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Install a oil catch can on a ecotec V6
How-to install an oil catch can on an ecotec V6 (+ ramblings)
I’ve seen this question asked a time or two, since it’s something I’ve been meaning to do for some time (and suffering from modification withdrawals) I though it’s about time I start this little project.
The Problem:
The standard PVC system on a factory engine is designed to ensure that any crankcase gasses are recycled through the combustion process so as to reduce pollution as much as possible. The standard system does this very well however the standard PCV system has a couple of design flaws primarily being that it introduces oil into the intake manifold/combustion process (in the pic you can clearly see excessive amount of oil around the intake runners for the number 5&6 cylinders).
Let’s have a quick look at the standard PVC system on an ecotec engine, The PCV system starts with a 10mm diameter hose that is connected between the bottom of the throttle body and the LIM (lower intake manifold) where the fitting allows clean air from before the throttle body into the engine crankcase. The air is then sucked into the inlet manifold through the PCV valve taking any crankcase gasses (mainly combustion gasses that have leaked past the piston rings as well as any oil vapour) with it so that it is then processed through the combustion cycle again.
This all well and good on a brand new engine, however by the time the engine has done 100,000km’s + the net result is a large build-up of oil scum inside the throttle body and intake manifold. If you spend enough time on any Holden commodore forum you will see multiple threads about idle issues which can mostly be solved by cleaning out the throttle body, especially the passages for the IAC (idle air control) stepper motor.
The Solution:
Modify the factory PCV system so that the oil vapour is removed from the air by installing a catch can (sounds simple enough) however with any MAF based engine management system you cannot introduce any air into the intake system other than what is measured by the MAF sensor.
There are a few options for modifying the PCV system and fitting a catch can, however I’m trying to set up a system where the basic principle of the PCV system isn’t compromised (i.e. it’s not causing any extra pollution by venting crankcase gasses directly into the atmosphere and therefor being EPA friendly).
The first major problem with modifying the PCV system on an ecotec engine is the fact that the actual PCV valve is fitted internally between the upper and lower intake manifolds. This severely limits the options you have to achieve the goal of removing the oil vapour from the crankcase gasses without making modifications to the intake manifold.
With that in mind I have chosen to fit the catch can in between the TB and LIM and then block the PCV valve between the upper and lower halves of the intake manifold. This will result (I think) in a small vacuum been created in the crankcase (because there is now no clean air source going into the crankcase). I’ve thought about this a bit and I don’t see this as been a problem, If you have a look at a lot of race car engines you will note that they run these engines with the crankcase under a very high vacuum (because it reduces/eliminates windage inside the crankcase reducing parasitic losses inside the engine), to test this theory I will endeavour to test to see if indeed I do achieve a vacuum in the crankcase (although I’m not expecting to see any performance increase from it).
Fitting the actual catch can (the bit you’ve all been waiting to see):
Required parts:
1. Catch can
2. Hose (approx. 1m of 3/8” or 10mm)
3. Basic hand tools and battery drill.
4. A cold brew
I choose to use a catch can from Supercheap because it was on special and it had 2x 10mm hose fittings which are the same size as the fittings on the intake manifold/TB. I also used 3/8” fuel hose because it’s black ( I don’t like the look of the clear hose supplied with the catch can and it wasn’t long enough any way) and I’m going for the stealth look
Optional extras, if you want to ensure maximum oil vapour removal like I do you can fit some steel wool inside the catch can before the air outlet.
To achieve this I have removed the top of the catch can and using some 2 pot epoxy, glued a small steel tube inside one of the hose tail fittings, I’ve then fitted some steelo pad inside the top of the catch can so that any air been sucked out will have to go through the steelo pad. I’ve then re-assembled the catch can ready for installation on the car. (see pics below)
I’ve chosen to mount my catch can directly to my MACE cold air intake as it seems to be the easiest and most convenient place for me (if you choose to do this you will need to remove the intake filter to fit the screws holding the catch can on).
1.Measure and drill the holes to mount the catch can (in my installation I haven’t needed to use the bracket supplied with the catch can).
2.Remove the intake pipe from the TB so that you can remove the factory hose from between the TB and LIM.
3.It's time to fit the new hoses. I’ve fitted my new 3/8” hose making sure to fit the hose coming from the LIM to the hose tail on the catch can which has the extra pipe glued inside. Connect the 2nd hose from the catch can to the bottom of the TB.
I’ve then used a couple of cable ties to tidy up the install and re-fitted the intake pipe to the throttle body. Hopefully you will end up with something that looks like this:
Make sure all you fittings are tight, start the car and check for any vacuum leaks.
The catch can is now fully installed, now all that is left to do is to block the PCV valve inside the intake manifold (I have a few ideas and once I have completed it I will complete this how-to.
Update: PCV valve has been blocked. In this case I have simply removed the valve and squished it flat and then bent it over and re-inserted it in it's original position. Ideally I would have preferred to tap the PCV hole in the upper manifold and then used a grub screw and some thread sealant to seal the hole without having to actually permanently stuff the PCV valve.
Interestingly, under the PCV valve I found a black plastic restrictor. From this one can only assume that the original PCV system was too efficient and was letting to much oil into the upper intake manifold. The black restrictor blocks off a 20mm hole and leaves 2 small holes of approx 3mm diameter for the PCV to breather through.
I've done a few other minor chores while I had it apart, I cleaned our the TB, especially the IAC stepper motor passages, cleaned the MAF and cleaned up a leaking rocker cover gasket.
From first observations, the idle is smoother and throttle response has come back (cleaning the MAF). Now it's a wait and see how things go.
Cheers
disclaimer: I've made every effort to make this as simple as possible, However I take no responsibility for any injury to your person (or others), damage to your vehicle or the accuracy of any information given here in especially with regard to EPA and ADR regulations or anything else for that matter.
How-to install an oil catch can on an ecotec V6 (+ ramblings)
I’ve seen this question asked a time or two, since it’s something I’ve been meaning to do for some time (and suffering from modification withdrawals) I though it’s about time I start this little project.
The Problem:
The standard PVC system on a factory engine is designed to ensure that any crankcase gasses are recycled through the combustion process so as to reduce pollution as much as possible. The standard system does this very well however the standard PCV system has a couple of design flaws primarily being that it introduces oil into the intake manifold/combustion process (in the pic you can clearly see excessive amount of oil around the intake runners for the number 5&6 cylinders).
Let’s have a quick look at the standard PVC system on an ecotec engine, The PCV system starts with a 10mm diameter hose that is connected between the bottom of the throttle body and the LIM (lower intake manifold) where the fitting allows clean air from before the throttle body into the engine crankcase. The air is then sucked into the inlet manifold through the PCV valve taking any crankcase gasses (mainly combustion gasses that have leaked past the piston rings as well as any oil vapour) with it so that it is then processed through the combustion cycle again.
This all well and good on a brand new engine, however by the time the engine has done 100,000km’s + the net result is a large build-up of oil scum inside the throttle body and intake manifold. If you spend enough time on any Holden commodore forum you will see multiple threads about idle issues which can mostly be solved by cleaning out the throttle body, especially the passages for the IAC (idle air control) stepper motor.
The Solution:
Modify the factory PCV system so that the oil vapour is removed from the air by installing a catch can (sounds simple enough) however with any MAF based engine management system you cannot introduce any air into the intake system other than what is measured by the MAF sensor.
There are a few options for modifying the PCV system and fitting a catch can, however I’m trying to set up a system where the basic principle of the PCV system isn’t compromised (i.e. it’s not causing any extra pollution by venting crankcase gasses directly into the atmosphere and therefor being EPA friendly).
The first major problem with modifying the PCV system on an ecotec engine is the fact that the actual PCV valve is fitted internally between the upper and lower intake manifolds. This severely limits the options you have to achieve the goal of removing the oil vapour from the crankcase gasses without making modifications to the intake manifold.
With that in mind I have chosen to fit the catch can in between the TB and LIM and then block the PCV valve between the upper and lower halves of the intake manifold. This will result (I think) in a small vacuum been created in the crankcase (because there is now no clean air source going into the crankcase). I’ve thought about this a bit and I don’t see this as been a problem, If you have a look at a lot of race car engines you will note that they run these engines with the crankcase under a very high vacuum (because it reduces/eliminates windage inside the crankcase reducing parasitic losses inside the engine), to test this theory I will endeavour to test to see if indeed I do achieve a vacuum in the crankcase (although I’m not expecting to see any performance increase from it).
Fitting the actual catch can (the bit you’ve all been waiting to see):
Required parts:
1. Catch can
2. Hose (approx. 1m of 3/8” or 10mm)
3. Basic hand tools and battery drill.
4. A cold brew
I choose to use a catch can from Supercheap because it was on special and it had 2x 10mm hose fittings which are the same size as the fittings on the intake manifold/TB. I also used 3/8” fuel hose because it’s black ( I don’t like the look of the clear hose supplied with the catch can and it wasn’t long enough any way) and I’m going for the stealth look
Optional extras, if you want to ensure maximum oil vapour removal like I do you can fit some steel wool inside the catch can before the air outlet.
To achieve this I have removed the top of the catch can and using some 2 pot epoxy, glued a small steel tube inside one of the hose tail fittings, I’ve then fitted some steelo pad inside the top of the catch can so that any air been sucked out will have to go through the steelo pad. I’ve then re-assembled the catch can ready for installation on the car. (see pics below)
I’ve chosen to mount my catch can directly to my MACE cold air intake as it seems to be the easiest and most convenient place for me (if you choose to do this you will need to remove the intake filter to fit the screws holding the catch can on).
1.Measure and drill the holes to mount the catch can (in my installation I haven’t needed to use the bracket supplied with the catch can).
2.Remove the intake pipe from the TB so that you can remove the factory hose from between the TB and LIM.
3.It's time to fit the new hoses. I’ve fitted my new 3/8” hose making sure to fit the hose coming from the LIM to the hose tail on the catch can which has the extra pipe glued inside. Connect the 2nd hose from the catch can to the bottom of the TB.
I’ve then used a couple of cable ties to tidy up the install and re-fitted the intake pipe to the throttle body. Hopefully you will end up with something that looks like this:
Make sure all you fittings are tight, start the car and check for any vacuum leaks.
The catch can is now fully installed, now all that is left to do is to block the PCV valve inside the intake manifold (I have a few ideas and once I have completed it I will complete this how-to.
Update: PCV valve has been blocked. In this case I have simply removed the valve and squished it flat and then bent it over and re-inserted it in it's original position. Ideally I would have preferred to tap the PCV hole in the upper manifold and then used a grub screw and some thread sealant to seal the hole without having to actually permanently stuff the PCV valve.
Interestingly, under the PCV valve I found a black plastic restrictor. From this one can only assume that the original PCV system was too efficient and was letting to much oil into the upper intake manifold. The black restrictor blocks off a 20mm hole and leaves 2 small holes of approx 3mm diameter for the PCV to breather through.
I've done a few other minor chores while I had it apart, I cleaned our the TB, especially the IAC stepper motor passages, cleaned the MAF and cleaned up a leaking rocker cover gasket.
From first observations, the idle is smoother and throttle response has come back (cleaning the MAF). Now it's a wait and see how things go.
Cheers
disclaimer: I've made every effort to make this as simple as possible, However I take no responsibility for any injury to your person (or others), damage to your vehicle or the accuracy of any information given here in especially with regard to EPA and ADR regulations or anything else for that matter.
Attachments
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Ecotec catch can setup 011(1).jpg314 KB · Views: 8,225
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Ecotec catch can setup 002(1).jpg279.4 KB · Views: 6,317
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Ecotec catch can setup 006(1).jpg197.9 KB · Views: 5,333
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Ecotec catch can setup 009.jpg281.5 KB · Views: 16,303
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Ecotec catch can setup 008.jpg280.4 KB · Views: 19,063
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Ecotec catch can setup 010.jpg115.7 KB · Views: 15,644
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Ecotec PCV valve1 003.jpg162.6 KB · Views: 33,101
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Modified PCV valve 1 004.jpg155 KB · Views: 24,794
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Ecotec PCV restrictor 1 002.jpg157.3 KB · Views: 22,085
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