Crack Manifold causing exhaust smoke fix

[ROH ECHT]

History: I began seeing smoke from the exhaust under high boost situations and oil usage began to increase. I ran compression tests and the numbers from cyl 1 to cyl 4 are 195psi, 191psi, 192psi, and 192psi so I believed that a common failure of a cracked valve cover was the issue. ←That is that there is a cowling adhered to the underside of the v-cover where the adhesive often separates allowing oil to enter the turbo inlet via the EVAP ducting along the red line. There is a bypass kit for this: http://www.performancebyie.com/evap-crossover-tube-relocation-kit-for-2-0t-fsi-with-integrated-engineering-valve-cover, but I did my own in order to bypass the problem area in the v-cover.

I put 5/8" and 1/2" rubber caps over both ports along the red line after disconnecting those two. Then added a 3/8" coupler to the rear hose. Then added a 3/8 hose that fit onto the front and the rear bypassing the valve cover altogether...smoke is gone and no need to replace the valve cover.


Here are some pics for the evap v-cover bypass I did (remember I had to trim the coupling features from the front evap hose to v-cover connection using dikes/wire-cutters):

Rear:


Front:


Overall:


Video: https://www.youtube.com/watch?v=JUP5Lh4tonA&feature=youtu.be

[Shaw]

How did you diagnose the issue in the first place? Is it a considerable leak?

[ROH ECHT]

It began to smoke under boost and the oil consumption increased from 0.5qt per 5k miles to 1qt per 2k miles. Also, there was a lot of soot deposits appearing on the hatch. I ran compression tests to eliminate the rings and valve guides. I then inquired on another forum and found others having an issue with what they called cracked valve covers. Then discovered that there was a molded duct adhered to the underside of the valve cover and the adhesive was separating allowing oil to enter through the crack and into the turbo inlet where the EVAP dumps into. I thought if I bypass the EVAP route and the smoke stops coming from the exhaust that I too have the same issue ("cracked valve cover"). Then there was no need to remove or replace the valve cover.

Watch my car's exhaust smoke @ 3:04:

t=168

compare exhaust to a year prior @ 7:10: