G.A.S. BMW M54 CCV Kit Installation DIY

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****** IMPORTANT - IMPORTANT - IMPORTANT - IMPORTANT - IMPORTANT ******

****** Read all three sections marked 'IMPORTANT' before you begin ******

This DIY guide is only recommend for people with a reasonable amount experience wrenching on cars and with access to professional quality tools. I HIGHLY recommend that you completely read through the entire instructions several times before you begin to familiarize yourself with procedure. If you don't feel comfortable with any part of these instructions please do not attempt this project on your own.

If you cannot have a computer nearby during this procedure, print off these PDF instructions. I highly recommend using a laptop computer at the vehicle location if available over using the printed PDF instructions. The ability to enlarge the pictures on a computer display will ensure that all the important detail information in the pictures will be visible.

DO NOT attempt to perform these instructions using a Smart Phone! The pictures contain important details that would be very difficult to view properly on the small display of a smart phone.

Make sure that you read each step fully from beginning to end before you perform any part of a step. Some steps may contain multiple procedures, and some steps contain information at the end of the step, that is crucial to completing the step properly.

****** IMPORTANT INFORMATION ABOUT THE REMOVAL OF THE INTAKE MANIFOLD ******

The German Auto Solutions CCV System can be installed with or without removing the intake manifold. This DIY guide provides instructions on installing the CCV System without the removal of the intake manifold. If you prefer to remove the intake manifold you will need to consult a shop manual or one of the many internet forums threads covering OEM CCV replacement.

There are two advantages to removing the intake manifold to physically remove the OEM CCV, neither of which I think justifies the additional amount of work involved. First, by removing the OEM CCV you will by removing an insignificant amount of weight (a couple of ounces) from your BMW, and second, you gain much easier access to the dip stick tube area for cleaning and removal of the dip stick tube and installation of the drain back hose.

If you follow these instructions and leave the OEM CCV screwed to the bottom of the intake manifold it will IN NO WAY remain connected to your new G.A.S. CCV or any other part of the engine. We chose to provide our instructions without manifold removal to make the procedure simpler for use by people with a wider variety of skill levels.

If you have the time and the skills and prefer to remove the intake manifold, go for it, I have no reason to discourage it.

****** IMPORTANT INFORMATION ABOUT THE OEM DIP STICK TUBE ******

There are two versions of the M54 dip stick tube, the one that came stock on the vehicle and the cold climate version. The original equipment dip stick tube has a 'tube within a tube' construction where the CCV drain back hose attaches. The cold climate version has a 'single tube' construction. BMW came out with the cold climate version of the dip stick tube to address the problem of the CCV drain back portion of the tube clogging up in cold weather.

If your original equipment dip stick tube isn't clogged it can be reused, although it is highly recommended that it is replaced with the cold climate version. Using the cold climate dip stick tube allows full use of the included drain back hose cleaning wand. The wand is designed to clean all the way thru the 90 degree bend in the dipstick tube and into the center chamber of the tube. When using the original equipment dip stick tube the cleaning wand will bottom out against the wall of the 'tube within a tube' and prevent the wand from cleaning the entire drain back path.

The BMW part number for the cold climate dip stick tube is 11437565437

The first section of these D.I.Y. instructions involves removing trim panels, air box and other necessary items required to install the German Auto Solutions CCV Kit. The vehicle shown here is a E46 330i. This initial procedure for other BMW models will vary.

Mouse over images in the instructions to view full size

 

This is what comes in the German Auto Solutions CCV System Kit.

Make sure that you have everything pictured here before you begin.

 

These are the three major components of the G.A.S. CCV System Kit.

Clockwise from upper left are: Vacuum Regulator, Oil Separator, and Mounting Base Assembly.

#1

This is the starting point on an E46 330i.

#2

Start by unhooking the clips that hold the air box cover in place then remove the cover.

#3

Unhook the connector to the Mass Air Flow sensor.

#4

Pull the hose and 90 degree fitting from the rubber intake boot as shown.

#5

Loosen the hose clamp and separate the Mass Air Flow sensor and rubber boot.

#6

Remove the plastic cover that holds the wiring loom and hose from the front of the cabin air filter housing and drop the wiring loom and hose out of the way.

#7

Pull up to remove the rubber weather strip surrounding the cabin air filter housing.

Twist to release the three captive fasteners holding the metal trim panel then lift it out.

#8

Trim panel removed.

#9

Slide out the cabin air filter element then remove the screws holding the cabin air filter housing in place.

#10

Remove the cabin air filter housing.

#11

Cabin air filter housing removed.

#12

Remove the trim caps over the two intake manifold trim cover screws then remove the screws.

#13

Lift off the intake manifold trim cover.

#14

Remove the torx screws securing the CCV air distribution manifold.

Make sure to use the proper torx bit as these are very tight and you don't want to strip the heads of the screws.

#15

Lift off the distribution manifold by pulling up on one end to get it started.

You will probably need to wiggle and rock the manifold to get it loose.

#16

Once the distribution manifold is free, squeeze the sides of the CCV hose connector and pull it free of the manifold.

Again, these are usually stuck pretty good and a lot of wiggling and rocking may be required to break it free.

#17

Using the same procedure removed the secondary CCV hose connector from the distribution manifold.

Set the distribution manifold aside for now.

#18

Remove the valve cover hose from the valve cover.

Once the connector is free, grab the entire plastic hose firmly then pull and twist until it separates itself from the CCV body which is mounted under the intake manifold. Discard the removed section of hose.

#19

Remove the bolts securing the air box.

#20

Remove the air box.

#21

Unplug the connector from the DISA valve (adjuster unit in BMW terminology) then remove the two bolts securing the DISA valve to the intake manifold.

 

Again, use care to prevent stripping the heads of these bolts.

#22

Remove the DISA valve from the intake manifold by pulling straight outward while rocking the DISA valve housing.

#23

Remove the bolt holding the dip stick tube bracket.

#24

This picture shows the dip stick tube mounted to an engine on an engine stand to better show the area that needs to be thoroughly cleaned. The next picture shows the same area with the dip stick removed.

CAUTION - Before removing the dip stick tube make every effort to clean all of the dirt and gunk around the base of the oil pan hole.

Most of what you miss cleaning off will fall down into the oil pan. Use aerosol brake clearer and brushes to clean the area as good as possible before pulling out the dipstick tube. Blow area with compressed air if available. Because of the limited ease of access to this area, this may be the hardest part of the CCV install.

#25

This picture shows the dip stick tube already removed so that you can see the area that needs to be cleaned with the engine in mounted in the vehicle.

You can see from this picture how any dirt around the base of the dip stick tube can fall directly into the oil pan as the dip stick tube is removed.

Once clean, pull the original CCV drain back hose off of the dip stick tube nipple then pull out the dipstick tube.

#26

 

Reach down and grab a hold of the old CCV drain back hose that you just disconnected from the dip stick tube and pull or break it free of the stock CCV unit and throw it away.

If plan on re-using the original dip stick tube, make sure that the area between the inner and outer tube is thoroughly clean. Spray brake cleaner down the drain back nipple and it should easily pass all the way through and out the bottom of the tube.

For the reasons stated at the beginning of these instructions, it is highly recommended that you replace your original dip stick tube withe the "Cold Climate" version.

#27

Reinstall the new or modified dip stick tube using a new o-ring wetted with oil.

Reinstall the dip stick tube bracket bolt.

#28

Find the 19.5 inch long rubber hose with pre-installed hose clamps, Push the hose down from between the power steering reservoir and oil filter housing in the most direct path to the dip stick tube nipple as possible and push the end of the hose over the nipple on the dipstick tube.

Position the hose so that the two wings of the hose clamp are facing away from the engine. You will need to be able to grab them with a pair of pliers.

You can somewhat see the hose routing in this picture. The next picture show the routing in more detail.

 

#29

Here is a better picture of the hose shown on an engine mounted on an engine stand.

#30

Pinch the wings on the hose clamp with a pair of pliers (channel-lock style works best) then slide it down over the tube nipple and release.

Depending on BMW model this may be a very cramped area to work in.

#31

Find the hex spacer with 8mm stud from the kit.

Remove the M6 x 30mm cap screw, flat washer and bushing from the hex spacer and set them aside for now.

#32

Remove the front bolt holding the power steering reservoir and replace it with the spacer and stud as shown.

Screw the spacer in just until it contacts the reservoir mounting bracket then loosen the rear mounting bolt a little.

While pulling the reservoir away from the oil filter housing, snug, then tighten the rear mounting screw and hex spacer. The object is to use any slop in the reservoir mounting bracket holes to gain a little more room for the CCV.

#33

Wet a rag of shop towel with brake cleaner or other solvent and thoroughly clean the inside of the valve cover port.

The G.A.S. CCV manifold will seal with an o-ring on the inside of this port so it's important that it's clean.

#34

Before removing the oil filter cap you will need to file a little material off of the lip on the intake manifold.

If you look straight down at the oil filter cap from directly above the cap, the lip on the manifold needs to match the outer rim of the filter cap.

In other words, if you pulled exactly straight up on the filter cap, it should be able to pass by the lip of the intake manifold without touching it.

#35

Remove the oil filter cap using a 36mm socket.

Dispose of the used filter.

#36

Firmly grasp the filter cage with one hand and the filter cap with the other then twist and pull to separate the cage from the cap.

Nothing will break here, the cage just snaps into the filter cap.

#37

Install a new oil filter element onto the filter cage.

In this case the customer had just changed his oil and filter so the old filter was reused.

Set the filter and cage aside and temporarily set the oil filter cap back onto the oil filter housing to prevent any dirt, etc from falling in.

#38

Prepare the G.A.S. CCV mounting base for installation by thoroughly coating the threads and bottom o-ring (the one next to the threads) with clean motor oil.

#39

Remove the old oil filter cap again then wipe the inside of the oil filter housing above the threads clean. Wipe a little clean motor oil around the just cleaned surface then set the mounting base assembly in place as shown.

You will need to tilt and maneuver the base into place. It's a tight fit.

Make sure that the CCV mounting base is sitting square and flat on top of the oil filter housing and that it is not rubbing against the intake manifold lip. If the base won't sit flat without rubbing you will need to put the oil filter cap back on then file off a little more material from the intake manifold lip where it's rubbing.

#40

Set the custom install tool into the top of the G.A.S. CCV mounting base assembly.

#41

First by hand, then using a 36mm socket and ratchet, slowly screw the mounting base into place. Use caution for the first few turns to make sure that you do not cross thread the base.

You will need to hold the upper base portion in the orientation shown and keep it from rotating while screwing the assembly into place.

Screw the base in until it is fully seated then tighten just snug with the 36mm socket and ratchet. The mounting base should still be able to swivel back and forth a little, if it won't, back off slightly on the base tightness.

Leave the custom tool in place for the next few steps to keep any dirt from falling into the oil filter housing.

#42

Find the distribution manifold and replace the six o-rings with the supplied new ones.

Thoroughly clean the inside of the larger of the two connecting ports. The G.A.S. CCV manifold will seal with an o-ring to the inside of the port.

Wet the six new o-rings with clean motor oil.

#43

Wipe a little clean motor oil over the barb on the smaller of the two main ports. Push the supplied port plug over the port as shown.

Make sure you push the plug on all the way on until it stops.

The end of the hose should go past the ridge on the port.

#44

Find the G.A.S. CCV manifold. Remove the two screws holding the manifold extension then remove the extension and set it aside for now.

Wet the o-ring and the inside of the distribution manifold port with clean motor oil.

Slide the G.A.S. manifold into the distribution manifold as shown.

#45

Tilt the two manifolds as shown and slide the lip on the G.A.S. manifold underneath the fuel rail.

#46

Rotate the manifolds down then seat the distribution manifold down into the six holes in the intake manifold.

Firmly seat the manifold into place then reinstall the mounting screws.

#47

Find the manifold extension and short fitting shown.

Wet both o-rings on the fitting with clean motor oil then slide the fitting into the manifold from the "big hole" side.

#48

Fitting installed into manifold.

#49

Slide the manifold extension over the valve cover port and next to the main manifold as shown.

Push the manifold all the way in until it sits flush with the front face of the other manifold.

Install the two M4 x 16mm flat head screws to secure the two manifolds together.

#50

Remove the custom install tool then insert the oil filter and filter cage into the oil filter housing as shown.

Press the filter cage down until it's fully seated.

#51

Find the G.A.S. CCV oil separator.

Make sure that the all of the surfaces on the CCV mounting base and both o-rings are completely clean.

Wipe with a lint free cloth or your hand.

Lube the outside of the mounting base o-ring (not the small oval one) and the inner lip of the oil separator with clean engine oil.

#52

Set the oil separator onto the CCV mounting base as shown.

Press down squarely and firmly until the oil separator pops over the o-ring and is fully seated against the mounting base.

#53

Find the G.A.S. CCV Vacuum Regulator.

Slip the two nipples into the manifold assembly, then carefully seat the vacuum regulator down onto the oil separator by pushing it toward the manifold and down.

The center steel dowel pin will locate the vacuum separator in position for installing the three M6 x 80mm socket head cap screws.

If the vacuum regulator seems too high to sit down over the dowel pin, double check to make sure that the oil separator is fully seated onto the mounting base.

#54

Check that the double stacked x-rings on the vacuum regulator nipples are compressed fairly equally.

If one set does not seem to be compressed at all, rotate the vacuum regulator slightly as necessary to correct the problem.

Now rotate the oil separator and mounting base as necessary to align both of them with the vacuum regulator.

Once everything is aligned, drop in the three M6 x 80mm cap screws and washers. Screw them in a few turns by hand. If they don't want to drop in and start, something is not aligned correctly.

#55

Tighten the three 80mm screws until they contact the vacuum regulator body. Now tighten them in a rotational pattern until they are all snug. You do not need to over tighten these. As the assembly heats up and expands the screws get tighter.

Find the M6 x 30mm cap screw, washer, and bushing that were previously removed from the the hex spacer.

#56

Drop the spacer into the hole on the mounting base as shown.

Look down the bushing to make sure that the threaded hole in the hex spacer is not partially covered.

The hole doesn't need to be centered, it just can't be covered enough to prevent the screw from starting.

#57

Drop the M6 x 30mm cap screw into the bushing then tighten until snug. This permanently locks the alignment of the mounting base so that everything stays lined up for easy reassembly when servicing the CCV.

If you cannot start the bolt you may need to loosen the three M6 x 80mm cap screws and rotate the whole assembly a little until the threaded hole is exposed enough to start the screw.

#58

German Auto Solutions CCV System installation completed.

#59

Reinstall the the air box and any other components connectors and trim pieces that were previously removed.

Make sure all the tool have been removed from the engine bay and start the engine.

Listen for normal idle RPM and visually check for oil leaks around the base of the oil separator. Stop the engine and find the cause of anything abnormal.

Remove the oil filler cap then cover the valve cover hole with your hand. You should feel a little resistance and a small inrush of air when you lift your have off of the valve cover.