Thanks to CatManHHR, he PMed me while I was still in the build process. He had asked if I'd thought about running an oil catch can. I did not! After doing a whole mess of research, I didn't see any reason not to have one.
Let me start out by saying, catch cans in general are a confusing subject. Not that they are hard to understand, but the threads associated are usually long and full of questions. People will argue that there is no need or that we have defeated the engineers purpose of the pcv system.
I'm not sure either way, what I do know is when I pulled my intake and tubing from the gen 2 everything was covered in oil(IC,Charge pipes, manifold, etc). There was an actual pool of oil in the intake itself. I know that isn't suppose to be there.
Oil in the air supply causes all kinds of problems. It builds up on valves, turbo housings, intercoolers, everything! It's oil. It also lowers your A/F readings and can cause detonation. None of that is good, so why NOT have a catch can?
The purpose of a catch can is to filter the oil/air mix from the Positive Crankcase Ventalation (PCV) system. Engines build up excess pressure in their crankcases, especially turbocharged ones. The pressure is relieved via intake airflow through the pcv valve.
The valve itself is located on the braided stainless hose that runs from the center/rear of the valve cover. "Someone please chime in if I'm incorrect, my setup is no longer stock. I've got the Gen2 75% apart, going by memory!"
. It's removed with a fuel line disconnect tool. A simple test to see if it's functional is to blow through it. It should only let air through in one direction. Mine was working, still flooded with oil...
So what I've got now is a Mishimoto Baffled Oil Catch Can, there could be a whole other thread on what can to buy. They are very simple and could easily be DIYed if you so choose (made one for my friends Focus, for about $20 bucks! ). A word of warning, like everything else, you get what you pay for. The Mishimoto can cost me about $250 +some for fittings and hoses. That said, is definitely a quality piece. Billet aluminum, 30 micron brass filter. The box it comes in its 4x the size it needs to be...the rest is foam, and for show.
Okay, totally sorry for the 3 page intro. On with the install!
This is where my catch can is located. It's routed between the 3/8" tube on the valve cover and the 3/8 tube on my "sewer pipe" (thx 2005HHRAUTO!) intake tube.
These are the 2 PCV ports on the rear of the valve cover. Appropriately named #1 and #2. The PCV valve is located off of port #1.
Currently (as per ZZP instructions) I have port 1 plugged off. The wastegate wouldn't clear with it in the way. I'm pulling all ventalation from the crankcase out the valve cover from port 2. Also no longer using the pcv valve itself, there's no need.
Here is the valve cover flipped over. You can see port 1 is inside the valve cover gasket. It flows directly through into the head, then into the oil galley in the block. Port 2 is routed unseen into the baffles above the cams. Port 2 is my only ventalation.
Here we are following port 1 through the head. It is the 2 slots between cylinders 2 and 3.
The is where port 1 pulls excess pressure from the crankcase. Located in the oil galley between cylinders 2 and 3.
And the finished product! The fittings I needed were M20x1/2 NPT Reducer Bushings (online,or PM me) and 1/2 NPTx3/8 90*Barb (Home Depot).
On a sidenote, I've driven with the can for about 40 miles. 20 of that was limping home...Turned the manual boost contol up a hair (seriously like a HAIR!) I was already pegging the 30psi gauge, just wanted to see if I could quiet the wastegate. Getting on the freeway I got into it a little, instantly blew the coupler from the IC to lower charge pipe. Nothing broke, it actually blew the clamp around the IC! That's ridiculous! I definitely cranked it down, I'll be carrying my 7/16th ratchet wrench around..limped home. I'll fix it when I get up.