Boxster rescue problems

[bagpiperse]

Hi All,

First off, thanks for the very quick replies. To address the questions:

I forgot to mention that after I hand cranked the engine, I cranked it a few times (brief spurts) with the starter and without the coils/plugs in to get oil distributed. I never started the engine or ran it without the serpentine belt.

I replaced the water pump with a new aftermarket pump with the plastic impeller. I see no leaking from the water pump or thermostat install (my first ever on any car). The car did not overheat the first startup, and I ran it for a while (long enough for coolant to circulate...)

In regards to the oil in the airbox. There was no oil leaking from the car before the first start up. After the first round of work (waterpump, thermostat, fuel filter), I jacked the rear of the car up to put in the new AOS. A somewhat large quantity of oil started leaking from the car, which was a first. So the oil leaking from the airbox was after first start up (after the car sat for 2 more weeks) and before I replaced the AOS.
As I noted earlier, the engine and intake are very dirty with oil, but there was not a spot of oil on my neighbor's driveway, where he parked the car for years, and where the car sat for 18 months. I was concerned and bummed about the oil and it was definitely coming out of the bottom of the airbox (there is a drain tube there). I removed the air filter and saw the oil in the bottom of the box (and then removed what I could).

I am pretty sure the air filter is paper....It was not too dirty....with no oil stains (???)

I forgot to mention that at first start up there were no codes at all! I don't know what was going on at second start up, as I just needed to get the hell out of the car!

The smoke is definitely oil, and not coolant.

So, I have been reading alot on various forums to help me along the way. I guess oil in the airbox is not unheard of. I believe that I put the correct amount of oil in when I changed the oil. I have checked it a few times and it was good.

Thanks for your thoughts about the AOS. I bought an aftermarket URO brand, which had good ratings on Amazon. The bottom accordion tube with the clip went on fairly easily, once I unbolted the sensor that is in the way, and once I actually compressed the ring/clip enough to push the accordion tube onto the seat. The aftermarket AOS tube would not go all the way into the engine block, no matter how hard I pushed. I hate to admit that I worked on the AOS for more than 8 hours trying to get it back together....The lower clip also was extremely difficult to reattach....

So, based on your feedback, I am thinking that the AOS I got was bad or failed immediately. Perhaps I can return it. I will by the Porsche part this time. I will also follow your advice and take apart the intake system as you described and clean it up.

Thanks again. I am really wanting to drive this car! I am heading out of town for a couple of weeks to visit colleges/universities with my daughter, so I have to let the car set for a couple more weeks before I can do the new work. I'll post an update when I get to that point. I can't wait to remove and put in another AOS (although it should be a piece of cake this time!)