These three CAD images explain the functioning of the G.A.S. CCV’s unique secondary oil separator. This secondary oil separator feature is only available in the GAS CCV system, the OEM BMW CCV dumps this extra oil directly into the intake manifold. This one feature alone provides an improvement over the OEM BMW design.
The 1st CAD image shows the blowby gas flow thru the vacuum regulator and secondary oil separator when the engine is running. Oil gets separated out when the blow by gas velocity drastically increases when passing thru the vacuum regulator valve. Separated oil collects in the reservoir above the check valve.
The 2nd CAD image shows what happens once the engine is shut off. When the engine stops, the pressure differential across the secondary oil separator check valve drops to zero, allowing the check valve to open. All the oil captured in the reservoir then flows into the primary oil separator and then back to the engines oil pan. The reservoir will hold enough oil to support an entire fuel tanks worth of driving without shutting off the engine, a situation that could happen on long highway trips.
The 3rd CAD image highlights just a few of the many features that have been incorporated into the final revision of the German Auto Solutions CCV system. Every detail of the German Auto Solutions CCV replacement system is the result of extensive flow bench and real world testing.
Basic System Functions
As shown in the 1st image, the OEM BMW vacuum regulator design has a high failure rate due to several poor design choices. 1) All of the OEM silicone diaphragm’s flexing happens at a narrow band around the perimeter of the diaphragm which leads to premature fatiguing of the material. 2) That same narrow band of material is exposed directly to the pressure differential between the vacuum chamber and the outside atmosphere. That pressure differential is constantly trying to tear the diaphragm apart. 3) That same narrow band is also exposed to combustion gases, fuel and water vapors, and condensation which degrade the diaphragm material over time.
The 2nd image shows how the GAS vacuum diaphragm address all of these issues. 1) The GAS CCV vacuum diaphragm is more like a soft version of a trampoline. The flexing and stretching of the material takes place over the entire area of the diaphragm which eliminates the concentration of stresses seen in the narrow band of the OEM diaphragm. 2) The GAS CCV vacuum diaphragm is totally supported by a rigid aluminum support that takes 100% of the the pressure load. There is no way for the diaphragm to be torn by vacuum pressure. 3) Since the GAS CCV vacuum diaphragm is 100% covered by the aluminum diaphragm support there is no exposure of the silicone material to the degrading effects of the combustion gases, fuel and water vapors, and condensation.
Vacuum Diaphragm Design
The 1st image explains some of the G.A.S. CCV primary oil separator’s features and blowby gas flow. The blue arrows show the Primary Oil Separator’s oil separation passage. This sharp cornered zigzag path is better at separating oil from the blowby gases than the OEM CCV’s spiral path. This zigzag path is also better at holding the gooey emulsified oil mayonnaise in place until the heat from the oil separator can evaporate off the water content and turn the mayo back into engine oil. (See actual pictures of this further down this page)
The 2nd image shows more primary oil separator features plus more detail of the secondary oil separator check valve and how it easily drops out for cleaning when necessary.
In the 3rd image we show the bottom of the German Auto Solutions Vacuum Regulator. The regulator is fully cleanable and serviceable. The picture highlights the special QUAD SEAL vacuum sealing rings used. This type of seal is especially effective in low pressure applications like this with the added benefit of staying in place when the vacuum regulator is removed. These high quality seals should last for many years, but if needed, they are easily replaceable and one set of spares is included in the kit.
Some Key Features
The 1st image shows more of the Vacuum Regulator’s key features.
The 2nd image points out some of the pathways for the blow-by gases.
The 3rd image is a view of the Vacuum Regulator valve, diaphragm and diaphragm support. In the G.A.S. design the silicone diaphragm is completely shielded from the dirty blow-by gases. In the OEM BMW CCV the flexing portion of the diaphragm is fully exposed to blow-by gases which is
More Key Features
The 1st image shows the bottom of the primary oil separator. This is the portion that is bathed in oil and also supports the oil filter element. Keeping the German Auto Solutions CCV running at close to engine oil temperature may be the most important feature that separates our design from all BMW external CCV designs, and results in much greater efficiency and reliability.
The 2nd image shows the main CCV mount that replaces the OEM oil filter cap and serves as a mounting platform for the rest of the CCV.
In the 3rd image you can see the main parts mounted together. This is the way you will receive it if you order one, with the exception that the top cover and regulator diaphragm assembly will be installed.
The Oil Separator
The 1st image shows the result of 10 minutes of driving on an eighteen degree day, then removing the vacuum regulator for inspection of the oil separator. After ten minutes of driving in cold weather the CCV is warm but not hot to the touch. The goo you see is the normal emulsified oil that results from water that condensates inside a cold engine, then mixes with aerated engine oil.
The 2nd image is a closer look at the goo on the bottom side of the vacuum regulator.
The 3rd image is a closer look at the goo in primary oil separator passage.
You Don't Want This!
Here is the really cool part. The 1st image was taken the same day and time as above images, but after the system was reassembled and driven another 20 minutes to bring the CCV up to full operating temperature. It was then disassembled again for inspection. All the goo is gone!
The 2nd image is a closer look at the vacuum regulator. The increased temperature that results from the primary oil separator being heated by engine oil, allows the water content of the emulsified goo to evaporates off and return the goo back to just oil. Notice that the goo is completely gone. A stock BMW CCV will never get hot enough in very cold whether to de-emulsify the goo!
The bottom image is a closure look at the Primary Oil Separator after the additional drive time. Notice again that the goo is completely gone. Also take note of the amount of oil that was captured and released by the secondary oil separator (round pocket at the top left). We have found that more oil is separated out of the blowby gases by the secondary oil separator than the primary. Remember, the stock BMW CCV does not even have a secondary oil separator.
But This is Awesome!
G.A.S. M54 CCV Upgrade Kit
If you you have a M54 equipped BMW vehicle that is still using the OEM CCV, you need to consider this highly engineered CCV system upgrade.
We consider this upgrade a must for vehicles opperating in cold climates.
See What Our Customers Have to Say About the G.A.S. CCV
19 Reviews for German Auto Solutions M54 CCV Replacement Kit
-
Updated Review - Works Great
Thursday, November 7, 2024
After this equipment being installed on both of my 530I for 9 months they perform excellent with little to no oil consumption from either car.
Even with the increase in cost I feel this is an excellent upgrade due that if your BMW is in Good Condition and Fully Functional this is still less than a car payment and insurance for a newer car that is more expensive to work on -
Excellent addition to 525i E39 Touring
Wednesday, October 30, 2024
Install was relatively easy with the hardest part for me was the trimming down of the intake manifold. Did an oil change to see how it was, and with the included instructions its very easy. Will be purchasing the DISA replacement from G.A.S. as well as it looks like when taking it out the stock ones gasket is done for.
Mileage: ~127,000 -
Excellent Upgrade 03 & 01 BMW 530I
Sunday, April 7, 2024
Joe Walma 15781
Excellent designed upgrade. All components necessary for installation. If you can change spark plugs you can install this. Installation instructions excellent. Will update review after a couple weeks of driving on the impact this has made for oil consumption -
Excellent addition 2004 325xi
Saturday, June 24, 2023
I installed this into my car when I was repowering (with a well used motor, but no burnt valves, unlike the motor that it came with).
Drove it for a few months around town with some short freeway trips, and zero oil usage. I just returned from a 6,000 mile trip from the west coast to east coast and back, with some sightseeing driving included.
Upon return the oil level was exactly where it started. This is so far from my extensive BMW E46 / E83 M54 ownership, that it is not funny.
I would love to get more of these for other's in the family with these motors! -
Excellent investment! 2004 BMW 325xi
Sunday, February 26, 2023
This motor had been using oil and leaking it from the usual CCV areas when I bought it. Replaced the dipstick along with this kit and have put 2K miles on it with the oil level changing perhaps the width of the dipstick itself. This car had 211,000+ miles of semi-indifferent care prior to my purchase.
The design of the kit is spot-on and the instructions are clear and easy to follow.
Will order another for my siblings E83 soon.
Mario Perez -
Amazing! Definitely A Must! - 03 BMW 525i
Thursday, June 17, 2021
Purchased the M54 CCV Replacement Kit for an 03 BMW 525i. Had to wait for the next production run to get the kit, but it was worth the wait and every penny. Glad to get rd of the OEM plastic "octopus" CCV system. This kit has been such an upgrade. The car has been through emissions twice, now (testing every two years in Illinois), without issue. Not seeing any oil loss issues common in these bimmers - really amazed at how well it has worked. Great, quality machined parts. Definitely would make this a must if I buy another bimmer of this generation.
Thank you for a great, well designed piece of engineering. -
Excellent Quality M54 CCV Replacement for E39 BMW 530i 2001 Model
Wednesday, February 10, 2021
Hello from South Africa. I bought two M54 CCV Replacement kits and one DISA repair kit and Aluminum Coolant Cap for E39 BMW 525i Touring and 530i Sedan on 28 March 2019. The quality and design of the DISA Repair Kit , Coolant Cap and the CCV Replacement Kit is far far superior to BMW OEM. Installation took less than an hour. Most of this time was spent removing the original BMW @#$%^! plastic CCV.pipes. The plastic laminated instructions are superb. Fit and finish of the kit is perfect. $500 for the CCV Replacement Kit is reasonable considering the quality and design and NO MORE CCV VACUUM LEAKS. If you own an M54 engine auto I strongly recommend the three upgrade/repair kits
-
Essentially perfect
Sunday, January 10, 2021
I couldn’t agree more with the positive reviews. Just installed yesterday; it’s a dream. Perfect fit, detailed instructions, great customer service. What else could I ask for? Better than OEM quality, hands down. Wish I had purchased one years ago! If you are debating the cost, I had a oil hydro lock from a failed CCV (with only 15k miles on the new CCV) and it cost a lot more than $500 to tow and repair. Thankfully the engine was otherwise undamaged.
-
One of THE BEST mods I have ever installed
Monday, December 28, 2020
I simply can’t say enough great things about this kit! The SUBSTANTIAL machined unit is simply a work of art. Like others, I am incredibly impressed. The instructions were very thorough and included everything I needed to know.. The fit was tight but super accurate. I cannot thank the folks at GAS enough for taking this project on and developing such an elaborate solution. If you’re even slightly on the fence on this, don’t be. It is worth every penny!
-
Simply Amazing
Wednesday, December 16, 2020
Kit purchase was easy. GAS has excellent customer service and their products are amazing... Two things that aren't typically found together nowadays. The install is easy. Probably could have done it with one hand while blindfolded. The quality of the CCV kit is simply amazing. Its like a work of art. Stock unit was already removed for a catch can, but this unit has finally solved the oil burning problems that new rings couldn't solve. If I ever buy another M54 engined car... I'll buy another one of these for sure.
-
Incredible Machine Work – 2003 BMW 330i
Thursday, November 12, 2020
The kit arrived today and all I can say is WOW! Being a former CNC programmer / operator, I can appreciate the beautiful machine work done on this masterpiece. I love the fact that you took the time to program the de-burring process on every edge and corner, very nice.
This also makes installation much safer, thank you.
-
Very Easy to Install - 2004 E83 X3 3.0
Thursday, April 30, 2020
My only frustration is that I missed the first production run, before my stock unit failed again. I am looking forward to putting one in the other car. Thanks for the attention you put into this.
-
A Must-Have. 2002 BMW 530i
Sunday, December 29, 2019
How many times have you busted your knuckles trying to get to that defective CCV unit under your intake manifold? Or trying to route the fragile CCV plastic hoses into place?
Well, kiss all of that goodbye. G.A.S. has finally delivered on a CCV upgrade for all M54 engines. Not only does this kit make CCV maintenance easy, but it also better regulates oil consumption and vacuum within the crank case. I was amazed at how drastic the change was. Used to consume 1 quart of oil every 1000 miles or so. Going on 3000 miles now with NO consumption!
Yes, the price is steep. But if you want to never again worry about what might happen when you drive your car on a cold winter morning, or if you want to do everything you can to manage oil consumption, $500 really is a small price to pay. -
Excellent work, BMW e46 M54B22
Sunday, December 15, 2019
Greetings from Germany, this GAS CCV is awesome, never regret it.
No Oil Consumption at all, and the Intake is now Clean from Oil, just great!! -
Excellent replacement, I was the first tester of the kit!
Monday, December 9, 2019
I live near GAS and drive an E46, so my car was the guinea pig for this replacement and the first install. Happy to say that 30k miles and 2.5 years later it's still working flawlessly. Highly recommended.
-
Love my GAS CCV - 2004 BMW 330ci
Monday, December 2, 2019
Just letting you guys know I have finally installed my GAS CCV valve! You guys have manufactured a excellent unit that functions amazingly, after three weeks of driving the car has never been more fun to drive! Throttle feels crisp and gas mileage has gone up! I will keep up on my experiences with this product, I also have the 1.2 bar cap and have had it on for about two years now with no symptoms, keep up the good work, I want to just keep driving this car now!
-
Happy Customer!! - 2001 330xi E46
Monday, September 2, 2019
Thanks so much for your product!! I received it this week and got it installed right away! It’s amazing! Looks top notch and now my engine is “sucking” like a champ.
Thanks again for all your hard work to make this thing. Awesome!! -
The CCV has been great!
Monday, July 15, 2019
Last year was the first full winter with it and I've had no issues at all. Even had the car parked outside overnight occasionally in -15 to -20 c temperatures. Oil changes are easy and consumption is essentially nil.
-
Beautiful peice of workmanship
Sunday, July 14, 2019
Beautifully made kit. Good and detailed install instructions. Piece of mind that I no longer have to worry about the stock CCV ticking time bomb. Highly recommend.
