Doing the Air Oil Separator

[mortzz]

Hi all was going to do the AOS but decided to put it off until I get the correct cable pliers for the spring on the bottom rubber as I watched a video and they said that's the hardest clip to get off and on, can anyone point me to a good set of cable pliers for the clip , I'm unsure about the size of pliers I need , any help guys

[½cwt]

Just had a cheaper set of these fail on me only yesterday doing this job.  For the moment I plan to ask my indy to do it when it does for service in early Dec.  Don't usually bail on a job but for what is only 3 hoses and 2 bolts it has the making of a PITA.

[Daboy3000]

I feel the same @½cwt.   Been quoted just under £400 by a couple of Sussex specialists

[½cwt]

31 minutes ago, Daboy3000 said:

I feel the same @½cwt.   Been quoted just under £400 by a couple of Sussex specialists

That's lots, the part is just under £100 from Porsche so how long do they say it will take? Even at £150 (?!) an hour for an indy used to doing the job that should be too long. Allow a generous 15 mins to get the hood into service position and engine covers off, take left rear off on the ramp and same time to reverse.  Not sure what they are doing with the other 90 minutes even with a tea break.  I'm sure I'd have got is done in under that time with the right working tools on my drive with no previous experience.

[fizz]

3 hours ago, ½cwt said:

That's lots, the part is just under £100 from Porsche so how long do they say it will take? Even at £150 (?!) an hour for an indy used to doing the job that should be too long. Allow a generous 15 mins to get the hood into service position and engine covers off, take left rear off on the ramp and same time to reverse.  Not sure what they are doing with the other 90 minutes even with a tea break.  I'm sure I'd have got is done in under that time with the right working tools on my drive with no previous experience.

I rang a few local specialists, Prices ranged from £280 (inc VAT) to £350+VAT.

[mortzz]

So what size cable pliers do I need ,  I'm going to do this job, I've just done my Haldex pump on my Range rover and the bolts on that with out a lift was the hardest job I've ever done so won't let a clip on a rubber hose stop me 

[½cwt]

Something like these :

(although these are the design that failed on me on Saturday, the ferule came off the end of the cable on the lower arm on the pliers first time I used them, they had worked OK on a 'bench test' on a clamp off the car)

I've done a full suspension and brake system rebuild on the car so I don't back away from a challenge.

[paulo66]

Hi it doesnt matter what design clip pliers you use because most of the time the stupid clip is innaccessible to anything, it spins against the block and needs up in the air and cut off, good luck, ps i have tried this

[bally4563]

£400 !!! I’m undercharging!!!

[fizz]

Using a Chat GPT to ask how to change the AOS and got 2 different responses... 

Thought these were interesting to see where they got it from. 
 

To change the Air Oil Separator (AOS) in a Porsche Boxster 986 S, follow these steps:

1. Gather the necessary tools and parts: You will need a set of metric wrenches and sockets, a screwdriver set, pliers, a new AOS, and fresh engine oil.

2. Park your vehicle on a level surface and engage the handbrake. Ensure the engine is cool before starting the procedure.

3. Open the engine compartment and locate the AOS. It is typically located on the passenger side of the engine, near the firewall.

4. Disconnect the negative terminal of the battery to prevent any electrical mishaps while working on the AOS.

5. Remove the engine cover by unscrewing the retaining screws or clips.

6. Remove the air intake hoses and any other components that may obstruct access to the AOS. Take note of their position for reassembly.

7. Disconnect the electrical connectors and vacuum hoses connected to the AOS. Label them if needed for proper reinstallation.

8. Loosen the clamps securing the AOS to the engine. Gently remove the AOS from its housing, taking care not to damage any surrounding components.

9. Inspect the AOS for any signs of damage, cracks, or excessive oil accumulation. If it is damaged, replace it with a new one.

10. Install the new AOS by aligning it with the mounting holes and securing it with the clamps.

11. Reconnect the electrical connectors and vacuum hoses to the appropriate locations.

12. Reinstall the air intake hoses and other components that were removed earlier. Ensure they are properly secured.

13. Reconnect the negative terminal of the battery.

14. Start the engine and check for any leaks or abnormal noises. Allow the engine to idle for a few minutes to ensure everything is functioning correctly.

15. After confirming that everything is working as expected, replace the engine cover and close the hood.

16. Check the engine oil level and top up if necessary.

Remember, these steps are a general guideline, and it is always recommended to consult the vehicle's manual or seek professional assistance if you are unsure or uncomfortable performing the task yourself.

------------------------------------------

 

Changing the Air Oil Separator (AOS) in a Porsche Boxster 986 S can be a bit challenging, but it's doable if you have basic mechanical skills. Here's a simple guide:

Things you'll need:

1. Replacement AOS
2. Flat head screwdriver
3. Pliers
4. Torx screwdrivers
5. Car jack and jack stands
6. Mechanic gloves

Steps:

1. Safety First: First, make sure the car is parked on a flat surface. Use the car jack to lift the rear of your car and put the jack stands underneath for security.

2. Access AOS: Open the engine compartment. In the Boxster, this is located at the rear of the car. The AOS is located on the top of the engine, towards the back.

3. Remove Air Intake: Disconnect the mass airflow sensor and remove the air intake. This will give you better access to the AOS.

4. Unplug the AOS: There are two hoses connected to the AOS. Use your pliers to remove the clamp and then disconnect the hoses from the AOS. There's also an electrical connection that needs to be unplugged.

5. Remove the AOS: The AOS is secured with a couple of Torx screws. Use your Torx screwdriver to remove these. Once the screws are out, you can remove the AOS from the engine compartment.

6. Install the new AOS: Place the new AOS in the same position as the old one. Secure it with the Torx screws. Plug in the electrical connector and reattach the hoses, securing them with the clamps.

7. Reassemble: Reinstall the air intake and reconnect the mass airflow sensor. Lower the car back down from the jack stands.

8. Check: Start the car and let it idle for a few minutes. Check for any leaks or unusual noises. If everything seems fine, go for a short drive to make sure everything is working correctly.

Remember, if you're not comfortable doing this yourself, it's best to take your car to a professional mechanic. Also, always refer to your car's service manual for specific instructions and details.

[Daboy3000]

On 9/25/2023 at 3:51 PM, bally4563 said:

£400 !!! I’m undercharging!!!

Don't forget the South of England TAX though, everything down here is more expensive, especially labour. 

If you fancy a trip to the seaside though, just shout!!

 

also maybe mine is a bit more expensive as I have a very early car and I believe they changed the AOS and now I need an extra pipe?

Edited September 27, 2023 by Daboy3000

[Bradders59]

Ive never done the job, but I remember @TROOPER88 saying something like, he cuts the old pipe off rather than waste time trying to take it off complete which makes the job a lot easier / quicker.

Does that make any sense whatosever ?

[½cwt]

20 minutes ago, Bradders59 said:

Ive never done the job, but I remember @TROOPER88 saying something like, he cuts the old pipe off rather than waste time trying to take it off complete which makes the job a lot easier / quicker.

Does that make any sense whatosever ?

Yes.  I can see how that would work.  It is a bit like when doing the rear suspension, if the inner bolts don't come first time, just get the recip saw or cutting disc out.  Saves time, knuckles and stress.

[jonogt6]

On 9/25/2023 at 10:06 AM, ½cwt said:

Something like these :

(although these are the design that failed on me on Saturday, the ferule came off the end of the cable on the lower arm on the pliers first time I used them, they had worked OK on a 'bench test' on a clamp off the car)

I've done a full suspension and brake system rebuild on the car so I don't back away from a challenge.

I bought one of those to replace my AOS a few years back. Mine didn't break but was the most horrible device I've ever had the displeasure of using. In the end I abandoned it and used a jubilee style clip instead.

[hopz121]

I had my AOS done yesterday at a well respected specialist and the Bill for that scope of the work totalled £171.27 inc vat

£400 is a joke!

[Boxob]

10 minutes ago, hopz121 said:

I had my AOS done yesterday at a well respected specialist and the Bill for that scope of the work totalled £171.27 inc vat

£400 is a joke!

I see you're Surrey based. Where did you have the work done?

[½cwt]

23 minutes ago, Boxob said:

I see you're Surrey based. Where did you have the work done?

Torque Boxsters??

[hopz121]

1 hour ago, Boxob said:

I see you're Surrey based. Where did you have the work done?

I drove to cotswold  

Surrey prices are silly in comparison for the work I needed done it was nearly double for some stuff, I was happy to drive down there for the day. 

I found Cotswolds even cheaper than Torque boxers too but for the area his prices are reasonable. 

Going back next month to cotswold for some more suspesion work done. 

[Boxob]

1 hour ago, hopz121 said:

I drove to cotswold  

Surrey prices are silly in comparison for the work I needed done it was nearly double for some stuff, I was happy to drive down there for the day. 

I found Cotswolds even cheaper than Torque boxers too but for the area his prices are reasonable. 

Going back next month to cotswold for some more suspesion work done. 

Thank you.  Did Cotswold's price include the AOS or did you supply it?

[hopz121]

13 hours ago, Boxob said:

Thank you.  Did Cotswold's price include the AOS or did you supply it?

Included it, but bear in mind I have a cayman so it maybe slighter shorter labour time than a Boxster due to having a solid roof.

Either way I would expect it to be a lot cheaper than £400! The part isn’t overly expensive. 
 

Cotswold are booking for November now they are always extremely busy and the owner is a lovely guy and a huge petrol head.

Edited September 29, 2023 by hopz121

[½cwt]

Appreciate the roof dig, but I reckon access is probably more difficult in the Cayman due to not being able to lean in from the side of the engine bay so easily as with the roof in the service position on a Boxster, although you are working around the tonneau somewhat.

Cotswold certainly have a good reputation with people travelling quite long distances to use their services.

[hopz121]

31 minutes ago, ½cwt said:

Appreciate the roof dig, but I reckon access is probably more difficult in the Cayman due to not being able to lean in from the side of the engine bay so easily as with the roof in the service position on a Boxster, although you are working around the tonneau somewhat.

Cotswold certainly have a good reputation with people travelling quite long distances to use their services.

Wasn't a dig I have a Boxster too haha 

I didn't do the job but the space is pretty vast at the back of a cayman with the hatch open, that's the only reason i said it.

[mortzz]

Update on this is I've done the job but can say the bottom clip is really bad and nearly impossible to do even with the correct cable pliers,  I bought a full kit off ebay for £40 and with every type of pliers for different clips,  the issue is just space..  very very tight..  so Pelican parts sell the bottom clip with a special plastic clip attached to it, you then pull the  clip out once in place , still not foolproof for me as you only get one shot at getting it on correctly, probably took me 3 attempts even with the correct tool

[Boxob]

21 hours ago, mortzz said:

Update on this is I've done the job but can say the bottom clip is really bad and nearly impossible to do even with the correct cable pliers,  I bought a full kit off ebay for £40 and with every type of pliers for different clips,  the issue is just space..  very very tight..  so Pelican parts sell the bottom clip with a special plastic clip attached to it, you then pull the  clip out once in place , still not foolproof for me as you only get one shot at getting it on correctly, probably took me 3 attempts even with the correct tool

Would it be easier if the bottom tube is cut through (hack saw blade? secateurs?) The AOS is lifted out, then the remnants of the lower tube and clip removed with, presumably, better access from above.  Obviously a new bottom tube will be required. I think this is Torque Porsches method.

[½cwt]

1 hour ago, Boxob said:

Would it be easier if the bottom tube is cut through (hack saw blade? secateurs?) The AOS is lifted out, then the remnants of the lower tube and clip removed with, presumably, better access from above.  Obviously a new bottom tube will be required. I think this is Torque Porsches method.

I am thinking this is the way forward and then may be doesn't need the awful long reach hose clamp pliers.  The genuine AOS for Porsche comes with the O-ring for the stub that goes into the block and the bottom rubber hose which is clipped to the body of the AOS already, but no new bottom clip, that's a separate part 999 512 630 00 a 32 x 12mm hose clamp which is the 'Pelican' one with a clip holding the clamp open for about £1.60 It might be worth saving the aggro....

porsche 986Air Separator Boot Clamp 99951263000 - 99951263000 | Design 911