Mishimoto Build Thread: BRZ/FR-S Direct Fit Baffled Catch Can Kit!

[Mishimoto]

Hey guys,

Our team recently began development on a direct fit baffled catch can kit specifically designed for the BRZ/FR-S! Check out the progress of development on our blog, or posted below!

http://engineering.mishimoto.com/?cat=196

Mishimoto 2013+ Subaru BRZ / Scion FR-S Direct-Fit Baffled Oil Catch Can System, Part 1: Product Introduction

Why a Catch Can?

Catch cans are used only for turbocharged vehicles, right? This is a question we hear all the time. Yes, a turbocharged vehicle is more likely to produce greater blow-by, resulting in a more prominent collection of debris in the intake manifold and tract. That being said, any engine is certainly susceptible to oil and fuel collection due to the use of PCV and CCV systems, which improve engine efficiency and provide cleaner emissions. Mishimoto has been working on developing several direct-fit oil catch-can systems for a variety of vehicles. So far we have completed kits for the Subaru WRX/STI for 2008–2015. We have also experimented with a kit for the BMW E90, a vehicle that suffers from intake valve buildups that require frequent servicing. With the arrival of our 2015 Ford Mustang EcoBoost test vehicle, we also began tackling a kit for that particular model. Our most recent project involves two of our favorite vehicles, the Subaru BRZ and Scion FR-S.

We already carry a ton of products specifically for this chassis, including an aluminum radiator, cold-air intake system, silicone coolant hose kit, and a direct-fit oil cooler kit. To round out the GT86, we decided to create an easy-to-install catch-can solution that would help vehicle owners keep their engines clean. The best time to install a catch can is before the serious buildup begins, so we are hoping to catch these engines before they have serious mileage on the odometer.


FR-S on Mishimoto dyno

One interesting factor that affects valve buildup is the use of direct injection systems on modern engines, including your FA20. You will find that several of the more recently released direct injection engines have valve deposit issues, and this is no coincidence. To understand why this occurs, you must first take a look at how these different injection systems function.

First, we have traditional port injection. In an engine with this system, the injectors are placed inside the intake manifold, and they produce a stream of fuel to atomize and mix with air. This mixture then enters the combustion chamber through a valve.


Port injection cutaway example

So, why is the port injection system less susceptible to valve deposit buildup? Well, as you may know, gasoline has very strong solvent properties, meaning it is fantastic for removing grease, tar, and waxes. (Some guys you find in the garage will even clean their greasy hands with a splash of gasoline!) The fuel mixes in the manifold and then passes through the valve to clean much of the debris and buildup. However, any point before the injection site is still susceptible to sludge buildup. This includes the throttle body and intake piping/tract.

Now to compare, let’s take a look at direct injection.


Direct injection example

The fuel injector is located right in the combustion chamber, unlike the intake manifold location for port injection. This means the valve will not be affected by fuel, so its cleaning properties are not utilized. This setup is one of the primary reasons for direct injection valve deposit problems.

Numerous large vehicle manufacturers use this technology, so it must have some benefit. Direct injection of gasoline directly into the cylinder, results in smaller, more controlled explosions. This allows automakers to squeeze out greater fuel efficiency, resulting in more miles per gallon for your commute! It seems as if a majority of the recent adopters are having reasonable success with these systems, with only some minor bugs to iron out.

Obviously buildup of deposits on the valves is not a good thing, but you probably want to know: What does it mean for me? Will I ever notice a difference or see any negative impacts on drive-ability or reliability? More great questions! Internal combustion engines are not the cleanest machines on earth. They contain numerous fluids, put out a ton of byproduct, and commonly build up dirt and grime. Valve buildup is a small problem that can quickly escalate to a more serious issue. Deposit buildup can cause turbulence around the valve opening and even restrict airflow if the buildup becomes more prominent. The result is decreased performance and even engine misfires, not something you want. Check out below a shot of a dirty BMW E90 valve.


Deposit buildup in intake valve

And take a look at what these are supposed to look like!


Clean intake valves

We want to keep these valves as clean as we can, to retain power output and keep the engine running optimally. So what should you do if you have an engine equipped with direct injection? Swap a port injection system? No, that would be quite expensive, decrease your fuel mileage, and be a complete nightmare. An easier way to reduce buildup is to install an efficient catch can setup. A catch can will remove contaminants (oil, fuel, etc.) from the engine before it enters the intake tract.

So why do these contaminants exist? Without going into too much detail, your engine features a CCV (crankcase ventilation) system that works to improve engine efficiency and emissions. During engine operation the crankcase generates pressure due to combustion gases passing the piston rings. This pressure is evacuated from the crankcase and is routed into the intake system to be burned in the combustion process. When the oil enters the intake, it coats the tract, throttle body, and valves. It is then burned in the combustion chamber, lowering the octane of the mixture. Although not optimal for performance, this creates a clean engine that requires no emptying of byproducts and contaminants (a common practice for most manufacturers.) Ideally, these contaminants should be separated, collected, and disposed of. This brings us to the function of our catch can!

CCV Systems Explained

For those who wish to learn more about CCV systems, read on! Otherwise, scroll down a bit for more information about this project.

Every engine is susceptible to blow-by from the piston rings, it is impossible to have a completely leak-free seal between the rings and cylinder wall. If pressure builds up in the crankcase, it will eventually find a weak point, normally a gasket or seal, and will result in fluid leaks. Two primary lines make up the CCV system equipped on the FA20 engine. The first, the makeup air line, routes from the valve cover to the intake piping. This line provides a light vacuum on the crankcase and is most used during wide-open throttle situations. The second, the ventilation line, routes from the back of the engine block to the intake manifold. This line utilizes the PCV valve and features a higher vacuum source than the makeup air line. The ventilation line is used during idle and part-throttle driving situations. The valve works to eliminate the pressure from the intake manifold so it cannot enter the crankcase. These two hoses/lines will function together to provide optimal crankcase pressures for efficient operation. Engines typically function better with a slight pull on the crankcase.

Mishimoto’s Plans

Now that we’ve discussed the need for a catch-can setup for the BRZ/FR-S, it is time to provide some detail for the kit we intend to put together. All our kits are direct-fit, but drivers could just purchase our universal catch cans and make them function with their vehicles. But, we want to take the guess work out of installing a can setup. We will include direct-fit brackets and lines and also provide detailed installation instructions so the process is simple and hassle free. Our goal is to make this kit appear as though it were factory-installed, and in reality it should be!

Before setting our engineers loose on this project, we decided to set a few guidelines for what our customers wanted out of this kit. We performed a reasonable amount of research through forums, our customers, and our vendors to help determine what product would best serve the BRZ/FR-S community. Check out our goal list below!

Project Goals

1. Kit must be 100% direct-fit and include all necessary components for installation.
2. Develop a PCV and a CCV catch can, and determine if both are necessary for the FA20.
3. Catch cans must be easy to service, and fluid removal should be an easy process.
4. Fully test the product to ensure safe and effective operation.

Now, as with other projects, we like to break these goals down and go into further detail about how/why we want to achieve each.

Fitment

One of our primary goals for essentially all projects coming out of our shop is direct fitment. Our catch-can kits should fit perfectly and bolt into position using common hand tools. Fabricating brackets, finding lines, etc., can be a challenging/lengthy process for DIYers. For most, a kit designed for specific vehicles is the way to go (especially if it’s a great value for your dollar!). This kit will include direct-fit catch-can brackets that will mount within the engine bay. We are hoping to keep the lines as short as possible to avoid clutter, so strategic placement of the cans is vital. Our lines included in this kit will be pre-formed silicone; we are not throwing a roll of rubber hose in a box and calling this a direct-fit unit! Lastly, we will be using our baffled catch can, an extremely efficient catch can that uses a 40 micron bronze filter and internal baffling to promote increased separation of oil from air. We have had a ton of success with this can and hope to make it function with our latest kit!

Take a look at our catch-can!


Mishimoto Baffled Oil Catch Can


Mishimoto Baffled Oil Catch Can

This is a highly engineered product that really displays the talents of our engineering group! More on selection of catch cans in Part 2 of this build!

One Car, Two Cans

We will be designing a kit with two cans, one for each of the systems. Unfortunately, these lines cannot be combined into a single catch can due to pressure differences. We will be selecting optimal engine bay locations to ensure that the cans are not impeding space for other components. Also, for our RHD (right-hand-drive) owners, the firewall differences between the two cans will be important. To ensure we will need two catch cans, we will be testing both systems to see which produces a greater amount of byproduct. More on that below!

Service

The baffled unit is completely serviceable and the filter is washable, providing a lifetime of use. We expect that most people purchasing this kit will appreciate a can that is easy to empty and does not require complete removal of the setup. Our plan is to have just the removable base come off, be emptied, and then reinstalled in a quick fashion. Once again, careful attention to can placement will be necessary.

Testing

Product testing is a huge deal within our engineering group. If it doesn’t pass our tests, it does not leave our garage. We do not produce products that are less than 100% functional, and we do our best to design the most effective solutions possible. For this particular project, we are planning to conduct real-world testing on an FR-S belonging to one of our accountants, and also a BRZ belonging to a member of our sales team. We should have no problem dropping by their desks to steal the keys for test fittings! We are also planning to install this kit on one of their vehicles for a long period of road use to determine the effectiveness of our system. Stay tuned for more on this later!


That rounds out our plans and goals for this project. If our R&D processes are effective, we should easily produce a kit that meets the needs of the enthusiast world.

Check back next time for a look at the mockup of our first prototype unit!

Thanks for reading, and feel free to follow up with any questions or comments!

[JohnJuan]

Very cool. I was looking for this just the other day.

[VacantSky]

Nice catch can! If I wasn't running one already I'd be interested in getting one of these. I have your radiator on order right now, by far some of the best R&D'd parts on the market.

But I'd like to note for the less informed, these cars do have direct injection, but also have port injection so our valves are not susceptible to build ups like the one shown on the BMW above.

[ck-GT86]

Can you guys show this actually working? So far, it seems like catch cans are just for show on the Twins. I haven't seen an effective one for NA, yet.

.ck

[Mishimoto]

Originally Posted by JohnJuan

Very cool. I was looking for this just the other day.

Thanks for taking a look!

Originally Posted by VacantSky

Nice catch can! If I wasn't running one already I'd be interested in getting one of these. I have your radiator on order right now, by far some of the best R&D'd parts on the market.

But I'd like to note for the less informed, these cars do have direct injection, but also have port injection so our valves are not susceptible to build ups like the one shown on the BMW above.

Thanks for the kind words! Correct about the port injection. These engines have 8 total injectors. It will be interesting to see how this setup effects buildups in the long term! Either way, oil in the intake tract needs to be addressed. We will be covering the FA20 D4-S system a bit further in part 2 of the build! Thanks for the comment!

Originally Posted by ck-GT86

Can you guys show this actually working? So far, it seems like catch cans are just for show on the Twins. I haven't seen an effective one for NA, yet.

.ck

Absolutely! We will be installing our prototype kit/kits on a few test vehicles to see how much accumulation we get during normal road driving!

[ck-GT86]

Originally Posted by Mishimoto

Thanks for taking a look!



Thanks for the kind words! Correct about the port injection. These engines have 8 total injectors. It will be interesting to see how this setup effects buildups in the long term! Either way, oil in the intake tract needs to be addressed. Thanks for the comment!



Absolutely! We will be installing our prototype kit/kits on a few test vehicles to see how much accumulation we get during normal road driving!

You've got my wallet if they work.

.ck

[dolo]

Get these out before the spring and I am in.

[Kodename47]

Will be interested for RHD application for my SC. Any idea on price point?

[IceFyre13th]

While the triplets do have direct injection, they also have port injection........Direct injection is only used during higher engine load events as well.

Watch this to see how or fuel injection systems work.

[ame="http://www.youtube.com/watch?v=zc8aUxBZlsU"]2013 Scion FR-S | D-4S Technology Explained - YouTube[/ame]

While catch cans have been shown to work on the triplets, having to need one because we have direct injection, is NOT a reason, as we also have port injection.

Your other reasons are valid, but the direct injection reason is not.

[Mishimoto]

Originally Posted by ck-GT86

You've got my wallet if they work.

.ck

Originally Posted by dolo

Get these out before the spring and I am in.

Originally Posted by Kodename47

Will be interested for RHD application for my SC. Any idea on price point?

Thanks for the interest guys! It is very likely that this kit will be available before spring. We do not currently have a price-point finalized, once we get a bit closer to completion we should have a better idea.

If we get enough interest here on the forum, we will likely be able to provide this product in the form of a group-buy!

Thanks guys!

Originally Posted by IceFyre13th

While the triplets do have direct injection, they also have port injection........Direct injection is only used during higher engine load events as well.

Watch this to see how or fuel injection systems work.

While catch cans have been shown to work on the triplets, having to need one because we have direct injection, is NOT a reason, as we also have port injection.

Your other reasons are valid, but the direct injection reason is not.

Correct! As mentioned above, we will be covering the unique system featured on the BRZ/FR-S in part 2 of the build. We should have that up at some point next week!

[F1fletch]

Great News!


I am in :-)

[Mishimoto]

Originally Posted by F1fletch

Great News!


I am in :-)

Thank you!

[Mishimoto]

We have an update for this build! Check it out below.

Mishimoto 2013+ Subaru BRZ / Scion FR-S Direct-Fit Baffled Oil Catch Can System, Part 2: Prototype 1

Welcome back to the build of our BRZ/FR-S catch can system! After laying out the guidelines from the last post, we were ready to get some hands on the vehicle and start piecing together some can brackets. Before jumping into product design, we will quickly cover the unique injection system featured on the BRZ/FR-S FA20 engine.

FA20 Fuel Injection

As many of you are aware, the FA20 is not what you could consider a traditional direct-injection engine. This specific system is identified as D–4S on the top of your intake manifold. The system utilizes four direct injectors and four port injectors for appropriate fueling. Yes, your 4-cylinder has eight injectors! The direct injection portion of the system is key for an efficient combustion process, and it allows for a high compression ratio without exaggerating the fear of detonation. Adding in port injection to work alongside this system promotes complete combustion and improves cold-start emissions.


D-4S System

At lower engine speeds, both the direct and port injectors are used, which help provide a smooth AFR and improved drivability. At high engine speeds, the direct injector takes over and handles all fueling. During a cold start, both injection systems work together to provide reduced emissions and rapid catalytic converter warm-up.

So with these systems combined, we get an engine that provides improved power output, greater efficiency, and reduced emissions. Additionally, the valves are still exposed to the atomized fuel from the port injectors. This means they are less susceptible to carbon buildup, just as you would see on an engine with only traditional direct injection.

Does this mean a catch can system is not needed? Not necessarily. Although the valves should remain reasonably clean, keep in mind that all points of the intake tract prior to the injector are still likely to get a coating of oil from blow-by in the CCV/PCV system. If there is a way to reduce or eliminate this oil buildup, it is certainly wise to do so. Our team will be installing our prototype kit on a test vehicle to gauge fluid accumulation. Stay tuned for this a bit later on in the development process. For now, let’s jump into the development and design of our first prototype unit.

Initial Bracket Design

Our first target was the PCV line. On the FA20, this line goes from the back of the block to the intake manifold. Take a look at an initial mock-up of our can bracket for this location.


Prototype catch can bracket mock-up


Prototype catch can bracket mock-up


Prototype catch can bracket mock-up

You will notice that we are using different colored fittings on this can. The black fitting is our standard CNC-machined aluminum straight fitting. The top fitting is actually a 3D printed prototype unit. Due to space constraints, we needed a banjo style fitting to clear the hood. It also improves aesthetics of the can/lines when fully installed. Check out a more detailed shot of this banjo fitting.


Prototype 3D-printed banjo fittings

At this point, you may be thinking exactly what our team was. This catch can is far too large for the engine bay of the BRZ/FR-S. In fact, we were finding that this catch can was proving to be a challenge to install in the smaller engine bays of more compact vehicles. Keep in mind, we still had to find space for our second can to install on the CCV lines. Although this project was not the only contributor, we now had more support to jumpstart a new catch can project. After evaluating our product line, we determined that a smaller, more compact, baffled unit was necessary to full flush out our line. This would provide support for more direct fit kits for vehicles that had tighter engine bay constraints. We also listened to feedback from interested customers regarding the release of our initial baffled unit, and the need for a smaller version was certainly evident. This does not mean the original product is negated, this unit is still perfect for vehicles with more space, and it provides a very large capacity.

New, Compact, Catch Can

With all of this in mind, the BRZ/FR-S catch can project was put on a slight hold until we could finalize a design for a more appropriately sized catch can. And so the Mishimoto Compact Oil Catch can was born!

I won’t dive into the detail regarding the design and development of that particular component, mainly because we already did in the form of a build-thread a few months back. Check it out at the link below if you want more information about the cans!

http://engineering.mishimoto.com/?cat=124

Check out a few quick shots of what we are working with!


Mishimoto Compact Baffled Oil Catch Can parts


Mishimoto Compact Baffled Oil Catch Can


Mishimoto Compact Baffled Oil Catch Can

Now that we had a new plan of attack, and some really nice new catch cans, we could move forward with a new design for this kit. Keep in mind, this project began months ago, with a larger break for the development and manufacturing of the catch cans. This break provided the time for our team to get a nice look at the engine by of the vehicle, and work on developing a plan for can placement.

Check back with us next time for the design of our second prototype!

Thanks for reading!

[Mishimoto]

Hey guys,

We have another update on this project! Check it out below.

Mishimoto 2013+ Subaru BRZ / Scion FR-S Direct-Fit Baffled Oil Catch Can System, Part 3: Prototype 2 Development

Second Prototype Bracket Fabrication

Now that we had our catch can ready to go, it was time to select mounting locations, and fabricate the mounting brackets. First, we will start with the PCV line we initially targeted with the large catch can we had. Check out some initial mock-up shots!


Prototype PCV Catch Can mounted


Prototype PCV Catch Can mounted

Compared to the previous mounting point, we have moved this catch can to a more centralized position. We are no longer using the battery tie-down as a mounting point. This provides a cleaner install, and it also provides space for the brake booster/master on RHD vehicles. The lines shown in the image are purely for mockup and routing purposes.

We will likely offer these lines in our standard three colors; black, blue and red. We also use silicone lines for all of our direct fit kits. Silicone provides improved resistance to heat and pressure compared to a rubber counterpart. Additionally, silicone is more resilient in terms of degradation due to oil/fuel contamination. In short, these lines will last quite a while, and are much more durable than a standard rubber line you would see included in another kit.

Next, we tackled the crankcase breather lines. On the FA20 engine, only one line exists and runs from the driver’s side valve cover to the intake. To keep line lengths as short as possible, we made our best effort to locate the can around the port located on the cover. Check out a few shots of what our team came up with!


Prototype CCV Catch Can mounted

And take a look at the line routing to the port and intake!


Prototype CCV Catch Can lines

You will notice that the line on the bottom of the image seems to disappear into the engine. This goes to the port we referred to on the valve cover. Access to this is rather tight, unfortunately the compressor will have to be unbolted from its position in order to fit the line into position. Once in position, the compressor can be reinstalled. Evacuation of the system is not necessary. There is no way around this. We will be providing full instruction on how to do so in the install guide, it is far easier than you think.

Now that we had both mounts fabricated and our lines routed, the prototype kit was complete. Take a look at the engine bay with this kit fully installed.


Prototype Catch Can system installed


Prototype Catch Can system installed


Prototype Catch Can system installed

Product Testing Details

Alright, so we are done with the project right? Wrong. We still need to test this kit before we can begin manufacturing the brackets and lines on a large scale. Luckily, like we mentioned earlier, we have two easily accessible test vehicles. We selected the BRZ owned by a member of our sales team (due to his longer commute) and we installed the kit. Our plan was to check back with the vehicle at 1,000 and 2,000 miles to evaluate oil collection in the cans. We gave special instruction for our test vehicle owner to beat on the car a bit so both lines get use.

Check back with us next time for details from our testing and completion of this project!

For those interested in purchasing this kit, we will likely be launching a discounted pre-sale for the first few units we complete!

Thanks for reading.