How To: Oil Catch Can

[andy666]

Today I finaly finished installing an oil catch can on my D4D hilux, so I thought that I would do a basic write up to help any one else that might be interested. I won't go into too much detail, as I figure that if you have the ability to install something like this then you can easily figure out the basics.
I started with a basic Drift brand catch can that I picked up from autobarn for $80, but then decided to modify it quite a bit so that it would fit where I wanted it to. Depending on the brand and mounting location other catch cans may not need modifying
Understandably, a catch can like this won't be as effective at removing oil vapor as one with a filter in it, but it is a lot cheaper.


Parts:
Drift catch can
25x5mm flat steel
5x Hose clamps
1.5m 5/8 hose (oil resistant)
5/8 double tail fitting
2x 3/8 BSP to 5/8 tail fittings (Drift catch can does not come with 5/8 fitting)
1/4 BSP drain tap
8mm Bolt
Thread sealant
12mm O.D. alloy tubing (Bunnings) (optional)


1: (optional) Shorten the main body of the catch can by 30mm off the top and 15mm off the bottom. I just used a drop saw to do this and it worked ok.
You will then have to drill and tap new holes for the end caps to bolt on. Easiest if you extend the original holes by drilling and tapping before you cut the ends off.
You will also need to drill and tap new holes for the oil level tube fittings and the drain plug. I chose to move the drain point to the bottom plate and fit a 1/4 BSP drain tap.



2: Make a mounting Bracket


3: Use a die nut to cut the correct thread onto the 3/8 BSP fittings. The fittings for the Drift catch can needed to be 5/8 UNF.


4: (optional) Cut off a piece of the 12mm alloy tubing. Grind down one end of it so that it is a tight (hammer) fit inside the 3/8 fittings that will be used for the inlet. This is so that the incoming air from the crank case is directed at the wall of the catch can and helps the oil vapor condense, it also inproves the swirl action inside the catch can.



5: Assemble catch can ensuring all gaskets and threads are sealed


6: Mount catch can in vehicle, using the 8mm bolt

7: Romove the original crank case breather pipe. This is the pipe that runs from the right hand middle of the tappet cover down to the intake pipe just before the turbo.

8: Plumb inlet of catch can (fitting with the alloy tube) to the tappet cover outlet.
Plumb the outlet of the catch can to intake pipe. Need to use original rubber reducing hose and the 5/8 double tail fitting for this.

Job Done.

[Zippy]

Nice one andy666 some people have allso thrown some steelwool in the can
to help catch & condense the oil vapour aswell

[andy666]

yeah I considered the steel wool, but I'm a bit worries about any small pieces getting sucked into the intake.

I also considered a block of carbon as a filter medium.

[WinM70]

Looks good mate, very neat.



Lee.

[Wing]

Today I learnt from a Prado forum that installation of oil catch can is a more preferable way than blanking the EGR to prevent built up of carbon deposit because it will not cause fault code and not affect the more complex hilux turbo air flow schematics.

Is this the reason you install the can? I am going to do the same if it is the case???? Thank you in advance.

[StevenS]

Very neat

I've done the EGR blockoff but as stated it isn't an ideal solution, and it still doesn't stop the intake getting coated in oil residue.

Am seriously considering giving this a go

Your one looks like a 1L catch can, with the modifications it's probably fairly close to 0.5L now (still plenty for the Hilux), I've seen a few cheaper ones on ebay same design only 0.5L so they might fit without much modifications. Have you got the external dimensions of yours? Some of the ones I'm looking at are around 130mm high

[andy666]

Yeah, I fitted the can as an alternative to blocking off the egr. It may work, it may not. But it definatly can't hurt.

The over all height of the catch can once I cut it down is 130mm. Sits just above the wiring harness that's there and the hoses don't rub on the under side of the bonnet.
If you order a can of ebay just check what size the fitting that come with it are or that they can be removed and replaced. You need to fit 5/8 (16mm) hose.

[dug1]

Instead of steel wool- I went to Woollies and bought a couple of those stainless swarf scourers and used them- works well.

[StevenS]

Excellent, will do!

[Walt]

According to me this thread and photos are useful for those people have the catch problem.Follow this photos and apply at your car.

[WomblingFree]

Anyone know where you can buy 5/8 oil resistant hose in Sydney without giving an arm or leg?
Preferably black.

[andy666]

It won't be cheap. The hose I used cost me about $30 for 1.5m

Try a hose supply company like enzed or hydrolink (they will also have any fittings that you need). Or a truck parts supplier may have some silicon hose that will also do the job.

[WomblingFree]

Found a place in SA that does blue silicon for $12 p/m
http://www.ministryofbass.com.au/moshop ... -16mm.html

however I don't want blue as the can is red and everything else is black.
Still at that price blue is starting to look good.

[Tys91]

How does this actucaly get mounted?


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[andy666]

I made the simple mounting bracket that is pictured in step 2.
There were 2 small threaded holes in the catch can I purchased. Then there is already a threaded hole on the inside of the gaurd of the hilux, that I bolted the bracket to.

[dirtyharry]

Is there any reason why the breather can't be disconnected from the air intake and run downwards and aimed at the ground?? My truck is set up that way...

[Tys91]

Is there any reason why the breather can't be disconnected from the air intake and run downwards and aimed at the ground?? My truck is set up that way...

Good idea much easier
Im not to handy so i think that woukd world best for me
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[andy666]

That is another option. The only negatives of having the crank breather vent to atmospher it that the oil that comes out will coat the underside of your truck. It's illegal to vent to atmo, because the crank breather it part of the pollution control systems on the vehicle. Also there is the risk of getting water into the engine during water crossings, if you stall.
Other then that, its fine.

[Tys91]

Can someone please show me a pic or explin which hose on intake and exactly where ?

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[Philby]

Hi All, Andy666, hope you don't mind if I add a few points that will assist fellow newhilux members. As you did, you fitted fittings that matched the original pipe size. Guys don't be tempted to use smaller hose or fittings. If the crankcase ventilation is restricted in any way, the oil will not drain from your turbo. Some members are fitting stainless scouring pads to catch the oil vapour. If you over pack then this could cause a restriction also. Andy666, if the oil level in your catch can reaches the alloy pipe, this will cause a restiction. If a restriction happens then the oil will not drain and make its way passed the turbine seal into the exhuast and there will be smoke.