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Discussion Starter #1
so i thought this would put a lot of your worries to rest.
please move this to bulletins.


Service Information
2008 Chevrolet Cobalt | Cobalt, G5 (VIN A) Service Manual | View All Bulletins | Document ID: 2260700
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#09-06-01-004: Clicking/Ticking Sound/Noise Heard from Rear of Engine (Install Sound Isolation Cover Over High Pressure Fuel Pump) - (Apr 1, 2009)


Subject: Clicking/Ticking Sound/Noise Heard From Rear of Engine (Install Sound Isolation Cover Over High Pressure Fuel Pump)


Models: 2008-2009 Chevrolet Cobalt, Cobalt SS, HHR, HHR SS

2007-2009 Pontiac Solstice GXP

2007-2009 Saturn SKY Redline

2007-2009 Opel GT

2007-2009 Daewoo G2X

Equipped with 2.0L Engine (VIN X -- RPO LNF)




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Condition
Some customers may comment on a ticking sound from the rear of the engine. Upon investigation, the technician may find the sound coming from the high pressure fuel pump and/or the injectors.

Cause
The 2.0L turbo engine (VIN X - RPO LNF) uses a direct injection fuel system that operates at very high fuel pressures. A direct injection fuel system produces a rapid, clicking/ticking sound that can be heard from the engine compartment. The sound is more evident when outside around the vehicle or when the hood is open. The sound is more noticeable during idle, and is more frequent during a cold start but lessens once the engine is warm. The rapid ticking noise on cold start up is the fuel pump (located on the rear of the cylinder head) building up high fuel pressure. When the engine warm-up is completed, the high pressure fuel pump will continue to tick at a lower rate of approximately one tick per second during idle. The clicking sound is the fuel injectors pulsing on and off under higher fuel pressures. These sounds are the results of a normal direct injection fuel system operating properly.

Correction
Install a sound isolation cover over the high pressure fuel pump following the procedure below. This will make the sound coming from the high pressure fuel pump less noticeable, but it will not completely eliminate it.

Important: DO NOT attempt to replace any parts for this kind of clicking or ticking concern.

Verify the noise is coming from the high pressure fuel pump.
Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement in SI.
Disconnect the engine wiring harness electrical connector from the high pressure fuel pump.
Remove the engine wiring harness from the high pressure fuel pump cover bracket.



Remove the high pressure fuel pump cover bolts (1).
Remove the high pressure fuel pump cover bracket.



Remove the old design cover and install the new high pressure fuel pump insulator, GM P/N 12628069.
Position the high pressure fuel pump cover bracket. Install the high pressure fuel pump cover bolts.
Tighten
Tighten the bolts to 10 N·m (89 lb in).

Connect the engine wiring harness electrical connector to the high pressure fuel pump.
Attach the engine wiring harness to the fuel pump cover bracket using a zip tie.
Install the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement in SI.
Parts Information
Part Number
Description
Qty

12628069
Insulator/PMP
1


Warranty Information
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

J7814*
Install Isolation Cover on Fuel Pump
0.7 hr

*This is a unique labor operation for bulletin use only. It will not be published in the Labor Time Guide.

GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the information.

WE SUPPORT VOLUNTARY TECHNICIAN CERTIFICATION


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u dont know HOW MANY cars come back for this... seriously... even some of the sales people bring the ones in off the lot... ive musta diaged atleast 20 of em...
 
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