G.A.S. BMW M54 CCV System Replacement Kit

These first three CAD images explain the functioning of the G.A.S. CCV's unique secondary oil separator. This secondary oil separator feature is only available in the GAS CCV system, the OEM BMW CCV dumps this extra oil directly into the intake manifold. This one feature alone provides an improvement over the OEM BMW design.

This CAD image shows the blowby gas flow thru the vacuum regulator and secondary oil separator when the engine is running. Oil gets separated out when the blowby gas velocity drastically increases when passing thru the vacuum regulator valve. Separated oil collects in the reservoir above the check valve.

This CAD image shows what happens once the engine is shut off. When the engine stops, the pressure differential across the secondary oil separator check valve drops to zero, allowing the check valve to open. All the oil captured in the reservoir then flows into the primary oil separator and then back to the engines oil pan. The reservoir will hold enough oil to support an entire fuel tanks worth of driving without shutting off the engine, a situation that could happen on long highway trips.

This CAD image highlights just a few of the many features that have been incorporated into the final revision of the German Auto Solutions CCV system. Every detail of the German Auto Solutions CCV replacement system is the result of extensive flow bench and real world testing.

The OEM BMW vacuum regulator design has a high failure rate due to several poor design choices. 1) All of the OEM silicone diaphragm's flexing happens at a narrow band around the perimeter of the diaphragm which leads to premature fatiguing of the material. 2) That same narrow band of material is exposed directly to the pressure differential between the vacuum chamber and the outside atmosphere. That pressure differential is constantly trying to tear the diaphragm apart. 3) That same narrow band is also exposed to combustion gases, fuel and water vapors, and condensation which degrade the diaphragm material over time.

The GAS vacuum diaphragm address all of these issues. 1) The GAS CCV vacuum diaphragm is more like a soft version of a trampoline. The flexing and stretching of the material takes place over the entire area of the diaphragm which eliminates the concentration of stresses seen in the narrow band of the OEM diaphragm. 2) The GAS CCV vacuum diaphragm is totally supported by a rigid aluminum support that takes 100% of the the pressure load. There is no way for the diaphragm to be torn by vacuum pressure. 3) Since the GAS CCV vacuum diaphragm is 100% covered by the aluminum diaphragm support there is no exposure of the silicone material to the degrading effects of the combustion gases, fuel and water vapors, and condensation.

The GAS CCV Vacuum Regulator is so well designed that we actually tested it without the silicone diaphragm membrane just to see what would happen if the diaphragm did actually have a catastrophic failure. The regulator actually performed properly even without the silicone diaphragm. Try that with an OEM BMW CCV!

This image explains some of the G.A.S. CCV primary oil separator's features and blowby gas flow.

The blue arrows show the Primary Oil Separator's oil separation passage. This sharp cornered zigzag path is better at separating oil from the blowby gases than the OEM CCV's spiral path. This zigzag path is also better at holding the gooey emulsified oil mayonnaise in place until the heat from the oil separator can evaporate off the water content and turn the mayo back into engine oil. (See actual pictures of this further down this page)

More primary oil separator feature explanation plus more detail of the secondary oil separator check valve and how it easily drops out for cleaning when necessary.

Here we show the bottom of the German Auto Solutions Vacuum Regulator. The regulator is fully cleanable and serviceable. The picture highlights the special QUAD SEAL vacuum sealing rings used. This type of seal is especially effective in low pressure applications like this with the added benefit of staying in place when the vacuum regulator is removed. These high quality seals should last for many years, but if needed, they are easily replaceable and one set of spares is included in the kit.

This picture details the gas flow thru the Vacuum Regulator from the bottom view perspective.

This picture details the gas flow thru the Vacuum Regulator from the top view perspective.

A description of some of the Vacuum Regulator's key features.

Here is a view of the Vacuum Regulator valve, diaphragm and diaphragm support. In the G.A.S. design the silicone diaphragm is completely sheilded from the dirty blowby gases. In the OEM BMW CCV the flexing portion of the diaphragm is fully exposed to blowby gases which is one of the reasons the OEM diaphragm can fail.

The shape of the diaphragm support went thru several revisions before we settled on this shape which concentrates flow toward the center of the Vacuum Regulator chamber. Keeping the flow in the center of the chamber prevents the gases from dragging oil up the side walls of the regulator chamber.

This picture shows the bottom of the primary oil separator. This is the portion that is bathed in oil and also supports the oil filter element. Keeping the German Auto Solutions CCV running at close to engine oil temperature may be the most important feature that separates our design from all BMW external CCV designs and results in much greater efficiency and reliability.

This picture shows the main CCV mount that replaces the OEM oil filter cap and serves as a mounting platform for the rest of the CCV.

Here you can see the main parts mounted together. This is the way you will receive it if you order one, with the exception that the top cover and regulator diaphragm assembly will be installed.

I imagine this will surprise you as much as it surprised me. This is the result of 10 minutes of driving on an eighteen degree day then removing the vacuum regulator for inspection of the oil separator. After ten minutes of driving in cold weather the CCV is warm but not hot to the touch.

The goo you see is the normal emulsified oil that results from water that condensates inside a cold engine then mixes with aerated engine oil. During testing I have seen twice as much goo as seen here after very short trips in very cold weather.

Here is a closer look at the goo on the bottom side of the vacuum regulator.

Heres a closer look at the goo in primary oil separator passage.

Here is the cool part.

This is the same day and time as above but the system was reassembled and driven another 20 minutes to bring the CCV fully up to temperature then disassembled again for inspection. All the goo is gone!

Here is a closer look at the vacuum regulator. The increased temperature that results from the primary oil separator being heated by engine oil allows the water content of the emulsified goo to evaporates off and return the goo back to just oil.

Notice that the goo is completely gone. A stock BMW CCV will never get hot enough in very cold whether to de-emulsify the goo!

Here is a closure look at the Primary Oil Separator after the additional drive time.

Notice again that the goo is completely gone. Also take note of the amount of oil that was captured and released by the secondary oil separator (round pocket at the top left). We have found that more oil is separated out of the blowby gases by the secondary oil separator than the primary. Remember, the stock BMW CCV does not even have a secondary oil separator.