It was time to tackle the oil drips on the Cobalt car.
I had noticed a problem with the sump plug dripping previously due to the sump taking a bash prior to my tenure, so replaced with a new plug and copper washer which meant it was nearly perfect, just a bit wet, however I had noticed spots of oil on the drive, especially if the car was left running while parked.
A look underneath suggested the sump gasket was leaking, which is a lot better than the crankshaft seal behind the flywheel. The rear of the flywheel is dry so I think the crank seal is ok.
This is a simple job, raise the car, remove the flywheel guard, drain the oil then unbolt the sump.
The offending split.
A quick wipe around revealed no sludge and the witness mark from the sump being bashed into the fixed baffle.
Note the design of the sump plug captive nut, to ensure a complete drain. It has dished underside to create arches which act as a channel.
Reform the bottom of the sump, dress the fitting flange where the bolts had distorted it slightly, smear both mating surfaces with none setting gasket sealant, smear the sump plug washer both sides and re-assemble.
When refitting the sump be aware there are three shorter bolts, which go into the No1 main bearing cap and the crank case where the oil breather pipe fits.
I also noticed oil high up on the front of the engine and injector pipes. After cleaning it off twice I realised it was coming out of the boosted air intake pipe only when under full boost. A check revealed the flexible coupling had split on the underside and was opening up under pressure.
I was going out so did a quick fix with PVC tape, reinforced with material tape.
Next moring I found the repair had held but oil had been forced through the tape.
I had a coupling, so cleaned it up and fitted that, another clean down then as the front of the sump and the underside of the subframe were rusty got the wire wheel out, then slapped on some paint.
Top of the engine.
Underside.
Having checked, it appears the sump is now dry, but I will keep checking and in addition the boost pressure is at proper pressure, so there is less smoke and more torque can be felt.
I did this on saturday and Sunday and am still in agony now, so hopefully it's been worth it.