I have used RTV only.....I always do, but when this happened twice, I used the cork gaskets that come with the 1206 Fel Pro kit w/ RTV over them. Still blows out. I will check the egr valves as you suggested, but everything was fine until I changed intakes. Now, I'm wondering about the oil pan capacity. I bought this motor fully assembled, and was told by the previous owner that it was a 7 qt. pan, excluding the filter. Maybe he was wrong, and I over filled this thing. I need to find the mfg. of the oil pan, and confirm the capacity....I would imagine too much oil + high volume pump might = blown intake seals. Thanks.