Inside of valve cover broken? Oil consumption Related.

**Danaldson** · 04-10-2016 07:58 PM

I wasn't really sure where to post this so i made a new thread. didnt want to bump a thread from a few years ago.

Has anyone had any experience with a broken valve cover? Im ripping through oil like crazy, and i believe its come down to my valve cover having a crack in the interior covers and sucking oil out through the breather and out the exhaust.

I pulled off the valve cover tonight and it looks cracked to me, but if someone with more experience could chime in that would be great. Really hoping replacing this will solve my issues so i don't need to do rings/seals.

underside of valve cover before cleaning oil off. There looks to be a lot of oil, and residue crap where the arrows are pointing. along the side where the pcv is and between cyl 2&3.

Closer look:

After wiping residue off:

Closer look between cyl 2&3.

**RickB_7** · 04-10-2016 08:17 PM

This is what my valve cover looked like. I was going through quite a bit of oil too and a new valve cover fixed that issue.

**ajdre** · 04-10-2016 08:26 PM

Yes-its sucking oil into the pcv system and is probably dropping the oil into your intercoolers. Replace the cover (bernardiaudiparts.com ~$275 delivered including the gasket and new bolts) and you'll also need to drain and clean the oil out of the intercoolers. Happened to mine a month after I bought it. Freaked out and finally figured it out when I punched the gas and a cloud of white smoke came out of the exhaust. Thought I was screwed but was relieved that I now have no oil loss for over a year. Was drinking a quart for every 600 miles. Poor design on the system....not a fan of plastic engine parts that disintegrate over the years. Keep us posted on the outcome.

**Danaldson** · 04-10-2016 08:30 PM

Originally Posted by RickB_7

This is what my valve cover looked like. I was going through quite a bit of oil too and a new valve cover fixed that issue.

I took a screwdriver like you have to yours, and mine is flexing/lifting, although not quite as much as yours. Im gonna take in to the shop and check with my mechanic just to make sure. he may also have a replacement valve cover in stock.

Originally Posted by ajdre

Yes-its sucking oil into the pcv system and is probably dropping the oil into your intercoolers. Replace the cover (bernardiaudiparts.com ~$275 delivered including the gasket and new bolts) and you'll also need to drain and clean the oil out of the intercoolers. Happened to mine a month after I bought it. Freaked out and finally figured it out when I punched the gas and a cloud of white smoke came out of the exhaust. Thought I was screwed but was relieved that I now have no oil loss for over a year. Was drinking a quart for every 600 miles. Poor design on the system....not a fan of plastic engine parts that disintegrate over the years. Keep us posted on the outcome.

I checked my intercooler piping a few months ago (was still experiencing heavy consumption back then) and they weren't filled with oil, they only had a little bit of residue in them. Wouldn't it be sucking it down into the breather and straight through the turbo? I will definitely update this as things go along.

for the record: some info on the car:

125,000kms/77,000 miles
United motorsports stage 1 tune
Apr intake and test pipe.

Have already replaced:
Breather x2,
Diverter valve
Pcv.

**vvenom800tt** · 04-10-2016 09:26 PM

Will such a crack in the valve cover also give you a boost leak? Im chasing a boost leak and im sort of at a loss

**your daddy** · 04-10-2016 09:33 PM

replace it. and vent valve.

**vvenom800tt** · 04-10-2016 09:42 PM

Is that for me or the OP ?

**Sanjman** · 04-10-2016 11:14 PM

The valve cover is part of Audis great engineering making it all plastic and using Elmers glue to piece it together. Shiro has a great writeup to the inner workings of the valve cover and I believe also explained how to fix a,broken one.

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**Denio24** · 04-10-2016 11:24 PM

Originally Posted by vvenom800tt

Will such a crack in the valve cover also give you a boost leak? Im chasing a boost leak and im sort of at a loss

It will probably cause a small boost leak but more adversely it will also pressurize the crankcase. Not sure how much but the theory behind it makes sense. I would replace it and complete logs before and after to confirm these issues.

**Sanjman** · 04-11-2016 11:21 AM

For what the PCV does i feel like is the ultimate cause for these other type of failures from broken valve covers to leaky valve cover gaskets to oil in the plugs and misfires. What a $h*t design.

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**vvenom800tt** · 04-11-2016 11:23 AM

Its a terrible design. i just wish a billet cover wast $400+

i guess i'll have to save up for one now since a new revision oem one is like $250+

Might as well fix it for good and get a pretty one

**JDillon15** · 04-11-2016 11:51 AM

Originally Posted by vvenom800tt

Will such a crack in the valve cover also give you a boost leak? Im chasing a boost leak and im sort of at a loss

I've had a slight boost leak as well and I'm pretty sure this is my culprit. I've been waiting til it warms up to worry about fixing it as it only seems to effect when I'm WOT (or trying to reach full boost).

That being said, the boost leak is very slight and I wouldn't have noticed without a boost gauge (peak at ~18 vs normal ~21psi)

There has also been a little more than normal oil in my IC piping, which also lead me to this conclusion. 90% sure it's not the turbo.

Originally Posted by Danaldson

I took a screwdriver like you have to yours, and mine is flexing/lifting, although not quite as much as yours. Im gonna take in to the shop and check with my mechanic just to make sure. he may also have a replacement valve cover in stock.

I hope this solves it for you; I've seen several of your posts. Seems like you've been chasing it for a while.

**Low and Behold** · 04-11-2016 12:17 PM

Thank you for this thread Danaldson, I literally just replaced my VC on Saturday for the exact issue. However, I didnt replace it with a brand new one. A friend of mine (CleverA4name) replaced his with a billet cover so he gave me his old one. I figured it would work fine seeing as he wasn't suffering from consumption issues whatsoever.

I noticed with BOTH VCs that the rear section was loose/flexing, so I'm not sure if thats normal. Let us know what your mechanic says about it.

I replaced it anyway, cleaned out my intercoolers and will check it in a week or so. Fingers crossed.

Im also seeing/hearing some engine knock under heavy load. I assumed it was from the oil being sucked through the intake? Not sure if you were having the same issue

**Danaldson** · 04-11-2016 12:25 PM

Originally Posted by JDillon15

I hope this solves it for you; I've seen several of your posts. Seems like you've been chasing it for a while.

Yeah I've had this issue for about 6 months now. But now I'm trying to get to the bottom of it.

Originally Posted by Low and Behold

Thank you for this thread Danaldson, I literally just replaced my VC on Saturday for the exact issue. However, I didnt replace it with a brand new one. A friend of mine (CleverA4name) replaced his with a billet cover so he gave me his old one. I figured it would work fine seeing as he wasn't suffering from consumption issues whatsoever.

I noticed with BOTH VCs that the rear section was loose/flexing, so I'm not sure if thats normal. Let us know what your mechanic says about it.

I replaced it anyway, cleaned out my intercoolers and will check it in a week or so. Fingers crossed.

Im also seeing/hearing some engine knock under heavy load. I assumed it was from the oil being sucked through the intake? Not sure if you were having the same issue

I'm not getting any knocking, I'm seeing a ton of smoke out the exhaust. Which my guess is that oil is getting dumped through the breather into the turbo.

Brought in the valve cover today, and unfortunately he didn't have a replacement in stock, but he took a look and said the inner cover could be cracked. He plastic welded it up and epoxied it. told me to give it a shot And let him know.

I'm just about to put it back on the car here, so I'll take it for a drive and I should know right away if I'm throwing smoke out the back. Will report back.

**vvenom800tt** · 04-11-2016 12:43 PM

I have a spare cover that i might double check and plastic weld just to be safe as potential temp fix, ive never looked under my original one (my car is on 05 with 191k on it)

**Low and Behold** · 04-11-2016 01:23 PM

I might just take my old one to the dealer and compare it with a new one. I don't think that rear plate is supposed to lift/flex like that, yet both of my VCs do

**Danaldson** · 04-11-2016 02:56 PM

Well I just put the car together and took it for a hard drive.

The exhaust seems to smell less like burnt oil, and more like exhaust fumes. Good signs.

I still saw some smoke out the back, but not nearly as much as before. Could be normal, or could just be cleaning out the turbo/breather/exhaust. I'll keep an eye on this.

Boost seems to pull harder now (boost numbers haven't changed) but it's feels less clogged if that makes sense. Probly because there is less oil going through the turbo.

On a side note, when the car backfires, it's MUCH louder than before. Not sure how loud backfires tend to be with a test pipe.

I'll keep an eye on this for the next few days and update. Hope this solves the consumption.

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**JDillon15** · 04-11-2016 03:32 PM

Originally Posted by Danaldson

Well I just put the car together and took it for a hard drive.

The exhaust seems to smell less like burnt oil, and more like exhaust fumes. Good signs.

I still saw some smoke out the back, but not nearly as much as before. Could be normal, or could just be cleaning out the turbo/breather/exhaust. I'll keep an eye on this.

Boost seems to pull harder now (boost numbers haven't changed) but it's feels less clogged if that makes sense. Probly because there is less oil going through the turbo.

On a side note, when the car backfires, it's MUCH louder than before. Not sure how loud backfires tend to be with a test pipe.

I'll keep an eye on this for the next few days and update. Hope this solves the consumption.

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If it does, I would probably replace the VC with one that doesn't have JB weld all over it... lol

But that's just me.

**Danaldson** · 04-11-2016 03:37 PM

Originally Posted by JDillon15

If it does, I would probably replace the VC with one that doesn't have JB weld all over it... lol

But that's just me.

It should hold up fine with the epoxy, but I am going to look at getting a billet aftermarket vc with a catch can. Any recommendations for aftermarket valve covers?

**Denio24** · 04-11-2016 03:42 PM

Originally Posted by Danaldson

It should hold up fine with the epoxy, but I am going to look at getting a billet aftermarket vc with a catch can. Any recommendations for aftermarket valve covers?

IE

**Danaldson** · 04-11-2016 03:44 PM

Originally Posted by Denio24

IE

That's one of the only ones I could find, but I haven't seen any reviews of it.

**vvenom800tt** · 04-11-2016 04:00 PM

Get the IE but dont get it from them, its cheaper elsewhere. Just google it and find the cheapest place.

**Schweini** · 04-11-2016 06:15 PM

I may be way outdated here, but wasn't there an issue with the IE VC's on not having taps for after market CCs?

**vvenom800tt** · 04-11-2016 06:37 PM

It just has the top hole for a 10an fitting i believe. Youll have to run your can to that and the other end to the breather port on top of the oil filter housing where the plastic ribbed tube usually goes down from the oem pcv valve

**Schweini** · 04-11-2016 06:42 PM

Ahhh ok. I knew there was something a bit different. That's good then

**Danaldson** · 04-11-2016 06:48 PM

I'm not able to run the ie cover without a catch can am I?

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**vvenom800tt** · 04-11-2016 06:57 PM

You can run it without a can i think, but youd just have to run a 10 an line from there into the port on top of the oil filter housing.

I know the exterior diameter of the ribbed tube is 22mm. So you can get a silicone hose thats 22mm that will run to a 90º -10an to barb adapter thats 22mm or 7/8"

**Danaldson** · 04-11-2016 06:59 PM

Originally Posted by vvenom800tt

You can run it without a can i think, but youd just have to run a 10 an line from there into the port on top of the oil filter housing.

I know the exterior diameter of the ribbed tube is 22mm. So you can get a silicone hose thats 22mm that will run to a 90º -10an to barb adapter thats 22mm or 7/8"

yeah that makes sense. I think i can use get this. right?

**malathion** · 04-11-2016 07:30 PM

I personally wouldn't run that valve cover with the epoxy mickey mouse fix, I'd be afraid of that shit falling off and getting into my motor

**vvenom800tt** · 04-11-2016 07:54 PM

http://www.autosiliconehoses.com/sil...one-hoses.html

i think the biggest -10an to barb youll find is 5/8" so you might need a hose that goes from 16mm to whatever the exterior diameter of the filter housing (which is 28mm)

They dont have that reducing size. But maybe run a 16mm to 22mm from the fitting on the valve cover then a brass barb thats 7/8" on both sides and run a 22mm to 28mm to the oil filter housing. 22mm = 7/8"

http://www.autosiliconehoses.com/sil...5-colours.html

http://www.autosiliconehoses.com/sil...5-colours.html

**907DAVE** · 04-12-2016 12:19 AM

Looping the bottom breather into the vc port won't do anything, they are both cc vents. You must vent one or both to the atmosphere/ intake pipe for the system to function.

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**Okedokey** · 04-12-2016 01:58 AM

And venting to atmosphere is illegal in some parts...

**Brillo** · 04-12-2016 07:08 AM

^^ Yes, it is a violation of federal law in the USA as well. Specifically the Federal Clean Air Acts of 1970 and 1977, and the amendments to the Federal Clean Air act of 1990. This would apply to PCV defeats, venting to the atmosphere, modifications of catalytic converters, use of cats that are not as efficient as OEM, and test pipes etc. for anyone that cares.

**Danaldson** · 04-12-2016 07:09 AM

I'm in canada and yeah it's also illegal to vent to atmosphere. So in order to run the ie cover ide need the catch can setup as well.

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**vvenom800tt** · 04-12-2016 08:26 AM

Originally Posted by 907DAVE

Looping the bottom breather into the vc port won't do anything, they are both cc vents. You must vent one or both to the atmosphere/ intake pipe for the system to function.

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Then he can run an inline T fitting with a filter on it

**Danaldson** · 04-12-2016 09:18 AM

Ill probably just pickup a catch can while I'm at it.

Im 99% sure the broken valve cover was the source of my consumption. Im going to keep a close eye on it but i had a few friends follow me, and they didn't notice any smoke coming out the back. Very good signs

**Low and Behold** · 04-12-2016 10:03 AM

Originally Posted by Danaldson

Ill probably just pickup a catch can while I'm at it.

Im 99% sure the broken valve cover was the source of my consumption. Im going to keep a close eye on it but i had a few friends follow me, and they didn't notice any smoke coming out the back. Very good signs

Thats good news. Im still getting smoke/knocking at WOT, though it doesn't happen every time. I fear I may have gotten bad piston rings...

**mtroxel** · 04-12-2016 10:15 AM

Originally Posted by Danaldson

Im 99% sure the broken valve cover was the source of my consumption. Im going to keep a close eye on it but i had a few friends follow me, and they didn't notice any smoke coming out the back. Very good signs

Keep us posted. Some day when mine goes bad, I might just JB Weld it.

**Danaldson** · 04-12-2016 10:18 AM

Originally Posted by mtroxel

Keep us posted. Some day when mine goes bad, I might just JB Weld it.

will do forsure! I would probably just recomend plastic welding it. I am a little nervous that the epoxy may come off on mine, so thats why I'm going to go with the IE cover.