For 1990-2009 cars

# Excessive Oil Consumption, Blue Smoke on Acceleration (Inspect Intake Manifold and/or Cam Cover, Replace if Necessary)

Subject: | Excessive Oil Consumption, Blue Smoke on Acceleration (Inspect Intake Manifold and/or Cam Cover, Replace if Necessary)

Models: | 2004-2005 Chevrolet Cavalier, Classic, Malibu

| 2005 Chevrolet Cobalt

| 2004 Oldsmobile Alero

| 2004-2005 Pontiac Grand Am, Sunfire

| 2005 Pontiac Pursuit (Canada Only)

| 2004-2005 Saturn L-Series, ION, VUE

| with Ecotec 2.2L 4-Cylinder Engine (VINs D, F -- RPO L61)

Attention: | This bulletin covers any vehicle with the Ecotec 2.2L L61 engine built during calendar year 2004.

This bulletin is being revised to add additional warranty information. Please discard Corporate Bulletin Number 05-06-01-003B (Section 06 - Engine/Propulsion System).

### Condition

Some customers may comment on excessive oil consumption or blue smoke on acceleration. Excessive oil consumption, not due to leaks, is the use of 0.9L (1 qt) or more of engine oil within 3200 km (2,000 mi).

### Cause

Incorrect sizing of the PCV orifice and/or misalignment of the oil baffle in the cam cover may allow higher than desired amounts of oil into the combustion chamber.

### Correction

Important: If the following information in this bulletin does not resolve the concern, refer to Oil Consumption Diagnosis in the appropriate Service Information (SI) procedures.

Inspect the cam cover for heat stake marks and inspect the intake manifold for PCV orifice size. Replace either, as necessary, based on inspection. Follow the procedures below.

#### Camshaft Cover

1. Remove the camshaft cover and inspect for heat stake marks in the locations shown. Refer to Camshaft Cover Removal in the appropriate Service Information (SI) procedures.

Important: The oil fill tube must be replaced along with the camshaft cover for the following models:

• | 2005 Chevrolet Cobalt

• | 2005 Pontiac Pursuit

• | 2005 Saturn ION

2. If the heat stake marks are not present, replace the camshaft cover with a new one.
3. If the heat stake marks are present, re-install the camshaft cover on the engine. Refer to Camshaft Cover Installation in the appropriate Service Information (SI) procedures.

#### Intake Manifold

1. Remove the intake manifold from the cylinder head. Refer to Intake Manifold Removal in the appropriate Service Information (SI) procedures.
2. Attempt to insert the chuck end of a 2.0 mm (5/64 in) drill bit into the PCV orifice where shown. The orifice is slightly below the surface.
3. If the chuck end of the drill bit can be inserted, replace the intake manifold with a new one.
4. If the chuck end of the drill bit cannot be inserted, re-install the intake manifold to the cylinder head. Refer to Intake Manifold Installation in the appropriate Service Information (SI) procedures.
5. If the information in this bulletin did not correct the excessive oil consumption condition, refer to Oil Consumption Diagnosis in the appropriate Service Information (SI) procedures.

### Parts Information

Part Number | Description | Qty
--- | --- | ---
24426069 | Camshaft Cover | 1 as Req'd
12587202 | Intake Manifold | 1 as Req'd
24455112 | Intake Manifold Gasket | 4 as Req'd
12584084 | Cam Cover Gasket | 1 as Req'd
24455111 | Throttle Body Seal | 1 as Req'd
12575851 | PCV Gasket | 1 as Req'd
12589431 | Oil Fill Tube (For 2005 Cobalt, Pursuit and ION Only) | 1 as Req'd

### Warranty Information

For vehicles repaired under warranty, use:

Labor Operation | Description | Model | Labor Time
--- | --- | --- | ---
J7504 | Camshaft Cover And Intake Manifold - Inspect and/or Replace | A-Car | 1.1 hrs
J-Car | 1.6 hrs
N-Car | 1.9 hrs
Z-Car | 1.9 hrs
J0318 | Cover and/or Gasket, Camshaft Housing - Replace | ION, VUE, L-Series | Saturn Use Published Labor Time
J0250 | Manifold, Intake - Replace | ION, VUE
L-Series
J0251 | Gasket, Intake Manifold - Replace (if manifold replacement not necessary) | ION, VUE
L-Series