G.A.S. BMW M54 CCV Kit Oil Change Procedure

WARNING—THE G.A.S. M54 CCV IS A PRECISION DEVICE THAT CAN BE DAMAGED IF NOT HANDLED AND SERVICED PROPERLY. FAILURE TO FOLLOW THESE INSTRUCTIONS CAREFULLY COULD RESULT IN DAMAGE TO YOUR CCV AND ENGINE.

WARNING– NEVER START ENGINE WITHOUT THE COMPLETE CCV INSTALLED AND BOLTS TIGHTENED! YOU WILL MAKE A HUGE MESS AND DAMAGE YOUR ENGINE!

Run vehicle long enough to warm engine oil but not so hot that the CCV assembly is too hot to handle with bare hands. If engine is already hot, to avoid possible burns, DO NOT attempt to remove and service the CCV assembly if CCV is uncomfortable to touch. DO NOT drain the engine oil yet. It is best to drain the oil after the G.A.S. CCV has been serviced and the oil filter changed.

This guide walks you thru cleaning the CCV components. Cleaning of the CCV is not always necessary when changing engine oil and those steps can be skipped if cleaning is not needed. Always make sure that all mounting surfaces of the CCV components are cleaned even if you are not doing a full cleaning of the CCV.

#1

If the intake manifold trim cover has not been cut to allow access to the left-rear cap screw shown in the picture, remove the two screws holding the trim cover then remove cover.

DO NOT remove any of the eight phillips head screws holding the black cover in place. The cover should not be removed for routine oil changes and basic CCV service.

#2

Loosen then remove the three 6mm cap screws shown.

#3

To remove the CCV vacuum regulator, lift up on the right hand side of the regulator then side it to the right and away from the docking monifold.

#4

Set the vacuum regulator aside on a clean surface for later cleaning. Be careful not to bump the aluminum regulator against anything solid.

Dents and dings on any of the mating surfaces can prevent proper sealing of vacuum regulator to the oil separator and result in vacuum leaks.

#5

Lift up slightly on right hand side of oil separator to break the o-ring seal, then let it sit for a minute to allow oil in filter housing to drain back a little. To remove the oil separator lift straight up while putting a rag underneath the separator to prevent dribbling oil as you move the oil separator to a plastic oil drain pan for cleaning.

#6

Clean the oil filter side of oil separator with aerosol brake cleaner. A plastic drain pan helps to protect the oil separator from dents and scratches on sealing surfaces. Blow dry with compressed air if available.

#7

Clean vacuum regulator side of oil separator in the same way. It is not necessary to remove the brass check valve and sleeve for routine oil changes. Just spray area above and below brass check valve to rinse out dirty oil and debris. The sleeve is held in place by the friction of an o-ring. The sleeve can be pulled straight out for cleaning if necessary. DO NOT PRY on any machined surface to remove sleeve.

If you remove sleeve and check valve for cleaning they MUST BE reinstalled before assembling the CCV.

TO PREVENT ENGINE DAMAGE CHECK VALVE & SLEEVE MUST ALWAYS BE IN PLACE WHEN INSTALLED ON THE ENGINE!!!!!

#8a

Temporally set cleaned oil separator aside on a clean dry surface.

Again make sure that drain sleeve and brass check valve get reinstalled correctly if removed!

#8b

Just a view of the cleaned "oil filter" side of the separator.

#9

With vacuum regulator positioned with fittings pointing downward, spray the bottom of the regulator and the passages shown with brake cleaner. Try not to spray into vacuum the chamber.

Spray with cleaner until passages are rinsed clean. When finished, wipe clean the bottom of vacuum regulator with clean soft cloth.

#10

With bottom of regulator pointing downward, spray clean the docking port passages shown with brake cleaner. You will be rinsing some dirty oil back into the area you just cleaned so you may want to give another spray or two again from the other direction.

Blow regulator dry with compressed air if available then wipe the bottom surface of regulator again with clean soft cloth.

#11

Grab the used oil filter by the center of the filter cage then wiggle and pull up to remove the filter from the filter housing. It's OK to carefully grab the filter cage with needle nose pliers if it’s too slippery to hold on to.

#12

Push the filter cage from used oil filter then discard the filter.

Wipe or spray clean the filter cage.

#13

If you are replacing the o-rings do so now. DO NOT use any sharp object to remove the o-ring and x-ring to prevent damaging the sealing surfaces. Usually a finger nail will do. The o-ring and x-ring shown should be replaced about once a year or every 2-3 oil changes. Two spares of each come with your CCV kit.

Spray brake cleaner down the drain back hose to rinse clean the oil drain back pathway. Blow with compressed air if available. This is why you do not want to drain the oil until after the CCV is serviced.

#14

Before reinstalling the oil separator make sure that the CCV mounting surface,  o-ring and x-ring are clean and free of any lint, dirt or dust.

#15

Wipe clean the inside of the docking manifold ports shown.

Insert the filter cage into a new oil filter then reinstall the filter and cage into the oil filter housing.

#16

Press down firmly on the filter cage to fully seat the filter. Wipe a film of clean engine oil onto the outside surface of the o-ring before reinstalling oil separator.

#17

Reinstall the oil separator onto the CCV mount with the left rear corner of the separator tilted downward, and the right front resting up on the o-ring as shown. This makes the separator easier to seat into place in the next step, especially after installing a new o-ring.

#18

Press down firmly on the high side of the separator until it is fully seated to its mount. Make sure the oil separator is seated properly before reinstalling vacuum regulator. Check for any gaps between the oil separator & mount.

#19

Tilt the port side of the vacuum regulator downward while sliding the regulator into the docking manifold ports.

Push the regulator in to compress the x-rings until the regulator seats itself over the center dowel pin.

#20

The center dowel will hold the regulator in position until you reinstall the three 6mm cap screws. The screws just need to be snug. DO NOT over tighten them. As the CCV heats up and expands during operation the screw tension increases.

Now that the oil filter has been replaced and the CCV assembly has been reinstalled, go ahead and drain the engine oil. You want to drain the oil last so that any gunk that was washed down the oil drain back hose and into the oil pan gets drained out with the used engine oil. Make sure to check the engine oil level after refilling the crankcase with new oil of the proper viscosity.

After the crankcase has been filled to the proper level with new oil, wipe clean the outside of the CCV assembly or spray clean with brake cleaner. You want the CCV clean enough to be able to see any possible oil leaks after starting the engine.

Start the engine and check for any oil leaks around the base of the CCV where the oil separator seats against the mounting base. There should not be ANY leakage. If you see ANY sign of oil leakage stop the engine and disassemble the CCV to find the source of the leak. The only place that the CCV can leak engine oil is from around the o-ring on the CCV mounting base that seals against the bottom of the oil separator. Check the o-ring, the mounting base, and the oil separator for damage and correct as necessary. If everything looks fine, shut off the engine, wait a few minutes, then recheck and adjust the oil level. The oil change and CCV service are now complete.