First let me say, thanks for following up so diligently. It's just that that makes these threads so informative in the long run. This is definitely getting interesting!

Second, some questions for clarification. You said that your car is CPO with 85,000 miles (with an extended BMW warranty (presumably to 6 year/100,000 miles). However, you said you bought the car from a non-BMW dealer. So how can that be a CPO? Are you the 3rd or 4th owner at this point? My point isn't to grill you, it's to understand how the work you had done wasn't covered under the CPO warranty.

Third, was the work done by a BMW dealer or an indy shop? The reason I ask is that they appear to have changed all the necessary parts out (even the cover at the back of intake manifold (must have been compromised during the leak I guess)), but as far as I know all those parts are just now 'new' and nothing has been done per se to address the actual problem. In other words, they fixed what broke, but didn't do anything to prevent it from happening again, as per the SIB write-up, which for your car (a 2003 4.4 made in 4/2003 with the M62 engine involves installing the heated wrap for the crankcase kit (P/N 11 61 0 390 846).

So IMHO you have 2 options. #1. Do nothing until the problem happens again and then take the SIB to the place that did the work and tell them you are not paying for squat this time and that you expect ALL the work to be done. or #2. Take the SIB to them now and ask them why that stuff wasn't done... and quite frankly it should be done under warranty.

Lastly, some of your part numbers were off by a digit. I fixed them below:

Parts / Part #'s for Oil Separator / Cyclone Valve Replacement

Cover: 11-61-7-508-541
Oil Separator: 11-15-1-705-237
Vent Hose: 11-15-7-556-837
Vent Hose: 11-15-7-556-838
Oil Return Hose: 11-15-1-438-302
Hose Clamp: 16-13-1-179-065
Oil Return Hose: 11-15-7-560-068
Hose Clamp: 16-13-1-379-229
Hose Clamp: 07-12-9-952-109

PS. I still don't know what the hell a 'cyclone valve' is?!