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Items required:
Oil Separator Tank
Aluminium Bracket for tank
2 Self Tapping Screws
2 25mm M4 bolts
2 M4 Nyloc Nuts
6 Small Cable Ties
Woven Heat Shield Pipe Cover
8 25mm Jubliee Clips
1 Metre of 16mm Silicon Piping
1 16mm Metal Bung Tools required:
Socket Set
Phillips Screwdriver
Flathead Screwdriver
Spring Clip Pliers
Electric Drill
5mm Metal Drill Bit
3mm Metal Drill bit
Allen Key set
Bradle
Pliers
Clean Cloth
Estimated Time:
2-3 hours.
Difficulty Rating:
Moderate.
WARNING: AS WITH ALL WORK YOU DO ON YOUR CAR, PLEASE BE CAREFUL AND USE COMMON SENSE - IF IT'S HEAVY, DON'T LIFT IT ON YOUR OWN. IF IT'S HOT, DON'T TOUCH IT, OR USE A RAG TO PICK IT UP. IF IT'S SHARP, WEAR GLOVES. IF YOU NEED TO DISTUB ANY ELECTRICAL COMPONENTS, MAKE SURE YOU DISCONNECT YOUR BATTERY FIRST AND IF IT'S ACID - LEAVE IT WELL ALONE!
An Oil Separator is used to clean and recycle the excess vapours produced by an engine. These vapours are mainly made up of water and a small quantity of Oil. Once emitted, these vapours are cycled back into the inlet pipe once the oil has been removed. This ensures that only air is allowed back into the system. On the GTI-R, the Oil Separator is the small cube-shaped, black box that sits on the front of the engine, below the standard intercooler. The outlet pipe from the rocker cover (Where the engine vapours are emitted) can be seen at the rear of the engine. This pipe exits the engine and splits into two. One of these pipes is directed forward down to the oil separator and then back down to the sump. This is used to remove the oil from the vapour and return it to the sump to be re-used. The other pipe is connected to the Inlet Pipe from the MAF and Air Box/Induction Kit. This allows the air to be returned into the inlet system, just before the Turbo.
The Oil separator works by passing the vapours past a series of plates which the oil sticks to and drains down into the sump.
Unfortunately, the standard Oil Separator is not very efficient and it tends to allow oil to be passed into the inlet pipe. On many GTI-R's, this can be observed by inspection of the intercooler. A lot of GTI-R's with the standard Oil Separator, will notice oil in the Intercooler core and in the pipes leading to and from the Intercooler. Also, oil leaking from a dump valve is a good indicator that your oil separator is not doing its job.
If oil is allowed to re-enter the inlet pipe, it can alter and ulimately lower the octane rating of the mixture being burnt in the engine. This can lead to Detonation which can quickly melt pistons and destroy an engine.
The best way to combat this problem is to fit an aftermarket Oil Separator to your car. There are several kits available but prices are fairly similar so it's a matter of personal taste as to which you use. I have used a Forge Motorsport Oil Separator. This is a complete kit which contains everything you need to complete the operation from start to finish. The separator itself is a highly polished cylindrical tank that is mounted on the front of the engine bay near the battery. Is looks great and is of excellent build quality.
The operation is a fairly simple one and involves the removal of the standard oil separator and the fitting of the new one along with the silicone piping to connect the oil separator to the rocker cover, sump and inlet pipe.
Instructions:
1. Take the Aluminium bracket provided in the kit and use the 5mm drill bit to drill 2 holes in the side of the Separator's aluminium bracket which has the corner removed. CAUTION! The bracket will be hot after drilling!
2. place the bracket against the metal shelf, running across the front of the car. Put the bracket as far over towards the battery as possible. You should notice a small, horizontal lip on the bottom of the bar which prevents you from lowering the bracket any further. This is OK, as the Tank has been designed to attach at this height. This also helps you to attach the bracket, level. The shelf narrows a little, nearer the battery and this should help you locate the bracket in the ideal position. Once in place, use the Bradle to mark out the points where you need to drill the holes.
3. Lift the Crap Flap up, in front of where you will be drilling and you should notice 2 small plastic points sticking through. Use the pliers to compress these points and push them to release the wiring behind the metal guard.
4. Use a Flathead screwdriver to open the round clip that secures the wires in place and move the wiring away from where you will be drilling.
5. Use the 3mm Drill to drill the two holes in the metal shelf.
6. Offer up the bracket and attach it to the metal, tightly, with the two self tapping screws.
7. Offer up the tank to the bracket (It should sit close to the Air Conditioning pipes) and make sure it fits. Attach the tank to the bracket with the bolts and Nyloc nuts.
8. Use the Spring Clip Pliers to slacken the clips on both ends of the pipe that runs from the rocker cover 'T' piece to the inlet pipe. Remove the pipe.
9. Using a 12mm socket or spanner, remove the 3 Bolts that secure the Intercooler frame to the engine.
10. Slacken the clips that secure the pipe running from the Standard Oil Separator to the small metal pipe and from the small metal pipe to the rocker cover 'T' piece.
11. Pull gently, but firmly on the intercooler frame and the oil Separator should pull free. Remove the Small Metal Pipe and the two rubber connecting pipes.
12. Detach the Oil Separator from the Intercooler frame.
13. Move the spring clips and detach the oil separator from the pipe running to the sump. Remove the small rubber pipe which connects the Oil seperator to the pipe to the sump. Remove the Oil Separator.
14. Remove the Intercooler Frame from the car.
15. Measure out and cut a small length of the silicone pipe (about 80mm). Attach this, using a jubilee clip, to the 'T' piece which used to lead to the Oil Separator. Insert the Bung into the other end and use another Jubilee clip to secure it.
16. Measure out and cut another length of the silicone pipe to join between the right hand side of the 'T' piece and the horizontal pipe on the Oil Separator. Use 2 jubilee clips to attach the pipe.
17. Measure out and cut another length of the silicone pipe to join the angled union of the Oil Separator tank to the inlet pipe connector. Use 2 jubilee clips to attach the two.
18. Measure out and cut a final length of pipe to go between the Sump connector and the horizontal pipe on the Oil Separator tank. Before fitting this pipe, feed it through the Heat Shield and use cable ties to secure the Shield to the pipe. Then, attach the pipe to the Sump connector and the Tank using the 2 remaining Jubilee clips.
The Oil Separator is now plumbed in!
CONGRATULATIONS!
You have successfully installed an Oil Separator into your car!
HAPPY MOTORING!