Oil leak present AFTER VCG & head plugs change Help Please?

This one has be scratching my head.

Working on a buddy of mine's car- leaking oil like a sieve. Diagnosis: Valve cover gasket- bad!

I replaced the valve cover gasket and plugs with Victor Reinz- the one with the thin red silicone band. The plugs were not OEM, I believe MTC from ECSTuning. Mating surfaces were cleaned thoroughly, and no apparent warping was noted.

Installation was a bit curious on the front intake cam plug. It did not seem to want to fit flush. Perhaps 1mm off (rise). I mashed it down, and it seemed willing to behave, so I torqued down the valve cover.

After test drive, oil leak is still present, as bad as, or as worse as before.

Oil is dripping from the bottom of the A/C bracket. Underneath the car, and from above, I cannot locate directly the source so I removed the VC for inspection. This revealed what looked like a good seal, but I am not above making a mistake or overlooking something.

As a measure of eliminating the potential for that plug not making perfect contact / level seating surface, I decided to introduce some black RTV (high oil resistance) and let it cure fully before testing again. I applied to the half-moon surfaces and the area where the head meets the plug. The front intake side plug did not want to fit flush again. WTH? I even moved the plugs around.

Result: SAME AS BEFORE- leaking like a sieve. Oil drip still present, trickling down off the A/C compressor.

Request: I've turned a million wrenches, but would appreciate any insight on this. I'm not an E30 expert, and have done some searching, but this has me scratching my head. Thanks kindly for advice!

Hi, The half moons sound like your problem. Try genuine and you should only need sealant at the top 'corners'. Without any gasket does the VC rock on the head or fit 'square'? Also clean down engine and watch for new oil. It might not be coming from where you think.

BMWFatherFigure-
Thank you for that advice. I have cleaned it thoroughly. Peering into the timing area is very difficult with the radiator and timing components in place. I'm convinced it is coming from that area, since the drip appears on that side. And, it is clearly coming from the front since the drip is apparent after shutting off the engine (on the A/C compressor).

Is there anything else in the front part of the engine that could be also leaking? I have not removed the timing belt cover etc- but the GEARS on the top, and belt, which can be slightly seen-- are DRY. This makes me think the leak is following gravity, trailing down the front, slightly diagonal side of the head, then onto the front of the block, ultimately at the A/C compressor.

I did not test for rocking with the valve cover gasket removed, but with that particular plug in place, there is a certain mis-fit. Only under torque will the plug square up. I am puzzled as to why the plug I pulled out fit flush (albeit the entire area leaked horribly before repair), but the new plug will not fit properly. I wish I had the "old" plug-- I would install it with a new gasket and try that.

If your engine in question is the m20 I'm betting your problem is in your timing area

It is the M20.

I'll look into the timing area diagrams.

Has anyone experienced issues like this with one of the plugs?

i know my cam seal was starting to leak before i did the head gasket. so while i had the head off i changed it, no more leak.

Torch and mirror. Awkward but to eyeball the leak is gold! Oil won't go uphill so work from the highest dry area down. Maybe worth dropping off the cover and check for warp. One possibility out of the way..