Installing Catch Cans on N63 & S63 Engines

[Sophisticated Redneck]

Below is a write-up on installing catch-cans & eliminating most of the CCV tubing that is prone to failure. There are several advantages to this setup as it not only will capture much of the oil that bypasses the stock air/oil separators greatly reducing carbon buildup on the intake valves and ports, but also increases the crankcase vacuum under idle and part-throttle conditions, helping with piston oil ring control and reducing oil leaking past the valve guides. I have over 30,000 miles on this setup so far and it is incredible how much oil it captures that otherwise would have been injected back into the intake stream to become carbon deposits (plus oil in the intake decreases octane)

Please note you will not be able to use the stock engine cover anymore (you shouldn't have that piece of heat trapping crap on anyway) and you need to bend the stock metal frame that attaches the air filters as you can see in the pictures below to make room for the connections so do not proceed unless you are ok with this.

The parts list is as follow for setting up with -AN connections and braided line, it can also be done much cheaper with just regular fuel line and hose clamps.

Vacuum control valves are used in this setup that serves two purposes: Controlling the amount of crankcase vacuum (they are adjustable) and serving as a one-way check valve for boost pressure. This allows complete elimination of the original cheap stock plastic CCV tubing check valves are prone to failure.

(2) Catch Cans: https://www.amazon.com/gp/product/B07F12W7BX

(2) Vacuum control valves: https://www.amazon.com/gp/product/B0081TJQ52

(1) 8AN braided line kit: https://www.amazon.com/gp/product/B077GSGDC5

(1) 6AN braided line kit: https://www.amazon.com/gp/product/B07CZWDLLN

(8) 8AN to 3/8"NPT adapters: https://www.amazon.com/gp/product/B07DQQJQ38

(2) 6AN to 1/8"NPT adapters: https://www.amazon.com/gp/product/B06XRZD92P

[Sophisticated Redneck]

The first step is to modify each CCV connection on the valve covers by cutting away most of the old tubing and installing the 8AN to 3/8"NPT fitting. The size is perfect for the fitting and you can screw the fitting right in with a little effort (taping is not necessary but will make it easier to install)

[Sophisticated Redneck]

Next assemble both sides of the braided lines for the CCV Valve cover connection. IF you wish to mount your catch cans in the same location as mine in the pictures, cut the lines to the following length

Drivers side - 29" braided line, 8AN straight, 8AN straight

Passenger side - 16" braided line, 8AN 45 degree, 8AN straight

[Sophisticated Redneck]

Next assemble the intake manifold CCV lines, you can see in the pictures where to cut behind the square flapper valves to install the 8AN to 3/8NPT adapter. Assemble the lines as follows:

Drivers side - 16" length, 45 degree 8AN connector, 90 degree 8AN connector

Passenger side - 9" Length, 45 degree 8AN connector, 90 fegree 8AN connector

[Sophisticated Redneck]

Now assemble the -6AN to 1/8"NPT adapter that will fit on to the lower Intake CCV tubes on each side of the engine. I recommend purchasing a 1/8" NPT drill and tap kit off amazon as this connection is critical and will be under pressure during boost and you want the 6AN adapter to fit very securely.

[Sophisticated Redneck]

Next assemble the braided lines for both side of the lower intake CCV connections

Drivers side - 24" length, 6AN Straight, 6AN 90 degree

Passenger side - 19" length, 6AN Straight, 6AN 90 degree

[Sophisticated Redneck]

Now assemble the vacuum control valves. Drill and tap the valve with 1/8" NPT and install the 6AN to 1/8" adapter.

I cut the spring about and 1/8inch shorter to allow more adjustment. Turing the body in will increase spring pressure on the check valve and decrease crank case vacuum, loosening it will increase crank case vacuum.

If you run much more then -10 psi crankcase vacuum, air will start to be pulled past the main seals from the crank case vacuum and make a screeching noise similar to a slipping belt. If you hear this then screw in the vacuum control valve body to increase spring pressure on the check valve and decrease crank case vacuum.

[Sophisticated Redneck]

Now assemble the catch cans with two 8AN to 3/8" NPT adapters and the Vacuum valves. You may wish to paint the vacuum valves before doing this.

[Sophisticated Redneck]

Next install the CCV valve cover adapters and braided lines on the engine

[Sophisticated Redneck]

Now install the air cleaners (N63) and install the Intake braided lines into the upper intake manifolds

[Sophisticated Redneck]

Now connect the braided lines to the lower intake CCV adapters and snap in to the stock lower intake CCV lines. I also have adapters installed that allows for pressure sensors to be connected for dual boost gauges in this picture.

[Sophisticated Redneck]

Now finally route the lines on the passenger side as shown and connect to the catch can

[Sophisticated Redneck]

And the final step is to do the same for the drivers side. Make sure to empty the catch-cans and soak the bronze filters in carburetor cleaner every oil change(every 5 to 7K miles) or they will become clogged and greatly reduce the systems effectiveness.

[lagniappe_718]

Fantastic write up. thanks for the amazon links. probably going to tackle this soon.

[Dawgz]

This is amazing. Thanks so much!!!!

[Dawgz]

Btw stupid question...how did you take off the ccv from the valve cover? I unbolted the two bolts and tried to take it off and it would not budge. I see there are two tiny tabs in the pics you posted...is there a trick to get this out?

[Dawgz]

Last question for now, do you absolutely need the vacuum control valves? This isn't much different from the stock setup other than condensing the vent onto the baffles to collect the droplets. Right?

[frankenm]

Damn that is a wonderful idea for the NPT adapters fitting right in can't believe I never thought of doing this....

- This should be the 1st priority for anyone with the S63/N63 turbo engines if you plan on doing ANYTHING to your car -

I did this a while back and had a significant improvement in highway MPG ( 20+ MPG ) in my x5m, I made a thread but not many seemed to believe me

[Sophisticated Redneck]

Originally Posted by Dawgz

Btw stupid question...how did you take off the ccv from the valve cover? I unbolted the two bolts and tried to take it off and it would not budge. I see there are two tiny tabs in the pics you posted...is there a trick to get this out?

They are kinda stuck on the first time you remove them, there is another gasket underneath that gets kinda melted in. Just work at with a large screwdriver but be careful not to Mar any mating surfaces and you will knock it loose

[Sophisticated Redneck]

Originally Posted by Dawgz

Last question for now, do you absolutely need the vacuum control valves? This isn't much different from the stock setup other than condensing the vent onto the baffles to collect the droplets. Right?

Yes you absolutely have to, without it you will pressurize your crankcase as soon as you go into boost and this would be very bad as they also act as a checkvalve. What makes this work so well is the bronze micro filters. You will catch everything with them, it's amazing how much oil sneak past the stock baffles they are inside the valve covers. The stock baffles just suck.

You also apply much more crankcase vacuum, the stock check valve limits it to just -1 psi, with this system you can go to about -10psi. You will notice an improvement in throttle response and it will burn less oil

[Sophisticated Redneck]

Originally Posted by frankenm

Damn that is a wonderful idea for the NPT adapters fitting right in can't believe I never thought of doing this....

- This should be the 1st priority for anyone with the S63/N63 turbo engines if you plan on doing ANYTHING to your car -

I did this a while back and had a significant improvement in highway MPG ( 20+ MPG ) in my x5m, I made a thread but not many seemed to believe me

Thanks! Ya I also noticed an improvement in throttle response too. I am building an electric vacuum assist pump add-on to it to turn on during boost, will post up results once I finish jt

[0-60Motorsports]

That is an awesome DIY. Thank you so much for posting it. If i wanted to get the Fuel line hoses what size and length shall i get? Thank you