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960 oil leak. Valve cover? Rear main seal? 900

Hi all. I am still struggling with tracking down this oil leak.

I have somehow minimized the leaking to what might be considered acceptable IF it was not blowing onto the lower exhaust pipes. I have cleaned the engine as clean as I could possible get it (many times), put ultraviolet dye in the oil, looked with my UV pen light and I STILL cannot trace the source of this leak. It is clearly showing up on the passenger side of the engine on the lowest point available on the oil sump.

But when I follow the oil upwards I lose it in the upper third of the rear of the engine. I stick my hand in the rear of the engine and feel nothing in or around the exhaust cam area which I know is a frequent flyer for leaks. I do feel oil on the metal beneath and to the drivers side of the rear of the engine. I doubt that a mirror is going to show me more because it is a very thin layer. My question is what or where would be the sealing point on the rear most upper side of the engine. Where the valve cover of conventional engine might be. If it was any other car I would immediately replace the valve cover gasket to make sure that this was not the leak just because it is so easy to do. On this car I have heard that there is no conventional valve cover gasket but some sort of unusual 'chemical seal' in its place.

So while I am treating the rear main seal as the number one suspect I really do not want to go to the effort of replacing that without knowing, as certainly as possible, that the leak is not above that rear main seal towards the top rear of the engine. I am confident that I can do the repair and replace the rear main but it is surely going to be a struggle in my garage. Replacing the starter almost killed me....psychologicially.

I have found the instructions for replacing the rear cam seals but nothing for the 960 equivalent of a valve cover gasket. Can someone give me the approximate level of difficulty on this job and any step by step directions that might be available? Or compare the level of difficulty between that job and doing the rear main seal.

Thanks very much,
Jim Lee

1996 960 Wagon 125k








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    960 oil leak. Valve cover? Rear main seal? 900

    The suggestion that the oil filler cap gasket is leaking is great a starting point.

    Oil only at the bottom of the spark plug well? If there is no oil around the top of the well then it can only come from the o-ring seal that is at the bottom of spark plug well. Make sure it is not coming from another source around the hole.

    I would wash your engine down to get it clean, maybe leave your oil in so it gets a little dirty so it easier to see. Clean it up, and then do another search, suspects besides the oil filler gasket, cam seals, there might not be a seal on the intake rear, many mechanics just use some silicon on the cover instead of messing with seal placement, check front and rear seals, the oil separation system including the flame trap and all of it's hoses.

    Has this head been off for any reason? Could the repair not been made correctly if it was?

    DanR '94 964 360,000 miles (126,000 on the new engine)
    --
    DanR








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    960 oil leak. Valve cover? Rear main seal? 900

    Take the top plastic cover off the engine and see if you can see the oil leek.








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      960 oil leak. Valve cover? Rear main seal? 900

      It is very interesting that you mention that. I do have oil under my 'sparkplug/coil' cover. In fact the last time I inspected my plugs there was enough oil in either the #2 or #3 cylinder that I had to blow it out. I have replaced the coils since then and was hoping that it was just the seal of the bottom of the coils on the top of the spark plug hole but I still see oil there...on the top of the head. I haven't removed coils to look in the plug holes. I will do that.

      What I don't get though is where that oil could be coming from that it could dump oil up that high?

      Thanks very much,
      Jim Lee








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        960 oil leak. Valve cover? Rear main seal? 900

        I've had three 960s now and all have had problems with the filler cap leaking and oil pooling at the base of the plugs. None has been really awful but it's there.

        But, I do think you have a RMS problem. ALL three of my 960s have developed bad RMSs; one was so bad I was going through more than a quart per week. I had to let it go at that point (although I should have repaired it - loved that car). So, if it has anywhere north of about 125,000 miles, it's probably the RMS.

        I have two right now that need a RMS and I'm trying to figure out if I pull the motor or have someone do it for me in the car (not attempting that in my driveway).








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        960 oil leak. Valve cover? Rear main seal? 900

        The oil can come from the oil cap seal and find its way under the cover. Mine was also leaking oil out from under the bolts that hold the rocker gear housing down next to the col packs they are 7mm in size. I had to tap out the holes and put in some 8mm bolts. Both of my spark plug holes were over flowing with oil and running down the back of the engine.







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