how is the pcv valve?
If your getting that much oil through to a catch can then your sucking oil from the valve cover I would think. Catch cans can also catch residual water in engine also. How is your catch can conected. Valve guide seals could be another cheaper fix if oil is seaping into chambers. Bottom line would be to do a compression check also. Check and make sure your compression isn't under spec too far between cylinders.
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