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Pelican Technical Article:

Catch Can Installation

Nick Czerula

Time:

2 hours2 hrs

Tab:

$300

Talent:

****

Tools:

Screwdrivers, Allen wrenches, hose cutter

Applicable Models:

R56 MINI Cooper Hatchback (2007-11)
R56 MINI Cooper S Hatchback (2007-11)

Parts Required:

Catch can kit

Hot Tip:

Work with a cool engine

Performance Gain:

Car will run well

Complementary Modification:

Change engine oil and air filter

The R56 MINI Cooper S is prone to excessive oil vapor within the intake system from the crankcase breather system. This can cause a build up of oil residue on the intake valves as well as moisture and oil in the intake air ducts.

A catch can separates the oil vapors from the crankcase air before it is returned back into the intake system, keeping your intercooler and sensors working at peak performance. If you've ever taken off your intercooler, you most likely noticed a build up of oil within each rubber boot sealing each end of the intercooler. Spray some cleaner into it and you'll quickly discover massive amounts of oil that build up inside the intercooler. This oil coating is not in itself harmful to the general operation of the engine, but it does affect the performance by limiting the efficiency of the intercooler in cooling the compressed intake charge, not to mention gumming up various sensors and components including the critical intake valves.

Keep in mind that when your car was serviced before, parts may have been replaced with different size fasteners used in the replacement. The sizes of the nuts and bolts we give may be different from what you have, so be prepared with different size sockets and wrenches.

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If you're working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Do not work on your vehicle if you feel the task is beyond your ability.

Vehicle models change and evolve, as they grow older, so the vehicle shown in our illustrations may vary slightly from yours. If something seems different, let us know and share your info to help other users. Do you have questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.

The catch-can (red arrow) can be mounted to the firewall or the metal radiator support (blue arrow).
Figure 1

The catch-can (red arrow) can be mounted to the firewall or the metal radiator support (blue arrow). It connects between the valve cover (yellow arrow) and the intake air duct (green arrow).

This photo shows the common components in a catch can kit.
Figure 2

This photo shows the common components in a catch can kit. The hose (red arrow), hose adapters (yellow arrows), the catch can (green arrow) and the mounting hardware.

Note the oily moisture build up inside the turbocharger inlet (red arrow).
Figure 3

Note the oily moisture build up inside the turbocharger inlet (red arrow). A catch can will help reduce this type of contamination.

Working at the crankcase breather heater (yellow arrow), cut the plastic hose tie off the hose (green arrow).
Figure 4

Working at the crankcase breather heater (yellow arrow), cut the plastic hose tie off the hose (green arrow). Then lift up to detach the hose lock (red arrows) at the valve cover.

Remove the hose from the valve cover (red arrow).
Figure 5

Remove the hose from the valve cover (red arrow). Then remove the hose from the intake air duct / crankcase breather heater.

Working at the valve cover, install the supplied hose adapter (red arrow) into the hose connection (green arrow).
Figure 6

Working at the valve cover, install the supplied hose adapter (red arrow) into the hose connection (green arrow). Then install the locking clip (yellow arrow) to secure it.

Working at the crankcase breather heater, install the hose adapter (red arrow) by pushing it into the valve opening.
Figure 7

Working at the crankcase breather heater, install the hose adapter (red arrow) by pushing it into the valve opening.

I have decided to mount the catch can to the firewall on the plastic mount (red arrow).
Figure 8

I have decided to mount the catch can to the firewall on the plastic mount (red arrow). If mounted here incorrectly, the mount can break. Be sure the catch can will not be tugged by the engine, and the hoses have some slack.

Attach the catch can mounting bracket (red arrow) to the can.
Figure 9

Attach the catch can mounting bracket (red arrow) to the can. Then bolt the bracket to the plastic mount. Use a metric Allen (throw away the fractional one if it came in the kit -- nothing worse than searching for a fractional Allen later) (green arrow) and counterhold the nut (yellow arrow) to tighten the bracket mount.

Measure and cut the hose into two pieces.
Figure 10

Measure and cut the hose into two pieces. Attach one hose (red arrow) to the valve cover connection and one (green arrow) to the crankcase breather heater connection. Leave the clamps loose for now. Move each hose to the catch can and make a mark to remove the excess hose (yellow arrow). Leave enough hose so there is space between the intake duct and the hose. This will reduce tension on the catch can.

Use a hose cutter to ensure straight even cuts.
Figure 11

Use a hose cutter to ensure straight even cuts. A crooked cut may result in a sealing problem.

Next, install the hoses and recheck the clearance to the intake duct (red arrow).
Figure 12

Next, install the hoses and recheck the clearance to the intake duct (red arrow). Position the hoses and tighten the clamps. Keep your old parts in case you want to remove the catch can one day.

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Comments and Suggestions:
Harv Comments: In figure 2, where can I get those parts, they don't seem to be in the parts pages, spoke with a rep and they don't know. What size are those black connecters. ?
June 15, 2016
  Followup from the Pelican Staff: All the parts come with the oil catch can kit. - Nick at Pelican Parts  

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