AOS breather line replacement

[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

[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.

[Josephjochoa]

I have an 02 Boxster S tiptronic. I cracked the lower AOS breather hose as well when installing new AOS. . It was brittle from heat and age. How did you get the new lower hose on? I have a new one but can’t even snake it in on the drivers side. Once one side is in how would you get in the other? Did you remove everything on top including the plenum? I’ve removed both cross tubes but still can’t get it in. Has anyone replaced this breather line with something more flexible like heat shielded rubber or silicone hose?

[Gilles]

Originally Posted by Josephjochoa

I have an 02 Boxster S tiptronic. I cracked the lower AOS breather hose as well when installing new AOS. . It was brittle from heat and age. How did you get the new lower hose on? I have a new one but can’t even snake it in on the drivers side. Once one side is in how would you get in the other? Did you remove everything on top including the plenum? I’ve removed both cross tubes but still can’t get it in. Has anyone replaced this breather line with something more flexible like heat shielded rubber or silicone hose?

Hola Jose,

If you remove the engine access cover behind the seats you will have more room (and you will be able to see what are you doing..), that way you don't have to remove the intake plenum.

Good luck!

[Josephjochoa]

I removed the access panel behind the seats. Unfortunately, it’s blocked by pulleys and the view is terrible. I can’t really see. Has anyone done a write up, or can they tell me how they did it. I am stuck. I don’t really want to remove the intake manifolds.

[Starter986]

Is there not a workaround? Maybe employ the connecting ends of the tube with a flexible silicone hose or something along those lines? It's an obvious question for which I don't have the answer.

Actually, aren't there a variety of hoses and lines that could be replaced with less challenging alternatives?

I look at that hose and, not yet having seen the actual one in my bay, wonder why you couldn't cut off the ends and secure a flexible hose. It seems so simple, so I'm sure someone will tell me why you can't.

Thank you.

[Starter986]

Originally Posted by Starter986

Is there not a workaround? Maybe employ the connecting ends of the tube with a flexible silicone hose or something along those lines? It's an obvious question for which I don't have the answer.

Actually, aren't there a variety of hoses and lines that could be replaced with less challenging alternatives?

I look at that hose and, not yet having seen the actual one in my bay, wonder why you couldn't cut off the ends and secure a flexible hose. It seems so simple, so I'm sure someone will tell me why you can't.

Thank you.

In the absence of a why it can't be done, I'll assume it can. Gravy.

[JFP in PA]

Originally Posted by Starter986

In the absence of a why it can't be done, I'll assume it can. Gravy.

Perhaps it can be done that way, but all that fuss is completely unnecessary as the factory hose can be installed, albeit with a bit of effort, but without any cutting or folderol.....

[Starter986]

Originally Posted by JFP in PA

Perhaps it can be done that way, but all that fuss is completely unnecessary as the factory hose can be installed, albeit with a bit of effort, but without any cutting or folderol.....

Yeah... I've been reading about that effort, and it sounds like a real pain in the ass.

"Effort" sounds like an understatement, from what I've been reading.

Thank you for your response. With all due respect, "perhaps" doesn't answer my question.

Can someone tell me why you can't cut off the connecting ends... affix a silicone or rubber hose... then snake it to the fitting opposite the AOS? Is there a way to effect the replacement of the AOS absent the hard line that is a fuss to install?

Thank you.

[The Radium King]

i'd love to get rid of that hose. impossible to get at, gets brittle, and is in the way of a lot of tasks on the engine - pretty much anything that requires moving the intake. and, with my ac, sai, and ps off the engine, it is the last piece of clutter. i've often thought of fabricating a replacement. doing as start says must be possible, as it is often done with with the shorter aos hose to the intake.

[Starter986]

Originally Posted by The Radium King

i'd love to get rid of that hose. impossible to get at, gets brittle, and is in the way of a lot of tasks on the engine - pretty much anything that requires moving the intake. and, with my ac, sai, and ps off the engine, it is the last piece of clutter. i've often thought of fabricating a replacement. doing as start says must be possible, as it is often done with with the shorter aos hose to the intake.

You know... specifically I was going to quiz you on my inquiry... but somehow I knew you'd chime in. I'm glad you did.

Since you've had the intake, sai and ps out... did never you say to yourself "I'm going to employ silicone/rubber."? Do you believe that it could be done with silicone/rubber tube/hose? isn't there an alternative to the hard line? Would it be terribly difficult to affix the new silicone/rubber to the connecting ends (once they've been sawed off the hard tube)?

Thank you.

[The Radium King]

[Starter986]

Originally Posted by The Radium King

Outstanding! Thank you.

That's the top hose. Do you believe the lower hose would be amenable to the same procedure... cutting the connecting ends... snaking the flex/sil/rub hos from the AOS to the final destination?

I'm just looking for finality. Don't want to beat this subject to complete death.

Thank you, RK.

[The Radium King]

i presume they are very similar - diameter, end connectors, so see no reason why not.

[Josephjochoa]

Is there a lot of vacuum in that line that could cause a softer hose to compress, thereby causing problems?

[The Radium King]

don't think much of an issue - all kinds of aftermarket aos systems for flat four subuarus on the market - use whatever hose they do.