The existing head cover is having external oil and blow by separation unit, which is not only costlier but also complex and leads to increase in overall height of engine which was difficult to integrate in new variants of vehicles.A new head cover has been designed with internal baffle type oil and blow by separation system to ensure efficient separation and proper packaging of the system in new variants. The new system has been finalized after 26 DOE’s of different wire mesh sizes and different baffle plate size and positions. The final system has two bowl shaped separation unit with wire mesh, two cup type oil separation passages and one baffle plate for separating blow by. The system works on condensation and gravity method. The blow by is guided through a well-defined passage integrated in aluminum cylinder head cover itself. The passage angle is maintained to ensure minimum oil flow with blow by.The new seal has been designed with the head cover to ensure no oil leakage during engine running. The seal compression has been controlled by introducing a metal cup in bush and stopper assembly, which is used to ensure uniform compression of the seal. The metal cup controls the rubber bush compression which indirectly controls the compression of the seal.The complete head cover with advanced sealing system has been validated rigorously for durability, oil consumption, leakages, vibrations and oil carry over and thus it is proved a better solution over the existing design. Same methodology can be benchmarked for the other existing engine variants.