suspected oil leak is classified as category 3 only WITHOUT a customer complaint (add-on repair):
- You must follow the procedure for add-on repairs as described in Warranty Policies and Procedures Manual.
- Then proceed with repairs as described in Step C.
Cylinder Head Cover Gasket, Installing Sealant at Critical Points
- Before installing cylinder head cover gasket(s), apply a small amount of sealant on six critical transition points of the sealing surface on cylinder head.
Before new sealant is applied:
- Thoroughly clean old sealant and oil residue from the cylinder head, sealing surface MUST be clean and dry.
Sealing Transition Points Between Double Bearing Cap(s) and Cylinder Head (2 points)
- Apply a small quantity of sealant Part No: AMV 174 004 01 to sides of joints (arrows) on upper sealing surface of cylinder head.
Sealing Camshaft Adjuster/Cylinder Head Transition (4 points):
- Apply a small quantity of sealant Part No: AMV 174 004 01 to sides of joints (arrows) on upper sealing surface of cylinder head.
Tip:
^ Apply sealant prior to installing gaskets.
^ Sealant is considered shop supplies and may not be claimed under warranty Also, additional time to add sealant is not claimable under warranty
^ Always refer to the Repair Manual and published Technical Bulletins for latest repair information.
^ In cases where parts are replaced, perform test drive to verify oil leak is eliminated.
^ If oil leak is traced to cylinder head cover gasket you must file the claim under PID 1580.
Warranty:
For warranty information and procedures regarding this technical bulletin, please follow indications included in the Warranty Service Circular "Oil Leaks From Upper Engine Area", VWA-05-31 dated Nov. 2, 2005.