E39 SMOKING 2.5 ENGINE

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   Hi, I am new to this forum so take it easy if I am going over an old problem!
I have a 1996 E39 523I with approx 140,000 miles on the clock.
The engine has always been serviced every 5,000 miles with a new oil & filters.
I recently discovered a crack in the rocker cover and replaced it with a good clean 2nd hand one, in addition I installed a new rocer cover gasket.
The problem since changing the rocker cover........
Everytime the I take the revs up to 4,000 rpm in 3rd, 4th or 5th it will bellow huge amounts of smoke out of the exhaust. Providing the revs are kept below 4k it NEVER smokes and you wouldn't tell there is a problem.
There are no noises coming from the engine and nor does it misfire or run lumpy or have a loss in power.
I have removed, stripped, cleaned and refitted the Oil Seperator valve and pipes, it appears that it is in good condition with no holes or tears in the diaphram. However; it is obvious from the amount of oil in the inlet manifold that the oil is entering the engine from the sump breather pipe that connects to the oil seperator valve.
I have the benefit of Carsoft 6.5 diagnostics and it has thrown up a code "38 GAS-VALVE-ADJUSTMENT ERROR", although once this fault was cleared it did not return. Where is the "GAS VALVE ADJUSTER"?
The engine only uses oil if it is smoking out of the exhaust after going over 4k rpm, it uses no water, there is no oil in the water or visa versa, the running temp is also fine.
I have bought another engine with 30k on it, however; prior to undertaking the task of an engine change I would like to be satisfied that I have tried everything!!!
I have had mechanics of varying abilities look at the car all of which have drawn a blank, I have had the compression checked / tested and the valves guides checked tested and piston rings checked / tested and I have been told that everything appears to be within limits.
Are there any valves etc, electronic or mechanical that I could try or any other tips to try out on it before I pull it apart.
Regards,
Gary

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1996523i Members Profile Send Private Message Find Members Posts Add to Buddy List Newbie Joined: 04-June-2009 Status: Offline Points: 4	Post Options Post Reply Quote 1996523i Report Post Thanks(0) Quote Reply Topic: E39 SMOKING 2.5 ENGINE Posted: 04-June-2009 at 23:49
	Hi, I am new to this forum so take it easy if I am going over an old problem! I have a 1996 E39 523I with approx 140,000 miles on the clock. The engine has always been serviced every 5,000 miles with a new oil & filters. I recently discovered a crack in the rocker cover and replaced it with a good clean 2nd hand one, in addition I installed a new rocer cover gasket. The problem since changing the rocker cover........ Everytime the I take the revs up to 4,000 rpm in 3rd, 4th or 5th it will bellow huge amounts of smoke out of the exhaust. Providing the revs are kept below 4k it NEVER smokes and you wouldn't tell there is a problem. There are no noises coming from the engine and nor does it misfire or run lumpy or have a loss in power. I have removed, stripped, cleaned and refitted the Oil Seperator valve and pipes, it appears that it is in good condition with no holes or tears in the diaphram. However; it is obvious from the amount of oil in the inlet manifold that the oil is entering the engine from the sump breather pipe that connects to the oil seperator valve. I have the benefit of Carsoft 6.5 diagnostics and it has thrown up a code "38 GAS-VALVE-ADJUSTMENT ERROR", although once this fault was cleared it did not return. Where is the "GAS VALVE ADJUSTER"? The engine only uses oil if it is smoking out of the exhaust after going over 4k rpm, it uses no water, there is no oil in the water or visa versa, the running temp is also fine. I have bought another engine with 30k on it, however; prior to undertaking the task of an engine change I would like to be satisfied that I have tried everything!!! I have had mechanics of varying abilities look at the car all of which have drawn a blank, I have had the compression checked / tested and the valves guides checked tested and piston rings checked / tested and I have been told that everything appears to be within limits. Are there any valves etc, electronic or mechanical that I could try or any other tips to try out on it before I pull it apart. Regards, Gary

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Dergside Members Profile Send Private Message Find Members Posts Add to Buddy List Really Senior Member II Joined: 16-May-2004 Location: Mid West, Ireland Status: Offline Points: 4000	Post Options Post Reply Quote Dergside Report Post Thanks(0) Quote Reply Posted: 05-June-2009 at 14:38
	How much oil is the car using and was the compression test done from cold or with a warm engine?
	Now: BMW 523i SE '00, 318i SE - e91 '07, 325i Coupe '93. Prev: e46 328i SE Touring, 330Ci, 318Ci. e39 523i SE. e36 325i Coupe *2, 323i SE, 316iSE. e30 325iSE 2dr, 320i Conv, 320i 2dr, 316i.

1996523i Members Profile Send Private Message Find Members Posts Add to Buddy List Newbie Joined: 04-June-2009 Status: Offline Points: 4	Post Options Post Reply Quote 1996523i Report Post Thanks(0) Quote Reply Posted: 05-June-2009 at 17:20
	Hi Dergside, As far as I know the compression tests were done both warm and cold, also wet and dry by the local garage. If the engine is not taken over 4k rpm then its oil consumption is normal, however; over 4k rpm it is probably consuming lots judging by the amount of smoke coming from the rear!!! I don't want to say that the engine is shot just yet, becuase I have a feeling that this problem is going to be electrical and really don't fancy changing the lump to find that the problem still exists

Dergside Members Profile Send Private Message Find Members Posts Add to Buddy List Really Senior Member II Joined: 16-May-2004 Location: Mid West, Ireland Status: Offline Points: 4000	Post Options Post Reply Quote Dergside Report Post Thanks(0) Quote Reply Posted: 05-June-2009 at 18:28
	The fact that the compression test was done from cold and hot is a good thing as some nikasil engined cars could pass a test when hot and fail from cold. Also, the fact that you can be fairly certain about the circumstances of the oil consumption and that there isn't a head gasket issue is positive too. Obviosuly there is a problem, but it doesn't sound like its of the "nikasil - throw away your engine" kind. Can't offer a great deal of further ideas than that I'm afraid but can say that its worth a bit more diagnosis before doing the heart transplant.
	Now: BMW 523i SE '00, 318i SE - e91 '07, 325i Coupe '93. Prev: e46 328i SE Touring, 330Ci, 318Ci. e39 523i SE. e36 325i Coupe *2, 323i SE, 316iSE. e30 325iSE 2dr, 320i Conv, 320i 2dr, 316i.

Stone-IslandV8 Members Profile Send Private Message Find Members Posts Visit Members Homepage Add to Buddy List Really Senior Member II Joined: 31-January-2003 Location: North Somerset Status: Offline Points: 3015	Post Options Post Reply Quote Stone-IslandV8 Report Post Thanks(0) Quote Reply Posted: 05-June-2009 at 18:54
	Try a small split on the cyclone valve, not sure but worth a try. With the car running how easy is to remove the oil filler cap? If its stuck in place then the system could well be under too much pressure.
	Gentlemen I may not have a brain but I do have an idea Past; E39 540T/E46 328CI/ E39 535/ E39 520/ E36 M3/ E36 318iS jet black Mtech/ E46 320d/ E36 318iS diamond black/ E36 318iS blue Mtech kit

1996523i Members Profile Send Private Message Find Members Posts Add to Buddy List Newbie Joined: 04-June-2009 Status: Offline Points: 4	Post Options Post Reply Quote 1996523i Report Post Thanks(0) Quote Reply Posted: 05-June-2009 at 19:34
	Thanks for the support... I will assume that the cyclone valve is also called the Oil seperator valve and it enters the bottom of the inlet manifold, with rocker and sump breather pipes going into it? I've had it out, cleaned it and checked it for holes with sun light! If its not, where is the cyclone valve located? Any other electronic valves that might play a part in the fault? I'm still waiting for delivery of the haynes manual. Sorry to all those poor people driving south out of Aberystwyth this afternoon - the smoke was caused by meeeeeeeeeeeee! I'm giving it this last weekend then I'm going to pull the lump - its my everyday car and can't stand driving it at 3k rpm anymore, although fuel consumption is fantastic! Thinking caps on..........

Stone-IslandV8 Members Profile Send Private Message Find Members Posts Visit Members Homepage Add to Buddy List Really Senior Member II Joined: 31-January-2003 Location: North Somerset Status: Offline Points: 3015	Post Options Post Reply Quote Stone-IslandV8 Report Post Thanks(0) Quote Reply Posted: 06-June-2009 at 18:11
	Not sure but telltale is a fart noise when accelerating as its a bellows mechanism inside that splits. Leak in vacuum pipes? Edited by Stone-IslandV8
	Gentlemen I may not have a brain but I do have an idea Past; E39 540T/E46 328CI/ E39 535/ E39 520/ E36 M3/ E36 318iS jet black Mtech/ E46 320d/ E36 318iS diamond black/ E36 318iS blue Mtech kit