cam cover keeps leaking oil into spark plug holes any help?

Hi, Steve,
Did you use any sealant (blue Hermetite, for example) on the gasket. It's very common for DIY folk to put too much on. You only want the slightest smear. If you put too much on, you may have a gap against a blob of sealant through which the oil's seeping. Worth also checking that the base of the cam cover is dead flat by smearing a light film of oil over the face running a straight edge (steel ruler or similar) over it to check that it clears all the oil. Another possibility is muck at the bottom of the bolt holes which means that, even though they appear tight, they're not fully home, hence leaving a gap under the cam cover. All you can do here really is take them out and have a poke around in the holes with a bit wire or something. Did you oil the bolts when you put them in? That can settle at the bottom of the hole and produce the same effect. Also, the hydraulic effect of tightening the bolts if there's too much oil on them can split the cam cover and even the cylinder head! All I do with my bolts is a very light smear of vaseline on the thread. Did you clean the threads of the bolts with a wire brush before you replaced them? Muck on them may mean again they appear tight when they're not. Going back to the sealant if you used it, did you leave it to set slightly before you finally tightened the bolts? You should put them in finger tight then torque them down properly after about 20 mins.
There's a few ideas for you. There's not any more that I can think of. Next step is a garage if these ideas don't work.
Best of luck, Steve.

Denis Langley (Car Aid Mobile Mechanic)
September 2008