AOS breather line replacement

[schoir]

Originally Posted by Sain0rs

I managed to crack the lower breather line coming off my Air/Oil separater in my 2003 986s. (the plastic accordion style hose that comes off the lower port on the right side of the AOS when standing at the back of the car looking towards the front). I did a homemade glue+tape job on the hose but I don't think it's a good permanant fix.

I actually cracked the upper plastic hose last year but that one was easy to replace. Anyone know the technical name for the hose coming off the bottom right port and where the other end of it goes? I tried looking on pelicanparts and in my bentley manual but I can't find any info. Looking in the engine bay is making me wonder if this is a "drop the engine" professional kind of repair job..

Any help is greatly appreciated

For a 2003, the part number is 996.107.147.58.

Porsche calls that part a "crankcase breather hose".

Also, did you crack the actual hose or just the flexible circular connector on the end?

If that's what you cracked, you can replace just the end by swapping it from the end of a new part.

Regards, Maurice.

[Sain0rs]

Amazing, thanks for the quick response. I can't thank you enough for taking the time to respond.

Wonder if I can manage to snake the old hose out and new hose in by taking out the throttle body or if I should just bite the bullet and have a dealer do it. I hate the idea of having to pay a ridiculous price for a (in theory) simple hose replacement.

Thanks again for your help

[schoir]

Originally Posted by Sain0rs

Amazing, thanks for the quick response. I can't thank you enough for taking the time to respond.

Wonder if I can manage to snake the old hose out and new hose in by taking out the throttle body or if I should just bite the bullet and have a dealer do it. I hate the idea of having to pay a ridiculous price for a (in theory) simple hose replacement.

Thanks again for your help

Sain0rs:

Before you go biting that bullett, why not inspect how much access you have if you just remove the two rubber intake distributors. That only involves unscrewing eight thin, large diameter screw clamps, two small vacuum connections and the throttle body.

Great opportunity to clean out the throttle body as well.

I recently did that with my friend Boxtaboy and it was very straightforward.

I'm not positive, but I'm reasonably sure that to be able to disconnect that end of the crankcase breather hose, you will also have to remove the driver's side intake manifold, but not the passenger's side one.

Here is a photo of that area after removing the two intake distributors and the throttle body:



The red arrow points to what I think is the crankcase breather hose in question. The yellow arrow points to the right rear corner of the oil cooler, for reference.

If you take a look at the parts diagram you can see the shape of that hose and the connection at the far end:



Regards, Maurice.

[Sain0rs]

Great idea, just ordered the new hose so we'll see how it goes after it arrives.

Can't hurt to try first before taking it to someone else.

Thanks for the pics, I've been looking around at pedro's garage etc for reference pictures as well.

[r00ster]

I recently broke this same breather hose and I'm about to tackle this same job. Anyone out there have photos, links, and/or insight they can share? If not, I will take pictures and jot down notes. Will post what I learn as I go through this job as I haven't been able to find much info on this task.

[Gelbster]

I recently did his with an engine on a stand in a well lit comfortable garage with all the tools and equipment. Awful !
1. the old hoses are very hard+brittle. This makes moving them into alignment very difficult.The consequences of a small crack/leak will drive you nuts with faults and problems
2.The old AOS connection used an "0" ring. This O ring swells slightly with oil+heat. When you try to refit ,the clip will not quite snap closed. Do not try force it ! Remove the old O ring an replace it with a new one Works just fine then!
3.The seal on the newer AOS is different. That may be easier ? The new seal looks like a sleeve on the AOS ,not an O ring in the hose. So figure out what you have first?There are some useful Youtubes on this.
4.Scrupulous cleanliness and a little Vaseline seem to help.
5.Be careful and patient because removing old cracked hoses and threading through new ones in such cramped conditions is difficult for a noob. I have no idea how anyone with large hands could do this.
6.Be ultra cautious about damaging other vacuum or electrical connections. There are many obscured ones buried underneath the inlet manifolds.
7. Ask for a referral to an Indie in your area?
8. Allow lots of time if you diy and have a backup plan in case any of the above happens
Good luck !Forewarned is forearmed

[SteelStroke]

I am having my AOS and both lines (Top and Bottom) replaced by my Ind Porsche repair shop on Monday 12 Sep 16. Could do it myself but having it done professionally is a piece of mind for me.

p.s. $500 to get done and I bought all the parts myself.