L67 Engine Oil Smell or Odor, Leak at Left or Front Valve Cover (Replace Valve Cover Gasket, Grommets and Spark Plug Wire Retainers for Cylinders 1-3-5)

This bulletin is being revised to add additional information on cleaning the engine, installing valve cover bolts/grommets, labor time and installation of the spark plug wire retainers. Please discard Corporate Bulletin Number 08-06-04-019 (Section 06 -- Engine/Propulsion Systems).

Some customers may comment that the vehicle has an engine oil smell or odor. Upon investigation, the technician may find that an oil leak is coming from the left or front valve cover.

This condition may be caused by drops of engine oil being deposited on the exhaust manifold through hard braking.

The following service procedure will aid technicians in the removal and installation of the left or front valve cover gasket/grommets and the removal of existing 1,3 and 5 spark plug wire plastic retainer channel (cover) clip/bracket and the installation of a new style of spark plug wire retainers for cylinders 1, 3 and 5.

Important: Clean the area around the tube/oil fill cap before removing the tube/oil fill cap in order to prevent contaminants from falling into the valve cover opening.

1. Remove the fuel injector sight shield (1).

1.1.	Twist counterclockwise to unlock the tube/oil fill cap from the valve cover.

1.2.	Remove the upper intake manifold cover nut holding the fuel injector sight shield to the fuel injector rail brace stud.

1.3.	Lift the fuel injector sight shield up at the front and slide the tab out of the engine bracket.

1.4.	Re-install the tube/oil fill cap in the valve cover to prevent engine oil contamination.




2. Remove the left engine mount strut (2).

2.1.	Remove the bolt and the nut from the left engine mount strut at the left engine mount strut bracket on the engine (1).

2.2.	Remove the bolt and the nut from the left engine mount strut at the left engine mount strut bracket on the upper radiator support (1).

2.3.	Remove the engine mount strut (2).




3. Remove the 1-3-5 spark plug plastic retaining channel (cover) clip/bracket from the engine and discard (1).

Important: It is not necessary to remove the spark plug wires from the spark plugs.

4. Remove all six spark plug wires from the ignition coils only. Set the spark plug wires aside.



5. Remove the supercharger drive belt (1).

Lift or rotate the supercharger drive belt tensioner using a 15 mm box end wrench on the pulley nut and remove the belt.




6. Remove the supercharger drive belt tensioner (1) and idler pulley (2).

6.1.	Remove the supercharger drive belt tensioner nut and remove belt tensioner (1) from the engine.

6.2.	Remove the idler pulley bolt (2).

6.3.	Remove the drive belt idler pulley (2) from the engine.





Important: It is not necessary to remove the ignition coils/module or the 14-way connector (1) from the left engine mount strut bracket.

7. Remove the left engine mount strut bracket as assembly (1).

7.1.	Remove the left engine mount strut bracket assembly nuts.

7.2.	Remove the stud holding the electronic ignition control module ground and left engine mount strut bracket assembly to the cylinder head.

7.3.	Remove the left engine mount strut bracket assembly (1) from the cylinder head and set aside.

Danger

8. Do not use a brake cleaner, or equivalent to remove the oil residue from the exhaust manifold; doing so may cause an engine fire.

Notice: Before the removal of the left or front engine valve cover, use an engine degreaser or equivalent in order to remove the oil residue from the exhaust manifold and the oil and dirt residue from the cylinder head and engine block. It may be necessary to use a brush or scraper.




9. Remove the left or front engine valve cover (1).

8.1.	Remove the valve cover bolts.

Important: If the valve rocker arm cover (1) adheres to the cylinder head, remove the valve cover by bumping the end of the valve cover with palm of hand or with a soft rubber mallet.

8.2.	Remove the valve cover from the engine cylinder head.

8.3.	Remove the valve cover gasket.

8.4.	Clean the sealing surface on the cylinder head and the valve cover with a engine degreaser or equivalent.

8.5.	Clean the valve cover bolts of all dirt, grime or thread locking adhesive.




10. Install a new left or front valve cover gasket (1) , P/N 24503937, and make sure that valve cover gasket is seated properly in the valve cover groove.

9.1.	Install the valve cover and gasket (1) to the cylinder head.

9.2.	Install the six valve cover bolts and six new grommets.

-	Replace with new grommets, P/N 25534749 (package - qty.5).

-	Two packages will be needed. Save the other four grommets for future repairs.

9.3.	Apply medium strength thread lock compound (blue), GM P/N 12345382 (in Canada use P/N 10953489) or equivalent, to the six valve cover bolt threads.

Tighten
Tighten the valve cover bolts to 10 N·m (89 lb in).




11. Install the left engine mount strut bracket assembly to the cylinder head (1).

10.1.

Install the left engine mount strut bracket nuts and stud.

10.2.

Install the stud holding the electronic ignition control module ground and left engine mount strut bracket assembly to the cylinder head.

Tighten
Tighten the left engine mount strut bracket nuts and stud to 50 N·m (37 lb ft).

12. Install all six spark plug wires to the ignition coils.

7mm Four-Wire Retainer P/N 88891792




13. Install a 7 mm four-wire retainer, P/N 88891792 (1) (Qty 5/pack) to spark plug wire number 4, then to spark plug wires 1, 3 and 5. If not available, use 8 mm spark plug four-wire retainer (1), P/N 14066248 (Qty 10/pack), or equivalent 7mm aftermarket spark plug wire retainer. Save the other 7 mm or 8 mm spark plug four-wire retainers for future repairs.

7mm Two-Wire Retainer P/N 12132229





12.2.

Install a 7 mm two-wire retainer, P/N 12132229 (Qty 10/pack) to spark plug wires 3 and 5 only (1). Save the other 7mm spark plug two-wire retainers for future repairs.





12.3.

Install the 7 mm four-wire retainer, P/N 88891792 to spark plug wire number 4 (1) then to spark plug wires 1, 3 and 5 (2). Make sure that spark plug wires 2, 4 and 6 are secured to the original retainers and under the left engine mount strut bracket.

12.4.

Install the 7 mm two-wire spark plug retainer, P/N 12132229 (Qty 10) to spark plug wires 3 and 5 only (3). Make sure the spark plug retainer (3) is approximately 50 mm (2 in) from the oil level indicator.




14. First install the supercharger drive belt idler pulley and bolt (2). Then install the supercharger drive belt tensioner and nut (1).

Tighten
Tighten both the supercharger drive belt idler pulley bolt and supercharger drive belt tensioner nut to 50 N·m (37 lb ft).




15. Install the supercharger drive belt (1).

Lift or rotate the drive belt tensioner using a 15 mm box end wrench on the pulley nut and install the supercharger drive belt.

16. Install left engine mount strut bracket (2).




14.1.

Install the bolt and the nut to the left engine mount strut at the left engine mount strut bracket on the upper radiator support (1).

Tighten
Tighten the engine mount strut bolt to 48 N·m (35 lb ft).

Important: If equipped, the P-clip on the engine wiring harness must be vertical to the left engine mount strut bracket when installed.

14.2.

Install the bolt and the nut to the left engine mount strut at the left engine mount strut bracket on the engine (1).

Tighten
Tighten the engine mount strut bolt to 48 N·m (35 lb ft).




17. Install fuel injector sight shield (1).

15.1.

Remove by twisting counterclockwise to unlock the tube/oil fill cap from the left valve cover.

15.2.

Insert the tab of the fuel injector sight shield under the engine bracket.

15.3.

Place the hole of the fuel injector sight shield onto the oil fill neck of the left valve cover.

Important: Make sure the newly installed spark plug retainers are not in contact with the fuel injector sight shield or the exhaust manifold.





Important: Make sure the new 7 mm two-wire retainer (2) is approximately 50 mm (2 in) from the oil level indicator.

Important: Make sure the newly installed 7 mm four-wire (1) and 7 mm two-wire (2) spark plug retainers are not in contact with the fuel injector sight shield, engine mount strut bracket or the exhaust manifold.

15.4.

Install the tube/oil fill cap into the left valve cover and twist clockwise in order to lock the detent on the tube into the notch in the valve cover.

Tighten
Tighten the fuel injector sight shield cover nut to 3 N·m (27 lb in).

18. Inspect for the proper oil level.
19. Inspect for any oil leaks.

Important: Do not order for parts for dealer stock.

Important: The service procedure contained in this bulletin is different from the service procedure found in the appropriate service manual. As a result, the labor time allowance has been revised to correspond with this new service procedure. In the near future the service manual and labor time guide will be updated with this new information.

For vehicles repaired under this bulletin, use: