Air/Oil Seperator write up?
 

I'm about to write one up with GOOD pictures, but decided I'd better check with the "locals" and see if a good one was already somewhere on the site. I used the search *feature*, but as with most forum software.. it is close to worthless.

Let me know if I should continue. I'll walk everyone through step by step with HIGH quality pics and a breakdown of the tools needed, and how I make one small change to the install procedure.


:cheers:



B

There are a couple floating around out there somewhere but if you are preparing one I am sure it would be much appreciated.

I'm currently going through and cropping the pics + adding arrows and such :)


B

+1 encouragement to go forth
:cool:

Working on the verbage :)

WHOA! Went to upload the first pics and the server took forever!! Let me post them on my server and I'll link to them from there!


B

Great. Please post the link.

I'm approaching my 1 year of ownership and to this day I have not opened up the eng compartment lid. I will be going in within the next week and AOS will be one of the things I'll be doing.

OK! This is what we are replacing in this particular write-up:

http://www.986motorsports.com/upload...2685_thumb.jpg

Until the post before this one, I *assumed* everyone knew how to get to the engine lid :) I'll give a quick walk through: Pull up e-brake, hit the button for bringing the top DOWN, release the button right as the top starts to move away from the windshield (3-4 inch gap is good) now with the rear top cover in an upright position, you now have access to the cables that help guide the bottom of the convertible top. These are simple cables attached to the car via "ball socket". I personally pop off the top ball socket on both sides and leave the cables laying flat. Once the cables are released (they should not have any tension on them at this point) the rear portion of the top can be MOVED towards the front of the car (it will pivot up and out of the way) I typically stick my hand into the rear window and create a crease for it to follow as I use my other hand to "collapse" the top (from bottom up)


The rear most trim piece is simply "clipped" into two small plastic holders. You can just pull down on this and it will come out of the holders. Once out of the holders, move the material, you will see your carpet covering for the engine cover.

Do this first:

http://www.986motorsports.com/upload...1605_thumb.jpg

Then pop these off on both sides.

http://www.986motorsports.com/upload...1628_thumb.jpg

Once you get the top "material" out of the way, you can pull the carpet off the top of the engine cover. There will be 4 plastic "twist locks". Flip one half of the locking mechanism up and simply "twist" It *should* be a counter clockwise rotation. It should take nearly NO effort for them to twist and release. They will break. Take your time.

This is the top material up and out of the way.. and the carpet up and out of the way. The engine lid itself has multiple "gold/cad" colored twist locks that hold it to the chassis. These have a small wire "hoop" on them. Flip the hoop up and "twist" it will release the engine lid, simply lift it off when you have all of them released.

http://www.986motorsports.com/upload...9029_thumb.jpg


Engine lid off:


http://www.986motorsports.com/upload...2425_thumb.jpg

Here is the location of the AOS:


http://www.986motorsports.com/upload...9061_thumb.jpg


You will need a 10mm deep socket, a pair of small channel locks, and maybe a 10mm zippy wrench (Gearwrench)


http://www.986motorsports.com/upload...9273_thumb.jpg

I start by removing the upper breather line, and moving the wiring harness out of the way. This requires nearly NO effort. Just barely squeeze and pull away from the AOS


http://www.986motorsports.com/upload...9389_thumb.jpg


Unclip the plastic wiring loom holder and move the wires back. Take the second loom you see that is NOT in the holder and move it up and over the fuel rail test port. This will give you more room later as you work


http://www.986motorsports.com/upload...0184_thumb.jpg

It should look like this when you get the loom unclipped and the second loom UP and over the fuel test port cover.


http://www.986motorsports.com/upload...9492_thumb.jpg


NOW you can see the lower plastic clamp that needs to be released!!!


http://www.986motorsports.com/upload...9722_thumb.jpg

From above and using the same Blue small Channel locks as I used on the breather line above, I reach down and carefully release the lower breather hose. I also move the shifter cables over and out of the way.


http://www.986motorsports.com/upload...9879_thumb.jpg

Now its time to visualize :) Take a look at the length and positioning of the stock bolts. I try to do as much as I can up on top prior to jacking the car up and getting underneath. I can easily remove the two M6 bolts (10mm head) from up top utilizing a short 10mm socket on a 1/4 inch drive ratchet and a Zippy 10mm wrench.

You will be removing these two small bolts. They thread into the block. Once you get them broke loose, use JUST the socket to unscrew them. They will come out pretty easy.


http://www.986motorsports.com/upload...0411_thumb.jpg


Use the 1/4 drive with 10mm socket on the top one, and the 10mm Zippy wrench on the bottom one. YOU CAN DO THIS from the top of the car. Just feel down the side of the AOS. I do my damnedest to stay out from under the car until I have too. I shot these pics from under the car, just to show everyone where the bolts where located.


http://www.986motorsports.com/upload...0559_thumb.jpg

I also go ahead (from the top) and remove this bracket seen here with the blue arrow pointing to it. This will allow you EASY access to the clamp we will remove later from the lower portion of the bellows.


http://www.986motorsports.com/upload...0717_thumb.jpg


In this shot, you can clearly see the bolts have been removed and the blue arrow is pointing to the clamp that needs to be removed NEXT!! You can also see in this pic, how I removed the M6 bolt for the bracket and moved the bracket out of the way. The bracket holds the plug for one of the O2 sensors.


http://www.986motorsports.com/upload...0981_thumb.jpg

After removing the lower clamp (I used the same small Channel locks as above) the AOS will slide up and out of the engine compartment. You will have to twist it and pay attention to things it could get caught on while coming out. FYI: There is a special tool for those clamps you see. I choose not to reuse those clamps and instead, replace it with something MUCH easier to deal with during the process of installing the new AOS


http://www.986motorsports.com/upload...1428_thumb.jpg


http://www.986motorsports.com/upload...1454_thumb.jpg

I go back in with a factory hose clamp :)


http://www.986motorsports.com/upload...1176_thumb.jpg


Stock spring clamp is on the left, factory hose clamp on the right! This hose clamp does NOT need 400lb. ft. of torque on it. Just snug. You'll find that trying to put the spring clamp back on with your arms fully extended from the wheel well will prove to be nearly impossible (unless you manage to locate the proper locking pliers that hold CLOSED on the clamp) I find it MUCH easier to stick a 7mm nut driver up there to a regular hose clamp and MOVE ON!


Here is the factory part number for the clamp I used. It is a "fluid" hose clamp meant for BoxsterS 3rd radiator hoses. Feel free to use any hose clamp you feel comfortable with. I choose factory parts as much as possible in my builds/repairs.


http://www.986motorsports.com/upload...1220251339.jpg

Slide the new AOS back down into the same hole you removed the other one from smile.gif I like to place a little oil on the rubber O-ring that goes into the block, and place a little oil on the bellows that slips down onto the steel tube protruding from the block. Make sure you watch the O-ring go into the block!!


http://www.986motorsports.com/upload...1220251911.jpg


This is the AOS installed with the new hose clamp. MUCH MUCH easier with the clamp. I preset the clamp so it *just* moves around the bellows. This allows me to "locate" it for easy access of the 7mm nut driver. You can also see I put the bracket back for the O2 sensor! AFTER tightening the new clamp for the bellows.


http://www.986motorsports.com/upload...1793_thumb.jpg

Once I get everything done on the bottom, I move back to the top where I "snap" back in the upper breather line, and snap back in the lower breather line. The lower breather line can give you fits. I use a HONKIN long flat blade and gently press against the plastic elbow until I hear it snap. You can see it from up above IF you moved the wiring like I showed. Once you hear the "snap" for both breather lines, put the wiring loom back into place and locate the shifter cables (if you moved them out of the way)


http://www.986motorsports.com/index....pe=post&id=364


VOILA!! NOW.. clean the damn engine. It is probably nasty :)


http://www.986motorsports.com/upload...2425_thumb.jpg


http://www.986motorsports.com/upload...1220252344.jpg

It should take someone who does not wrench on a regular basis, about an hour. I did one not too long ago for a BoxsterSpec guy up at Thunderhill on his lift. I *should* have put the car down and performed 70% of the removal from above, and only went under the car to remove the spring clamp and to tighten the hose clamp. The rest can all be done from above. :)



B

Thank You
 

Wow Brad, thank you for the How to. Nicely done!

great write up - many thanks.

now, WOW, how did you clean that engine?????? :cheers:


paul

I had to go back and shoot some of the pics.. I didn't think to document the install until I already had the engine cover off.. :)

I'll create a .pdf and ship it with the AOS's I sell.



B

Clean engine: Zep :) then wipe it down. I use brake clean on the engine case/throttle body/oil cooler. Try to keep the brake clean off the plastic. It will discolor it!! Took a whopping 4 minutes.

I have this weird issue of cleaning things before I work and after.



B

Hi, Thanks nice DIY.

:cheers: :cheers:

If anyone see's anything I left out.. please let me know!! I tried to cover everything.



B

I have to agree, what a great diy. I wish I had those instructions about a month or two ago. I spent too much time trying to remove the AOS itself, because I did not know to remove the sensor bracket. So i paid a shop to do it for me.

Honestly? if it wasn't for the DIY writeup, I would have YANKED really hard on it and broke the bellows while removing it. I'm not going to reuse ANY of the old AOS? so why be careful?

I see people being "careful" to remove their old wheel bearings!!! http://www.914club.com/bbs2/style_em...confused24.gif Why? You want to save it for a rainy day?? http://www.914club.com/bbs2/style_em...efault/lol.gif If the piece you are removing is JUNK, then treat it as such. You are going to throw it away!


B

Brad Roberst
 

Thanks for the great article on AOS are spec racers using the modified versions of the AOS?

Second Question have you shut of your TC and if so how was that achieved plus disconnecting the TC override. I tried taking the fuse out but that also cause the ABS to stop working.

Thanks

Catman

Very nice write-up. How often do those need to be replaced, anyway? My '02 Box S just broke 15k miles; I hope I don't need to do this for a while, but my engine probably could use a good cleaning.

Hey Catman!

We are currently discussing how to change the ABS module from 4 line to 3 line. Right now we know that you can install a different brake light switch for a NON TC car :) This way the ABS still works, but the TC does not :)


B

JayMatta,

I really have not seen a pattern of failure on these. I thought they would fail under the duress of racing, but I have only seen one failure out of 20 some odd Boxster race cars.. so I threw that out.. :lol:

Most of the failures I do see involve cars with 60-70k miles on them, and it appears to be heat related (air temp 100+ and ground temp 115+) which would equal REALLY high engine compartment temps. This is the ONLY "common" denominator so far.


B

I wonder if that would work on a 2000 standard?

Good question! Let me go through my parts systems and find!


B

$771 to replace the ABS module!! Not good. Now we are looking at the wiring connector to see if it is a PIN change from one module to another :) Could be as simple as removing a pin from the connector!



B

Aos and TC continued
 

I heard the Competition was more like $600 which seems rediculas! A pin would be good news. I be away for a few days but would love too know how to disable the TC....

I just replaced my AOS using the instructions here. At first I was hesitant because looking at the access room I had doubts. I started to call a repair shop and a dealer. Independant shop quoted 13 hrs of labor @ $115 per hr since the eng need to be dropped. The dealer quoted $900 but advised they revised the removal process and don't need to drop the Engine. I said I guess I'm going to get down and dirty and try harder.

I followed the instructions from this post except one area. Instead of trying to remove the clamp that is difficult to remove. I just cut the hose and remove the clamp once you have the AOS out of the way. The new AOS came with a hose.

I also didn't bother removing the lower vacuum hose clamp until I was able to raise the AOS. You have more room to remove the clamp once you raise the AOS.

Brad, Thanks for posting this. It was very helpful.

I put this picture on Bard's spec board, so here it is.

This is what I see the mechanics at the local dealer using for the lower spring band clamp. Once the clamp is in position the blue clip is puled away and the clamp closes. Marvin Weitz at RennShop in Santa Clara also uses it.

Cas! glad it helped.. I should point you to a shop that charges for what it takes.. not some BS book time from Mitchell systems.

If you need ANYTHING done.. check out Heyer Performance in Mountain View. They are just off of 101 and Rengstorff near Google. Tony (the owner) was on the 935 teams in the 80's with Garretson enterprises who beat all the factories teams at Leman with Jerry Woods built turbo engines. Bottom line: he knows his sh_t!!

Mention "Brad Roberts sent me" to Tony.. and he will take care of you. Promise. They are open 4 days a week from 7am-6pm. Tony has been a Porsche wrench for 30 years now and has been on MULTIPLR factory backed Porsche ALMS teams. He helped me get my foot in the door with the Porsche teams back in 99-00 with Dick Barbour.



B

Brad,
Thanks for the info. Yes I know where Hyer is located. I used to work nearby. Without the clear pictures you made I probably would not have done it. Now that I've done it once the next time will be a lot easier.

Thanks

awesome write up.

how did you get your engine bay so clean? did you steam clean it, or just spend a lot of time with a rag?

i recently had my engine cover off so the car could be smogged/visual exam - and it looked all dirty like yours and I seriously had the urge to clean it..even though it's all under a cover - i know it's all dirty and the anal side of me wants it to be clean, even though no one can see it.... we are sick people!!