AOS breather line replacement

[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.

[r00ster]

Thank you both for your responses! SteelStroke, thank you for sharing your quote. I will use it to earn points with my wife when I tell her I saved us approximately $500 in trying to fix this myself. I hear ya on the piece of mind. Hopefully, I don't screw anything else up in the process...

I'm half way through this job or at least I have the old hose out. Gelbster, I can attest to how brittle those hoses are. That, in fact, is why I find myself where I am today; I originally broke the old (lower) breather line while recently replacing my AOS. Then, while removing the hose out from the engine, I broke it two additional times. To get the old hose and the "connection piece" (part #6 in the previously posted parts diagram) out, I've had to remove the throttle body, and the two intake distributors and their boots (4). The new hose is much more pliable than the old one and so I'm hopeful I'll be able to thread it in without having to take anything else apart. Fingers are crossed! To clarify for anyone reading this, I have a 2003 986 with a 2.7L and Tiptronic Trans.

[Gilles]

Rooster,
I replaced mine a few months ago without removing the large intake hoses but I did remove the engine access behind the seats because it wanted to ensure that the hose will be properly connected to the breather valve on the crankcase.

Also as Gelbster mentioned, be careful with the small vacuum hoses and the electric connector (fuel breather valve?) that it is on the way of the AOS hose, just take your time and ensure with a mirror that the o-ring at both ends of the hose sits inside the connector all the way around.

Good luck!

[r00ster]

Gilles, thank you for the good luck. Yes, I also pulled the front engine access panel. I did it so I could disconnect the hose and replace that breather valve/hose connector piece (996.107.047.00) that bolts to the engine next to the air conditioning compressor.

I've taken a lot of pictures to help me for when I go to reconnect all the vacuum lines and electrical connections so hopefully it all goes smoothly.

In regards to the o-rings you and Gelbster mentioned: neither my AOS (996.107.026.01) nor my breather hose (996.107.147.58) had an o-ring for the connection between these two parts. A new design? Not sure but my parts catalog shows 4 versions of this hose and 8 versions of the AOS with my part numbers being the "newest" for both parts. I'll look at the lower breather hose nipple on the AOS again to make sure but I didn't see an o-ring.

Anyway, the hose has been completely threaded across the engine to each connection area. Now, I have to install the breather valve hose connector piece (996.107.047.00). Not looking forward to that. The bolt on the forward side of the engine was a breeze but the aft facing bolt - I'll be doing it blind and if I drop it, it will be a nightmare retrieving it. Anyone know the torque specs for these two bolts? My guess would be something in the neighborhood of 10lbs?

[Gilles]

Rooster,
Each end of the new hose should have an o-ring inside, where it mates with the AOS at one end and with the valve at also the breather end, and if I remember correctly mine where blue in color, you should lube these o-rings so they go in smoothly