2003 Boxster-S 3.2, AOS lower clamp trouble

[jay2015]

Hello,

I am replacing AOS on my 2003 Boxster-s 3.2 and having hard time removing lower clamp. Please note 2003 boxster has different AOS design (please see picture) and there are no bellows.

The issue: I am trying to reach AOS lower clamp from passenger side but can't see the clamp as it is hiding under the AOS so I am trying to go by feel (I have moved oil filler tube out of the way) and I can see the clamp from driver side but can't reach (I am not 10 feet tall).

Any tips on how to reach and remove this clamp? (BTW: It is porsche compression/spring clamp)

[JFP in PA]

Originally Posted by jay2015

Hello,

I am replacing AOS on my 2003 Boxster-s 3.2 and having hard time removing lower clamp. Please note 2003 boxster has different AOS design (please see picture) and there are no bellows.

The issue: I am trying to reach AOS lower clamp from passenger side but can't see the clamp as it is hiding under the AOS so I am trying to go by feel (I have moved oil filler tube out of the way) and I can see the clamp from driver side but can't reach (I am not 10 feet tall).

Any tips on how to reach and remove this clamp? (BTW: It is porsche compression/spring clamp)

[78F350]

This is on a 2000 model, but the position and reach is still the same:

[jay2015]

Originally Posted by JFP in PA

Thanks JFP, your advice is always valuable.

I guess time to spend some money on one-time use tool. I see that autozone has decent quality for $35, the similar tools on amazon has mixed reviews.

[mikehkang]

Originally Posted by jay2015

Thanks JFP, your advice is always valuable.

I guess time to spend some money on one-time use tool. I see that autozone has decent quality for $35, the similar tools on amazon has mixed reviews.

I used the above tool twice. Last week for AOS and 9 years ago to replace the coolant tank. It's cheap. Trust me.

[mikehkang]

Wait. You have 2003. The above tool was useful to undo the bottom hose clamp you see in 0:33 of the 78F350's video. If you are trying to remove the bottom 'quick connect', I can't see how above tool will help.

[jay2015]

Originally Posted by 78F350

This is on a 2000 model, but the position and reach is still the same:

I think it is different as the clamp and bolts both are above engine and access is better from the top. I don't know how the clamp can be reached from wheel for 2003 986-S. upto 2002, the AOS had bellows where the clamp and bolt where better suitable for approach from right rear wheel. Porsche redesigned AOS for 2003+ 986 and same AOS is used for 987.

Thanks,

jay

[jay2015]

Originally Posted by mikehkang

Wait. You have 2003. The above tool was useful to undo the bottom hose clamp you see in 0:33 of the 78F350's video. If you are trying to remove the bottom 'quick connect', I can't see how above tool will help.

There is a hose that connects to bottom of AOS (on that thin portion, the portion which looks like a funnel) and it is clamped, that hose turned 90 degree and connects to engine.

I was able to remove quick connect breather tube very easily, I pressed the top of clip with one hand and pulled gently and it was released in less than a minute.

[mikehkang]

Originally Posted by jay2015

There is a hose that connects to bottom of AOS (on that thin portion, the portion which looks like a funnel) and it is clamped, that hose turned 90 degree and connects to engine.

I was able to remove quick connect breather tube very easily, I pressed the top of clip with one hand and pulled gently and it was released in less than a minute.

Less than a minute?!!
THAT took me a day and only after destroying the breather tube. :ah:
Jeez... I need to upgrade to 2003!

BTW Jay, Can you upload a picture of how your car looks when it is in engine service position? Even though I have 2001, I 'upgraded' to a 2003 top so I don't have to Porsche Chop. Having done so, I have EXTREMELY difficult time accessing the engine bay. How much space do you have from the top? Let's see some pictures when you have time. Thanks

[junglegreen]

I have a 2000 so don't have any knowledge of the 2003+ top but one thing I found useful for engine bay access was to remove the trunk lid.

I managed to break the oil filler tube to the engine when replacing the coolant tank. 4 small bolts hold the rear trunk lid on. The lid has hooks on the hinge to hold in place so it is a one person job to remove. Once the lid is removed you can get in the trunk and have easy access to the engine bay. Kneeling in the trunk made removing the air tube between the intake manifolds much easier than leaning over the fender. When I put the lid back on there was no alignment issues.

[jay2015]

The clamp on my aos was at weird angle where I could not even fit the cable operated pliers. The clamp on engine side for that small hose was so close to engine that there was no space for even a flat screwdriver. I used pliers to move the angle of the clamp on engine side than use small pliers and I was able to remove AOS with the small hose. I got a new hose, put that on the aos first with clamp in the right angle and slide the assembly on to the engine. The throttle body and intake distributor was cleaned and cars works great.