Got excessive smoke or catch-can that keeps filling up after valve cover work?

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BradM

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Just FYI. Starting a new thread but this is a related to my recent timing set work where I also replaced the spark plug tube seals in the Bank 1 valve cover.

After I completed the project, my catch-can would fill up after 45 minutes of run time. It turns out that I damaged the air-oil separator located in the Bank 1 valve cover (explanation below). If you have this issue, swap the Bank 1 PCV valve and Bank 2 PCV port so that the PCV valve is now running on Bank 2. If the excessive oil stops, it's the Bank 1 air-oil separator. If you don't have a catch-can then you would see smoke and unexplained oil use.

Below is a picture of the air-oil separator. Air enters at the white arrows and the white dot shows where the PCV valve is located. The blue arrows show the two oil drains with one being valved to avoid sucking in oil. The red arrows show where the housing had separated allowing the PCV valve to suck oil directly from the engine, thus bypassing the oil-air separator. I think I damaged it when removing the original spark plug seals but I could see this happening when removing the valve cover if you have to flex it alot. The separated area sits directly above two exhaust cam lobes and they rotate clockwise, which slings oil directly at the broken seam.

Air oil separator
 
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