GrimmSpeed Air-Oil-Separator and Sludge

[kiwigene]

So I checked my oil filler inlet after installing a GrimmSpeed Ail-Oil-Separator a week ago and found this









I don't think this milky/cheesy sludge substance can be good going into the oil inlet (or is it bubbling up from the oil???)
It doesn't really smell and seems more watery rather than oily (evidence of clear-ish water-like substance too).

Timeline:

I've been running E85 for about 6 months. Changed my oil in February after running E85 for about a month.
Changed my TMIC a few months ago - only noticed a small amount of oily residue (normal black/brown colour) in my throttle body intake.
Checked oil level - everything looked ok, maybe a little blacker than usual and maybe a bit of extra usage, so topped it up.
I believe this is not unexpected when running E85.

June 28th installed the GS AOS. TMIC came off. Everything looked clean inside and the TBH was reasonably clean.
Breather pipes had the expected oily buildup - the reason to get an AOS... Oily residue was the usual blackish colour you'd expect of oil/grease.
Had it serviced last Monday (30th) - Subaru Upper Engine Cleaner and Super Injector Cleaner were used.
Dump pipe and silicon inlet pipe installed. Car has been feeling sluggish, but assume it just needs a tune since the dump/inlet install.

Yesterday noticed an air leak in a rubber plug used on the plastic crossover tube (part of the breather air return line to the manifold).
The plug was installed as part of the GS AOS install. Pics 7 and 8 in this .pdf http://www.grimmspeed.com/content/install_guides/subaru_aos_08wrxLGT.pdf.
I fixed the leak, but was late so stopped for the night. Then today I decided to check the oil filler inlet and discovered the cheesy mess.

Adam/Alexei have the same GS AOS - are you guys noticing this? In particular Alexei, as you run E85 too.
I was not expecting this after only one week! Or is it more likely caused by something happening during the service (UEC?) or the air leak???
What's doubly concerning is the substance looks like it might block the inlet(s) to the GS AOS and has migrated through to the air outlet side.
I don't fancy this cheese and water either in my oil or the air intake.
I had never seen any evidence of this stuff before - or is this just showing that the GS AOS is doing its job?

Any insights and advice gladly received.

[jslayz]

done any long trips since install?
Car needs to run up to full operating temp to get all the water to boil off.

[kiwigene]

My work-daily commute is 30 km each way. 50% urban and 50% highway (80 km/h or above).

But I've done a few short trips over the weekend - just a few kms, so probably not really up to operating temp. And the weather's been cold.

I guess not having the water/oil mixture going back through the intake and turbo is good.
But I'm just wondering now whether this sludge is ok going into the oil filler tube?

I guess I'll just check it each week for while to see what it looks like.

Was hoping this would a "maintenance free" AOS...

[bigBADbenny]

A theoretical alternative is to use the GS as a CC seperate from the oil filler.
Just mount the AOS on a stainless steel hiking water bottle with the appropriate sized neck and a rubber spacer and or clamp if required. Use a tube to direct the inlet/s to the bottom of the bottle and fill some of the bottle with stainless steel scourer media. Mount it under the snorkel on the radiator support.
Cold weather/e85 you're going to catch sludge imho.
I was planning to do this with twin SG AOS, but will be guinea pigging the KAP dual AOS instead.

[alexeiwoody]

Hey Gene,

I ran my AOS for 12 months now, and only last week saw the same thing. Last 12 months it was fine and had some very minor white stuff forming, winter or summer, nothing even worth mentioning.

Then my car recently spent a good 8 weeks off the road getting some work done (oil separator should have been clean right before), and in one week of driving - I notice all this crap, nearly as bad as yours.

Luckily it seems all the hoses are all clean, and the bottom of the oil filler tube (where it slides into the head) was clean, but basically the whole filler tube was collecting this gunk.

As a few people have already said - E85 has a big role to play in this, it gets into your oil and plenty of condensation will occur if you don't have fresh oil or if you leave it sitting around for ages like I did.

Out of curiosity - how old was your oil? And if it's just been changed - maybe check back in a week or so, you might have better results?

[kiwigene]

Yeah, it's probably a combination of E85 and the cold temps. If this is considered "normal" then I'm ok with it.
But it was just a shock to see it as I wasn't expecting anything like this.

Last Sunday installed AOS. Last Monday had service with fresh oil. Mechanic didn't mention anything.
(I'm only guessing but if he saw that cheesy mess I'm sure he would have mentioned it.)
I only checked yesterday - so it's a week of driving on new oil (with cold mornings).
But also would have had that air leak for the last week too. I'll be checking again properly next weekend - hoses and filler pipe.

I told the mechanic I'm running E85 and wanted to make sure they had an appropriate oil.
Was told they don't use "cheap stuff" and the main thing with E85 is regular changes (which I already knew).
Past services they have used Elf oil. I believe brand name changing means Elf = Total, now.
This time (according to my invoice/receipt) they use Total Quartz 7000 10W40, which on Googling I see is a semi-synthetic oil.
I can't find any info which says it is a suitable or a preferred oil for ethanol vehicles. Might have to make sure I provide my own oil next time...

[bigBADbenny]

Next oil change, put the used oil in a clear container to view, once separated, just how much water you're retaining, if any

[alexeiwoody]

I don't think it's the brand of oil guys, since I'm using arguably the best available and still getting it. Maybe I simply left the car sitting around too long, maybe it's the cold temps or a combination of everything..... I'll find out what my oil guys think...

In the meantime, contemplating going to 98 for a few months. Just looked under the cap and it's starting to get crap again