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Old 11-26-2010, 11:16 PM
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Ågent99 Ågent99 is offline
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Originally Posted by Fudman View Post
12. Installing the connecting line is the most difficult. It requires you to rotate the line about 1/3 turn to lock the line onto the CCV (practice this connection process on the bench). The other hoses use the locking snap connectors that just insert and snap to lock. After trying for over 2 hours to assemble these parts in their location , I was unsuccessful and decided to modify the locking mechanism. Use a Dremel tool and a sanding cylinder to sand the two retaining ridges on the CCV nozzle smooth from about 1” long to about 1/3 inch long (see photo). This simply reduces the rotation required to lock the connecting line to about 1/8 turn (~45 degrees). Mark the spots with paint where the connecting line aligns with the CCV nozzle to aid in assembly (see photo). Insert the connecting line into the original position from above the intake manifold. Much wiggling and bending of the line is required to get it into place. Once the lower connection is in place, insert the CCV into place. Align the marks, insert the hose into the CCV and rotate the 1/8 turn. This whole process took 10 minutes (vs. over 2 hrs!) with a minimum of effort after modifying the parts! Insert the upper connection line to the engine nozzle until you hear a click. Insert the CCV screws and tighten.
I finished the installation tonight on the crankcase ventilation/oil separator and it wasn't too bad on my 2001 530i.

I quoted the above step because I was able to rotate the connecting line (#3 in the part blow-up) and get it connected without too much trouble and with no modification.

Playing around a bit, I found I was able to insert the top of the connecting line (the section with the right-angle snap connector and smaller offshoot) from under the engine and kind of rotate it in place. When you play with how this connects on the bench, you'll see why this is important as fudman alluded to above: it connects to the CV/OS and then to lock it into place, one rotates the line.

So with the connecting line in place ready to be rotated into proper position, I inserted the CV/OS into its spot. I then pushed the connecting line into the CV/OS and then rotated it up through the available hole and into position.

To the best of my ability and triple-checking, that connecting line was indeed locked snugly onto the CV/OS. I then bolted down the CV/OS and snapped on the other lines.

Funny thing, I think trying to get the vent pipe (#2 on the diagram) snapped onto the CV/OS was tougher than the connecting line for me. It probably took me 15 minutes but eventually I got the click.

My car has been in California since day one and I did see that dreaded "mayo" in some of the lines. My M54 engine also uses about a quart of oil per oil change (~7500 miles).

Anyway, thanks for a great write-up...everything did go smoothly. My engine is still apart as I'm now going to tackle the VANOS seal replacement next.
2001 530i/5 (E39), Topaz Blue/Stone Green/Black (sold) *very rare interior/exterior color combo*
2005 545i/SMG (E60), ED Order, Titanium Grey/Grey (lease over)
2014 335i/Auto (F30), Mineral Grey/Black (lease over)
2017 340i/Auto (F30), ED Order, Estoril Blue/Black
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