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

Last Page Update 05/21/2017

Rather than try to keep CCV progress updated on multiple BMW forums we have decided to post all progress updates here.

German Auto Solutions has finished development of a long term replacement solution to the infamous BMW M54 CCV (Crankcase Controlled Ventilation) system. This system is notorious for a variety of failures, the most common of which is oil sludge induced clogging.

A clogged CCV will cause excessive oil consumption resulting in reduced spark plug, O2 sensor and catalytic convertor life. Excessive oil consumption can also result in reduce power and fuel economy due to retarded ignition timing, caused by carbon deposit induced pre-ignition. Complete clogging of the oil separator section can cause excess crankcase pressure and can even rupture the plastic valve cover. Failure of the CCV vacuum regulator could result in oil being sucked up from the oil pan into the intake manifold resulting in hydro-lock, a condition that can easily destroy an engine.

The stock CCV unit is located underneath the intake manifold and is very difficult to access for replacement. Replacing the CCV can be an entire day job and cost up to $320.00 depending on how much of the system you replace. The worst thing about replacing the stock CCV unit with another OEM unit, is that you will probably need to replace it again several more times during the life of your BMW. We have heard of BMW owners replacing their CCV as many as three times in three years.

The problem is a combination of the OEM design coupled with the location and non-serviceability of the CCV unit. As your BMW gets older it generates more blow by gasses which carry more oil through the CCV system. The oil that separates out of the blow by gasses in the CCV unit, tend to thicken into a thick gooey sludge (especially in cold weather) that clogs up the oil return path to, and through the dip stick tube and back to the oil pan. Once the system clogs, it's no longer able to remove oil from the blowby gases and keep the engine crankcase at the required constant vacuum level.

The lack of blowby gas evacuation promotes quicker engine oil contamination, and the lack of crankcase vacuum can reduce piston oil ring sealing which causes even more oil consumption.

The German Auto Solutions CCV system will be priced similar to a complete OEM system, be mounted on top of the stock oil filter housing and will replace the factory oil filter cap. Once installed, the bottom section of the unit remains in place and acts as a mounting platform for the oil separator and vacuum regulator. All that is required is the removal of three 6mm Allen screws to change your oil filter and service the CCV unit. The oil separator comes off as a separate unit and will be easy to inspect and clean during a routine oil change.

Since the oil separator sits directly on top of the oil filter and is bathed in engine oil, the entire CCV unit runs at engine temperature which will eliminate any of the freezing failures of the factory BMW unit. The G.A.S. CCV also eliminates all the failure prone factory plastic hoses with an aluminum manifold and replaces the factory rubber oil drain back hose with a higher quality hose that should last the life of the vehicle. The kit will also come with a long flexible brush to clean the inside of the drain back back hose and a complete set of spare o-ring seals. Our latest revision now includes a unique "secondary" oil recovery section that allows it to recover substantially more oil from the blowby gases then even a brand new BMW CCV. Like all German Auto Solutions products this CCV replacement system will be of the highest quality and manufactured 100% here in the USA.

All components of the G.A.S. CCV assembly will be serviceable and have replacement parts readily available. The pictures on the left show our revision-8 CAD models. This product has been almost three years in development, including wet and dry flow bench testing along with extensive in vehicle testing.

I have received many e-mails asking about the selling price of the our CCV replacement system. The initial price is going to be $379.00. We initially hoped to bring the kit to market at $299.00 but after adding up all the material and hardware costs, the machining time, and manual labor time, we have determined that $379.00 is the absolute lowest price that we are able to sell the complete kit for and still make some profit. Once anyone has seen the entire system with all of its components in person we think they will feel that the kit is an extremely good value for the price. Each customer will have to decide for them self what it is worth to eliminate all of the nagging problems and potential engine damage that come with the OEM CCV design.

The first ten CCVs kits will ship out as soon as we have completed another install into a local customer's car. We want to be very cautions to make sure that there are no final tweaks required to any of the kit components before we ship them all out, and we need to take more pictures for the DIY instruction page.

Updates Here

Update 04/30/2017

All of the machined parts for the new GAS CCV are finally finished (Finished Components) (Beginning Assembly) (Pretty new CCV's posing for a Photo Shoot) We are still waiting for a couple of the parts that make up our brush assembly to come in and we still need to stamp out the silicone vacuum diaphragms which we will complete this week. While assembling the CCVs I noticed that we have not yet machined the CCV mounting platform installation tools. There is very little to hold on to when installing the threaded CCV mounting platform into the stock oil filter housing so we will be including a custom tool to aid in that process. The tool design and machine programming are both finished so we should be able to knock out the tools this week as well.

Update 05/07/2017

The installation tools have been completed. (Install tool pic1) (Install tool pic2) (Install tool pic3). The installation tool is required for installation of the CCV filter housing mounting platform. The Mounting platform screws in just like, and in place of, the OEM oil filter cap. The internal section of the assembly screws in but the mounting platform section remains stationary. Since there is virtually no way to get a good hand grip on the internal threaded section to screw it in, the tool shown will be included in the kit. The tool has the same size hex as the OEM filter cap that it replaces, so if you have a socket for the filter cap you are all set.

The silicone diaphragms mentioned in the previous update are not yet completed. The temporary trim die we made to cut out the first batch of diaphragms failed after cutting four diaphragms. We will send out the other six to be waterjet cut so that we don't cause any more delays. We will make a real production trim die to cut them once they go into full production. I hope to have more updates in a couple of days.

Update 05/14/2017

The silicone diaphragms have all been completed and I started work on the instruction page using pictures from the M54 I have here on an engine stand. The only thing left is to perform a final test install into a local customer's car.

Update 05/21/2017

The last major hurdle has been crossed for the release of the first ten CCV Kit's. This week I installed a G.A.S. CCV System into a customers 330i which was the first install of the system on a M54 engine in a vehicle. (330i install pic) Our CCV system was designed around a M54 engine on an engine stand and the test vehicle that we have been using for real world road testing for the past 9 months is a 528i with a M52 engine. Since the engine stand M54 that was used for CCV design and fitment had all of the accessories and electronics in place, I did not expect any fitment issues when installing the system on to a M54 engine in a vehicle. I am happy to report that the install went off with out a hitch and did not require the removal of the intake manifold or the OEM CCV Body. I'm glad the install was on a 3.0L in a 3 series since that combination has the least amount of room to work in the engine bay. This means that 2.5L and 5 series installs should be easier.

Unless you are upgrading to the "Cold Weather" dipstick tube (recommended) or wish to completely remove the OEM CCV this is a pretty easy installation. Replacing the dip stick tube adds a little more work, and if you are a picky person like myself, and you want to remove the old CCV entirely, than removal of the intake manifold will be required. Let me clarify what it means to not completely remove the OEM CCV unit. If DOES NOT mean that any portion of the OEM CCV will remain connected or functioning in any way. What it does mean is that the OEM CCV connection tubes are removed and only the unconnected CCV body remains attached to the underside of the intake manifold. The old CCV body is obviously not visible and leaving it attached to the underside of the manifold is not detrimental in any way. Not removing the old CCV body just makes the installation of the G.A.S. CCV system easier and doable for people who may not feel comfortable removing the manifold.

So what's left? The only fitment issue that I found was that the alignment bolt that secures the position of the bottom mounting plate needs the ability to have a small adjustment range. Since the bottom of the G.A.S. CCV system is mounted to the oil filter housing, and the top of the CCV needs to line up with the ports attached to the valve cover. BMW manufacturing and assembly variables of all of the engine components can stack up to cause the CCV positioning to vary slightly from vehicle to vehicle. I knew this would be a possibility going in and a design update allowing a small adjustment range to the mount has already been been modeled. The new parts required for the update are simple and should be completed this week. Once the updated parts are finished and the pictures I took during the install have been added to the in progress instruction page I will start sending out the first ten kits.

I would like to apologize again for the agonizingly slow progress of bring this product to market. My reputation for designing quality products that fit, do everything I advertise them to do, and are installable by anyone with fairly good mechanical skills, is more important to me than getting a product out quicker in interest of more profits. German Auto Solutions does not do any advertising because our happy customers do that for us. I would never want to jeopardise that.

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German Auto Solutions M54 CCV Replacement System

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Price: $379.95