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NedHan79 said:Thanks wasz. I'll get a look when I get time this evening.
Just one question, I see AOS mentioned a lot. What is this?
One of the most common failures in the Boxster is the Air/Oil Separator, also referred to as the AOS.
The AOS is basically a small diaphragm distillery which distills the minute amounts of oil mist in the crankcase, liquifies it and sends it back to the crankcase. The 'clean" air is now sent into the air intake (after the throttle body) to be burned off by the engine.
When the AOS starts to fail it cannot separate all of the oil out of the mist and some liquid oil is sent to the air intake.
A few drops of oil is enough to generate the GREAT SMOKE BOMB for which our cars are famous for.
A big smoke bomb once in a while is completely normal, due to the architecture of the flat-6 engine, which may let a drop of oil flow into one of the combustion chambers sporadically.
But if you car smokes on a regular basis, this is the telltale sign of a bad AOS.
Don't let it go on for too long because it will only get worse and eventually, enough liquid oil can pass into the combustion chamber to cause hydro-lock which may cause terminal damage to the engine.
crash7 said:There is a flexible kit available, but I cant remember where I saw it!
Hel will make custom brake hoses for you if you decide to go the flexible route.
NedHan79 said:Thanks wasz. I'll get a look when I get time this evening.
Just one question, I see AOS mentioned a lot. What is this?
wasz said:OK you should check my thread linked in my sig: http://911uk.com/viewtopic.php?t=124928
The only time I served as a mechanic was under my dad's watch as a kid (a time served engineer) and I managed just fine on my back on axle stands.
I dropped the gearbox, flywheel, locked the cams and checked / re-sealed the IMS bearing, swapped the AOS and replaced the brake pipe.
My brake pipe had been spliced under the cover previously as DeMort described. In the hidden clips above the gearbox the old steel was pretty grotty so inspect it well if you are considering that.
I can imagine it would be possible to get a brake line in without dropping the box, but very fiddly, and likely not exactly matching the original route - probably easier with knifer as you can bend it more easily in place. I wanted to match the original to make sure it wasn't going to rub.
Not a hard job just really frustrating and fiddly I image......easy to drop the engine and gearbox a few inches I think for better access.
**** Also check the brake line that runs along the front in front of the steering rack. Mine was well grotty.
I have done all the old steel brake lines and flexi lines on my car.
I would not want a long flexi line, it would lead to that brake being slightly less efficient and move around a lot / risk rubbing through.