ronn

iTrader: (3)

I posted this on the *recall* forum but I just had it fixed under warranty and wanted to post it here as well. It's a pretty common leak and you will see a film of oil below the fuel pump area..back towards the end cover on the camsahft.
This isn't a *DYI* in my opinion, although there is one here under *how to* I beleive. It's a WARRANTY issue!
This my original post with pics:

https://www.cobaltss.net/forums/5662457-post1.html

This the actual fix..fuel pump gaskets and Cam cover gasket.

https://www.cobaltss.net/forums/4867528-post21.html

Service Information 2009 Chevrolet Cobalt | Cobalt, G5 (VIN A) Service Manual | Document ID: 2371867
--------------------------------------------------------------------------------

#09-06-01-014: Oil Leak by High Pressure Fuel Pump (Reseal Camshaft Cap) - (Dec 3, 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
•Verify the customer's concern.
•Remove the fuel pump. Refer to Fuel Pump Removal in SI.
•Remove the camshaft cover. Refer to Camshaft Cover Removal in SI.




•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.


•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.


•Install the number 6 intake camshaft rear cap.
6.1. Tighten the cap bolts evenly to 5 N·m(44 lb in).

6.2. Tighten the cap bolts evenly to 10 N·m(89 lb in).

6.3. Back the cap bolts out 120 degrees.

6.4. Tighten the cap bolts evenly a final pass to 10 N·m(89 lb in).

•Install the camshaft cover and gasket, GM P/N 12609291. Refer to Camshaft Cover Installation in SI.
•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
Part Number
Description

12609291
Camshaft Cover Gasket

12595951
Gasket, High Pressure Fuel Pump Gasket

12600313
High Pressure Fuel Pump O-Ring

12615401
High Pressure Fuel Pipe

12378521 (U.S.)

88901148 (Canada)
Silicone

Warranty Information
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

J7549*
Reseal Camshaft Cap
2.6 hrs

SSlobalt

I had this "repaired" a year ago. Yup, it's leaking again.

Iam Broke

iTrader: (10)

Fixt mine myself at the HPFP & Cam cover two years ago, no more leaks. Permatex Hi-Temp RTV FTW.

SSlobalt

That's because you rock *****, broke.

rukkee

iTrader: (3)

I remember that TSB..... Mine leaked in this area too. It seems to have stopped thou. The foam around the fuel pump was soaking it up . I've checked a couple of other SS/TC's and they all seem to leak there.

Iam Broke

iTrader: (10)

lol

FRQ FLYR

iTrader: (1)

Had mine fixed a few weeks ago @ 29k ("camshaft endplate seal")-sounds like same area.

ronn

iTrader: (3)

More info..
This is the sealant they used on my car:

GM (General Motors) - 88861417 - GM Engine Sealant - Gray Silicone Sealer 2.65 oz. Tube

This is the sealant called for in the actual recall:

GM (General Motors) - 12378521 - GM Vulcanizing RTV Engine Sealer - 5.3 Oz. (Half Caulking Tube) - GM Production Line Sealer

Turns out they're the same stuff! Just different sizes:

In 2005, GM consolidated the use of liquid gaskets/engine sealants (April 2005 TechLink).
At that time, two sealants replaced all previous sealants referred to in SI.

One of these, Engine Sealant 12378521 (p/n 88901148 ACDelco Canada), was released in a 150 gram cartridge, to be used in a conventional caulking gun.

The cartridge and conventional caulking gun proved to be too large and cumbersome in certain instances when used in on-vehicle service.

To address this concern, GM Powertrain Engineering suggested releasing the engine sealant in a 75 gram squeeze tube (fig. 23). This product will be available, packaged six to the carton, with nozzle.


P/N 88861417
US VehicleCare
Engine Sealant
75 gram squeeze tube

P/N 88861418
AC Delco in Canada

Permafried-

My friend had this done, picked up the car and drove around, seemed fine. Parked it, got back in, started it, drove 10km max, smellled something funny, stopped, popped the hood, oil everywhere. We all said the same thing "the dumbasses at the dealership re-used the headgasket"....sure enough, dealer cleans up the mess under the hood, calls him up 2 or 3 days later (it took that long to diagnose that?) and says "the tech as having a bad day and reused the headgasket new parts are on the way". Bad day....that's an understatement...that's an amateur mistake. In any case, make damn sure they follow the directions word for word when getting this done....if they don't, you coud end up with a hell of a mess on your hands .

ronn

iTrader: (3)

"the dumbasses at the dealership re-used the headgasket"....

This procedure doesn't call for taking the head off at all!

SSlobalt

He's probably talking about the valve cover gasket.

Permafried-

Oh I know that's my point. They thought they needed to remove it (must have gotten the camshaft cover mixed up with the head somehow?), replaced the documented parts, then they reinstalled it without replacing it with a new one and all hell broke loose from there . My guess is they realised they didn't need to remove the head and prayed that just smacking it back on would be ok....as it turns out, it wasn't!

Little oil leak became epic oil leak (explosion?)...needless to say I've just avoided getting mine done.