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Revhead Kev Profile
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Date Registered: 10-2006
Location: Mona Vale, Sydney, AUSTRALIA
TOTAL POSTS: 6002
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Re: Oil Catch Cans


Dual Catch Can DIY

Before I start I must appologise for the dirty engine in the pics but it does help to highlight the new catch can and piping emoticon

The catch-can I purchased was the Saikou-Michi DC3.
This is a dual catch-can for protecting the PCV line as well as the breather line from reverse blow-by under heavy load conditions.

The best mounting position for an Xtrail with the standard air intake system is on the firewall cowling just above the ABS actuator.
Later, if a Cold Air Intake (CAI) is fitted, relocating the catch-can to the left fender next to the battery will give better performance due to the colder environment which helps the condensing action.

Firstly, if there is a strut bar fitted, remove it from the pillar supports by undoing the hex screws.

Second, because the firewall cowling is at an angle, any mounting bracket needs to be bent so that the catch-can will hang vertically.
With the bracket correctly shaped, mount it to the catch-can and hold the catch-can in position so that the fixing holes can be marked in the firewall cowling.
Image - holding catch-can in position to mark holes.

With the holes marked, drill the appropriate size for the mounting bolts to be used.

Thirdly, remove the left side of the top cowl cover by popping out the 3 push-in pin locks using a screwdriver to lift the centre piece before lifting the outer part to remove.
Image - top cowl cover marked to show push-in pin locations.
Image - closeup of pin showing screwdriver popping up centre section.
Image - closeup of pin showing screwdriver under outer part to remove.

Lift the top cowl cover from the centre join to pop out the 3 clips along the window side of the cover and rest the cover on the engine to swing it out of the way.
Image - top cover held inplace to show clips underneath.

Fourth, mount the catch-can using the bracket holes previously drilled in the firewall cowling.
Image - catch-can mounted showing nuts on other side of cowling.

Replace the top cowl cover by aligning the clips and pushing into place, then inserting the push-in pins.
The pins are inserted by pushing the outer section through the hole with the centre piece raised, then pushing the centre piece down to lock.

Fifth, disconnect the original hose for the PCV line and connect the new hoses to the catch-can.
There will be an IN hose connection on the catch-can which connects to the PCV outlet on the rocker cover (dirty side) and an OUT hose connection which connects to the manifold point (clean side).
Image - PCV line connected to IN on catch-can.
Image - manifold line connected to OUT on catch-can.

If you are only installing a single catch-can then your installation is now complete.

Sixth, disconnect the original hose for the breather line and connect the new hoses to the catch-can.
There will be an IN hose connection on the catch-can which connects to the inlet on the rocker cover (dirty side) and an OUT hose connection which connects to the air intake point (clean side).
For this I had to use the 90 degree bend section from the original breather with a joiner, otherwise the bend radius of the 5/8" tube would have resulted in a loop of tube which almost covered half of the engine bay.
Image - air intake line connected to OUT on catch-can.

This finishes the installation of the dual catch-can.
Lastly, refit the strut bar if removed.
Image - dual catch-can mounted and piped.


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Kev X450(c) T30 Guru
03 Titanium Ti T30 Series 1 **MODIFIED**
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19/Sep/2007, 10:49 pm Link to this post Send Email PM   Send Private Message Blog
 
jalalski Profile
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Date Registered: 02-2004
Location: SUTHERLAND, SYDNEY
TOTAL POSTS: 29094
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Re: Oil Catch Cans


Excellent write-up Kev. Thanks for that.

I'll be linking this post to the DIY Guides section shortly.

One question: How easy it is for you to check the oil level and remove the catch can for cleaning and do you have to go through all this to get it off?

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20/Sep/2007, 7:52 am Link to this post Send Private Message MSN Blog
 
Revhead Kev Profile
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Date Registered: 10-2006
Location: Mona Vale, Sydney, AUSTRALIA
TOTAL POSTS: 6002
Reply | QUOTE
Re: Oil Catch Cans


quote:

jalalski wrote:
One question: How easy it is for you to check the oil level and remove the catch can for cleaning and do you have to go through all this to get it off?



The Saikou-Michi catch can does not have the sight glass like others.
There is a very easy drain valve at the bottom with adapter to take a 3/8" tube.
I planned to have a tube permanently fitted to the drain valves, hanging down to let me drain the captured oil into a container without having to remove the catch can.
Most I will have to do is undo the two bolts for the strut bar so I can reach down to get at the drain valves.

If I do have to remove the catch can occasionally for a full washout, it will be as easy as undoing 4 cable clamps on the catch can and the mounting bracket screw which holds the top of the catch can to the mounting bracket and it is out.

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Kev X450(c) T30 Guru
03 Titanium Ti T30 Series 1 **MODIFIED**
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X-TRAIL HOLIC
 


Date Registered: 12-2004
Location: Mount Isa, QLD
TOTAL POSTS: 1247
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Re: Oil Catch Cans


Hi Kev,

Wow, looks like a decent setup.

I'd expect the dual catch systems to have been primarily designed for turbo engines? I wouldn't expect that we would experience much reverse blow by with a naturally aspired engine, but I guess it doesn't hurt to take full precautions.

Great job, well done, emoticon

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Noel...
Member ID: X-072 (Retired Administrator)
2003 X-trail, TI, Manual, (Series 1) - (with the works)
2013 Toyota Prado, Manual, Turbo Diesel - (Snorkel-K&N-Full Exhaust, 20" Low Profiles, Chrome Bullbar, HID Spots, + All the Bling!)
22/Sep/2007, 9:28 pm Link to this post Send Email PM   Send Private Message MSN Blog
 
Revhead Kev Profile
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Date Registered: 10-2006
Location: Mona Vale, Sydney, AUSTRALIA
TOTAL POSTS: 6002
Reply | QUOTE
Re: Oil Catch Cans


Thanks Noel.

Yes, dual catch cans were initially designed for turbo engines due to higher internal pressures forcing blow-by through the breather, but as referenced in an extract from the service manual in one of my previous posts here and Eddie's comments after, the QR25DE engine suffers from higher than normal blow-by through the breather so I thought it worthwhile.

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Kev X450(c) T30 Guru
03 Titanium Ti T30 Series 1 **MODIFIED**
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22/Sep/2007, 10:14 pm Link to this post Send Email PM   Send Private Message Blog
 
jalalski Profile
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Date Registered: 02-2004
Location: SUTHERLAND, SYDNEY
TOTAL POSTS: 29094
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Re: Oil Catch Cans


Kev,

I have completed the modification of my oil catch can today and found the perfect spot for it on the left fender, but realized that the hose supplied with the catch can is not long enough to make 2 section from it, so I need to buy new hoses.

Is the size of the PCV and intake manifold hoses the same?

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22/Sep/2007, 10:25 pm Link to this post Send Private Message MSN Blog
 
Revhead Kev Profile
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Date Registered: 10-2006
Location: Mona Vale, Sydney, AUSTRALIA
TOTAL POSTS: 6002
Reply | QUOTE
Re: Oil Catch Cans


Since you are only doing the catch can in the PCV line, you will need 3/8" hose both from the manifold and to the PCV valve.

How much do you need ?
I have some left-over 5/16" you could have if long enough.

---
Kev X450(c) T30 Guru
03 Titanium Ti T30 Series 1 **MODIFIED**
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22/Sep/2007, 10:38 pm Link to this post Send Email PM   Send Private Message Blog
 
jalalski Profile
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Date Registered: 02-2004
Location: SUTHERLAND, SYDNEY
TOTAL POSTS: 29094
Reply | QUOTE
Re: Oil Catch Cans


quote:

Revhead Kev wrote:

Since you are only doing the catch can in the PCV line, you will need 3/8" hose both from the manifold and to the PCV valve.



What do you mean by this?

I will need a hose going from the catch can to the PCV valve and another hose from the catch can to the front inlet of the intake manifold..is this correct?

quote:

How much do you need ?
I have some left-over 5/16" you could have if long enough.



I need two lengths from the left fender (where the catch can is going to be) to these 2 spots. I haven't measured it.



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22/Sep/2007, 10:57 pm Link to this post Send Private Message MSN Blog
 
Revhead Kev Profile
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Date Registered: 10-2006
Location: Mona Vale, Sydney, AUSTRALIA
TOTAL POSTS: 6002
Reply | QUOTE
Re: Oil Catch Cans


You are correct Jalal.
I'll check how long my spare piece is and let you know.

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Kev X450(c) T30 Guru
03 Titanium Ti T30 Series 1 **MODIFIED**
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22/Sep/2007, 11:04 pm Link to this post Send Email PM   Send Private Message Blog
 
jalalski Profile
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Date Registered: 02-2004
Location: SUTHERLAND, SYDNEY
TOTAL POSTS: 29094
Reply | QUOTE
Re: Oil Catch Cans


I finally got around modifying the D1-Spec catch can and fitting it today.

I needed new hoses, as the catch can outlets are 1/2" in size while the PCV and Intake are 3/8", so I ended buying both size hoses and using a step down adapter.

Got the hoses from Repco and they're the fuel line rated 30R7.

Never imagined that the hoses will cost me more than the catch can itself LOL emoticon

Anyway, it's in and will see what happens and what it will collect with time.

Image

Image

Image

Image

Last edited by jalalski, 11/Feb/2011, 9:12 pm


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23/Sep/2007, 12:43 pm Link to this post Send Private Message MSN Blog
 


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