installing a moroso catch can on a 2010 r/t (with a mopar...

11:06 AM 7/22/2010 Installing a Moroso catch can on a 2010 R/T (with a Mopar CAI) Hey guys and gals! I’ve learned a lot from lurking and asking questions here on the Z. I wanted to pay it back a little. I worked up this guide with lots of pictures for those of you who are about to tackle your catch can install. For those of you who don't know what a catch can is let me just tell you that you really want one on your Challenger. I had no idea what a catch can was before reading about it here on the Z. It only took reading a couple of posts to convince me I needed one. In a nutshell, oil will accumulate in your intake system without one. There are many ways to install a catch can. This is my way. I am not suggesting other ways are incorrect or inferior. Everybody has a slightly different setup and their own preferences. Specifically, I wanted to retain the stock engine cover and go with plain rubber hoses. As you will see, I have a Mopar Cold Air Intake (CAI) already installed. If you have a different CAI I don't think it will matter much as long as the IAT sensor is not too far off from the "stock" location. I would imagine they would all be in the same place but I can't verify that of course. If you went with fancier hoses then you will have a little more work to do with cutting the lines and installing the clamp covers, etc. I went with the Moroso product because I love the built in drain. I purchased from BMC here on the Z. Great Service! They preassembled the can as much as possible. I believe they will also polish it for another $10. As others have pointed out, the Moroso included "instructions" are quite pitiful. They are more of a "what this kit contains" than instructions. The 5.7 picture is not like any 5.7 I have seen. I think both pictures are a 6.1. Anyhow, this guide will remedy that! I read many people saying this is a 10 minute install. I was not that lucky but perhaps with my help you can get it done quickly enough and enjoy yourself. I am not a great mechanic but I enjoy playing one. I took many of these pictures after-the-fact so they may look out of order and/or out of place. Just read all the instructions completely before you start and I am pretty sure you will do just fine. On to the pictures!

moroso_cc_install_01

Illustrated above are most of the tools you will need for the install. From left to right...Unless you are lucky enough to own a proper hose cutter or very large diagonal cutters, you will need a sharp blade to cut your hoses. The cap simply holds some clean oil. It will be vital for both lubing the hoses/fittings/brass nipples and it makes your engine cover snap back on quite easily. The allen key is sized at 3/16". You must get an "L" shaped one just like that. Alternatively, I suppose you could use some small pliers if you were careful enough. A ratchet and a deep 5/8" socket will make short work of the nut. I used a deep socket but a regular one would probably work. The 5/8" wrench will let you tighten the nut with everything installed but it is definitely optional. Another optional item is a large pair of pliers. They will be used to twist off the stock hoses. Also not pictured is another item I am unsure you will need - extra plain rubber hose. Initially, I took a different install route and cut the supplied hoses. This meant I had to go to AutoZone and get some more hose when I changed my mind. I believe the size is standard 3/8" heater hose. The kit from BMC comes with two hoses. One is definitely enough hose for the "long straight line" on the right side. For the left side I believe you will need 28" of hose. I asked for 48" and I had 20" left over. Assuming they did give me 48" then my 28" estimate for the left side should be good. (I am not near my car right now to verify this).


The Moroso kit comes with two brackets. The one pictured above is NOT the one you will use for a 5.7 install. The 5.7 bracket is longer and has a small hole in between the two larger holes.


I also did NOT use the above lock washer, washer and nut. I decided to reuse the stock piece. This will leave you with 3 allen bolts – 2 silver ones and a black one (not pictured).


Ok, now let’s install this thing! First you must remove the engine cover. It is simply held in place by 4 plastic “studs.” There are two on each side. Just pull up carefully on each side on you will be fine. Please ignore the hoses above for now.


Here are the ones on the driver’s side. NOTE: The engine cover contains sharp edges! I cut my finger quite nicely on it. Use caution and more on those sharp edges later. Also, when you reinstall the engine cover put some oil on those studs and your will have a much easier time with it.


The stock hose setup is on the left. Again, ignore the hose on the right for now. You must remove this assembly. The end goal of this entire setup is to place a can in between those two points to “catch” any oil that would otherwise end up in the intake. You are going to run a hose from the back of the engine to the catch can in front and the return a hose from the can to the middle opening on the intake. TIP: Use a pair of pliers to grip the ends and break the tension on the hose ends by rocking them back and forth. I wrapped the pliers’ jaws with a shop towel so as to not nick the surface of the hoses too much in case I wanted to go back to stock later. If the smog man says the catch can is illegal then I have an easy way back. I have no idea if a catch can is emissions legal or not. I don’t see how oil in your throttle body is good for emissions but these things don’t always seem logical.


Next you install the bracket that holds the can. This is what the stock bracket looks like. My dealer installed my Mopar CAI and left it installed. If you have it, remove it. If you don’t then just move on. The main point of showing you this is that I reused the nut that held on this bracket. You may not have that option if the bracket and nut are missing.


Install the bracket as shown above. There is not much to it. Just try to line it up nice and vertical. It might take you a couple of tries. The nut feels very tight at first and then it suddenly seems to loosen right up. I went ahead and lubed the threads with some WD-40 to keep things smooth.


Just for reference, my first attempt at installation looked like this. I was very happy and thought it looked really cool until…I tried to put the engine cover on. I know others have had success routing it this way but I just wasn’t comfortable with fighting with the engine cover. Again, the edges of the engine cover are a bit sharp in that area and I don’t like the idea of the rubber hose constantly rubbing on it. After reading some other posts on the Z and feeling that the edge on the other side of the engine cover was quite smooth I changed my game plan. I would route that left hose away from the right one to exit on the other outlet of the engine cover.


After installing the main bracket you can now mount the other bracket that holds the actual catch can in place. It will be held in place by the two silver allen bolts. You can see one of them above. Remove the IAT sensor (attached to the CAI) just to give yourself some elbow room and protect the connector. I chose to mount my can fittings ABOVE the IAT sensor. I left just a tiny bit of clearance as you can see. I have seen people put it below the sensor but to do so you must move the radiator hose clamp to the rear to make space for the can. I didn’t want to mess with that big ugly clamp and I figured the more space under the can, the better for draining purposes. I did test the install to make sure it cleared the hood before I closed it. I used Play-Doh and discovered the clearance is TIGHT but it does clear. Close your hood carefully the first time just to make sure.


After you install both brackets you can go ahead and place the can in it. You simply insert the black allen bolt through the SMOOTH side first and then through the threaded side where it will pinch up and close the clamp tight around the can. Again, the bolt passes through the smooth side first. (You could mount that can bracket in reverse for more clearance with tightening the black bolt but let’s just keep things simple for now and go with what definitely works.)


Here is a good shot of that hose clamp. If you mount your can high there is no need to worry about it. Just make sure you don’t let your can drop or it might get scratched by it. Your can should have the orange lever in the horizontal position as shown. This is the closed position. After your can is in place all you need to do is attach the hoses. There are many ways to do this. I can’t stress the importance of measuring carefully. The way I did it was to install the hoses on the engine end first. Remember to lube all points of contact with a light coat of oil (or soapy water if you prefer)! After doing that you can mock the engine cover back on to figure out the lengths you will need on the catch can side. The right side hose is pretty much a straight shot. The left side curves a bit so don’t cut it too short. One problem with this method is that cutting the remaining ends on the catch can side will be tricky as you will be cutting right over the engine compartment. I suggest finding a nice piece of wood to use as a cutting board. You could mark where you needed the cuts, place the board over the fuse box, and make your cuts. If you have a proper hose cutter or some large diagonal cutters then you are ahead of the game.


This is what it should look like. I was pretty happy with this arrangement except for one thing. The left hose was resting on one of the engine cover studs. I remedied this by using a nylon tie to bring it away from it. (see next pic)


You can slip right under this existing tie if you are lucky enough to have a little clearance. May the force be with you.


This is the end result! I think it looks quite good. If it weren’t for the Moroso logo and that awesome stainless finish it would almost look stock, as if it belonged there. As stated before, the underside of that cutout on the left side of the engine cover is quite smooth with no risk of rubbing it raw over time. Of course, the Moroso logo screams musclecar and we all like that, right?! Make the sure the engine cover is nice and tight and be SURE to reinstall the IAT sensor before you fire up your engine or you will trip an error code. The engine cover should NOT come off with gentle force. It should somewhat snap back in to place. If yours doesn’t, try lubing the studs as suggested earlier. I could actually hear mine click in to place.

To sum it all up:

Remove engine cover Remove stock hose assembly Disconnect IAT sensor Remove stock bracket if necessary Install bracket Install catch can bracket mount Install catch can Install hoses Reconnect IAT sensor Reinstall engine cover Smile, you are done

I hope you found this guide useful. Please drop me a line here on the Z or just send me an e-mail ([email protected]) if you have any suggestions, comments, etc. I am just a hack mechanic who has loved musclecars since I realized flying a fighter jet was not in the cards for me! I am a pretty good musician though! Take care Zuma http://zumaz.com http://myspace.com/zumazmusic http://www.youtube.com/zumazmusic

installing a moroso catch can on a 2010 r/t (with a mopar...

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