Catch Can — Install Guide

GT40 Marine | SKU GT40-SD-CC-4TEC | Billet Oil Separator / Catch Can | Rev 1.0 — 2026-05-24

Fitment

|---|---|---|---|

| Sea-Doo | 1503 4-TEC NA | 130 / 155 / 170 | 2002–2018 |

| Sea-Doo | 1503 4-TEC supercharged | 215 / 255 / 260 | 2007–2015 |

Universal fit for all Sea-Doo 1503 and 1630 4-TEC engines. Bracket geometry suits the OEM engine bay mounting points. Confirm engine code stamped on the block before install.

In the Box

(1) Billet aluminum catch can body, hard-anodized
(1) Internal stainless mesh oil-separator core
(1) Quick-drain valve, brass, NPT
(2) Push-lock fittings, 3/8" hose barb, anodized
(1) GT40 mounting bracket, laser-cut stainless
(2) M6 × 16 mm SHCS bracket bolts
(2) M6 stainless flat washers
(2) M6 nylon-insert lock nuts
(1) 3 ft. fuel-grade reinforced hose, 3/8" ID, marine
(4) Stainless worm-gear hose clamps, #6
(1) Zip-tie pack, UV-rated
(1) Install hardware bag — spare clamp + extra zip ties
(1) GT40 product registration card
(1) This guide

Verify all components present before starting. Missing parts: support@gt40marine.com.

Tools Required

10 mm + 13 mm sockets + ratchet, 3/8" drive
T25 + T30 Torx drivers
5 mm hex (Allen) key
1/4" drive torque wrench, 5–25 Nm range
Flat-blade and Phillips screwdrivers
Hose-clamp pliers (spring-clamp removal)
Hose cutter or sharp utility knife
Trim removal tool
Shop towels — keep several handy, hoses will hold residual oil

Safety

Read in full before starting.

Battery disconnected for the duration of the install.
Cold engine only. Crankcase vapor lines can hold heat and pressure after operation.
Eye protection. Removing the stock PCV / breather line can release accumulated oil mist.
No smoking / open flame. Oil vapor in the system is flammable.
Catch can must be installed below the highest point of the breather line. Routing the can above the breather port traps oil at the valve cover — defeats the purpose.

If you are not comfortable with PWC engine bay work, take the install to a certified marine technician.

Pre-Install Checklist

[ ] Watercraft on stable trailer or stand, fuel drained from a recent burn cycle
[ ] Battery negative disconnected and isolated
[ ] Engine bay clean — wipe down any oil residue around the valve cover
[ ] Factory PCV / breather routing photographed before disassembly
[ ] Mounting location identified on the engine bay sidewall — accessible for future draining

Step-by-Step Install

Step 1 — Access the Engine Bay

Remove the seat and engine bay top hatch. On RXP-X / RXT-X, also lift the rear storage bin.

Disconnect the battery negative terminal. Secure the cable away from the post.

Step 2 — Locate the PCV / Breather Line

On the 1503 and 1630 4-TEC engines the crankcase ventilation system uses a single breather hose running from the valve cover to the intake side of the airbox or supercharger inlet. Trace the line from the valve cover port until you confirm both ends.

Photograph the routing in its stock state.

Step 3 — Identify the Mounting Location

The GT40 bracket suits two factory mounting locations:

Preferred: the M6 boss on the inboard engine bay sidewall, just forward of the supercharger
Alternate: the M6 boss on the cooling-line bracket, port-side

Choose the location with the cleanest hose run from the valve cover and back to the airbox / supercharger inlet. The can must sit below the breather port height — verify visually before drilling or bracket-bolting.

Step 4 — Mount the Catch Can Bracket

Position the GT40 bracket against the chosen mounting boss
Hand-thread one M6 × 16 mm SHCS through the bracket and into the boss
If the location uses a through-hole rather than a tapped boss, use a flat washer + lock nut on the backside
Snug, then torque to 10 Nm (89 in-lb) with a 5 mm hex key
Verify the bracket is plumb — no twist that would side-load the can body

Step 5 — Install the Catch Can on the Bracket

Thread the catch can body into the bracket clamp ring
Orient the inlet fitting toward the valve cover side, outlet toward the intake side
Tighten the clamp ring to 8 Nm (71 in-lb) — even draw, no gap

Step 6 — Install the Quick-Drain Valve

Apply two wraps of PTFE thread tape to the NPT drain fitting
Thread the quick-drain valve into the bottom of the can body
Snug by hand, then half a turn with a wrench — do not over-torque NPT in aluminum
Confirm the drain handle clears the engine bay floor and is reachable from above

Step 7 — Route the Hoses

Remove the stock breather hose from the valve cover (squeeze the spring clamp with pliers)
Measure the run from the valve cover to the catch can inlet — cut the supplied 3/8" hose to length, leaving 1 in. service slack
Slide a #6 hose clamp on each end, push the hose onto the valve cover breather port, then onto the catch can inlet barb
Position both clamps 1/8 in. back from the hose end — tighten with a flat-blade to 3 Nm (27 in-lb) equivalent (snug, no biting through the hose wall)
Measure and cut the second run from the catch can outlet back to the original breather entry point (airbox nipple or supercharger inlet adapter)
Slide #6 clamps, push hose onto both barbs, tighten as above
Confirm the routing has no kinks, no contact with the exhaust manifold, no zip-tie pinch

Step 8 — Final Reassembly and Verification

Walk the engine bay — every clamp, every bracket bolt, every hose run
Confirm the can sits below the breather port (visually trace water level — water would flow toward the can, not away)
Confirm the drain valve handle is reachable and closed
Reconnect the battery negative terminal — torque to 10 Nm (89 in-lb)
Replace engine bay hatch, storage bin, seat
Start the engine on the trailer with the cooling hose connected
Idle for 60 seconds — listen for any whistle (loose hose clamp on the breather side)
Scan with BUDS or compatible OBD diagnostic — no fault codes should appear

If clean: install complete.

Post-Install

Break-In

No break-in cycle required. The catch can will begin separating oil vapor on the first crankcase pressurization cycle (idle to mid-RPM warm-up).

Service Interval

First check: after the first 2 hours of run time — open the quick-drain valve into a catch container, observe the volume and consistency of separated oil
Routine drain: every 10 run hours or before extended storage
Mesh cleaning: every 50 hours — remove can from bracket, unscrew the top cap, solvent-flush the stainless mesh core, dry fully, reinstall
Hose inspection: every 25 hours — replace if any cracking, swelling, or oil-saturation softening

Drain Procedure

Engine cold, watercraft on a stable trailer
Place an oil-resistant catch container under the drain valve
Open the quick-drain valve — collected oil drains in 5–10 seconds
Close the drain valve fully before next operation

Troubleshooting

| Symptom | Likely Cause | Fix |

|---|---|---|

Oil pooling at the valve cover	Can mounted above breather port	Relocate per Step 3
Whistle at idle	Loose hose clamp on breather line	Retorque both clamps
Can fills with water after operation	Crack in hose or fitting	Replace hose, recheck fittings
Check Engine light + crankcase pressure code	Hose routing blocks PCV flow	Recheck for kinks, replace if hose collapsed

If symptoms persist after the checks above, contact GT40 Marine support before further operation.

Torque Reference Summary

| Fastener | Torque |

|---|---|

| Bracket to engine bay mounting boss | 10 Nm / 89 in-lb |

| Catch can to bracket clamp ring | 8 Nm / 71 in-lb |

| Quick-drain valve into can body | Snug + 1/2 turn (NPT — do not over-torque) |

| Hose clamps | 3 Nm / 27 in-lb (snug, no hose-wall cut) |

| Battery negative terminal | 10 Nm / 89 in-lb |

All torque values nominal — refer to current Sea-Doo factory service manual for any conflicting OEM specifications.

Warranty

GT40 Marine warrants this kit free from defects in materials and workmanship for ninety (90) days from date of purchase. Warranty covers replacement of defective GT40-supplied components. Warranty does not cover:

Damage from improper installation
Damage from operation outside design intent
Normal wear of consumable items (hose, clamps, mesh)
Damage from water ingress into the engine bay caused by hull breach or operation outside design conditions
Use on craft outside the listed fitment matrix

To submit a warranty claim: email support@gt40marine.com with order number, photographs of the installed kit, and a description of the failure mode. Response within two business days.

Support

Email: support@gt40marine.com
Site: gt40marine.com
Install help: include the GT40 SKU above and your hull serial number in any support correspondence

Built in the United States. Designed for buyers who want the best.