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noblebenn
Newbie


Joined: 10 Jul 2018
Posts: 8



PostPosted: Thu Nov 15, 2018 4:16 pm    Post subject: Air Oil Separator change Reply with quote

Will be changing the Air Oil Separator next week, is there anything else, parts wise, anyone recommends is changed along side it or any words of advice?

Thanks
 
  
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Robertb
Long Beach


Joined: 01 Sep 2003
Posts: 6721
Location: South Oxfordshire

2002 Porsche 996 Carrera 4S

PostPosted: Thu Nov 15, 2018 4:27 pm    Post subject: Reply with quote

I had this fail on my 4S a couple of years ago- cost a fortune for what was a cheap (and pointless) bit as the engine had to be dropped.

If the engine is coming out on yours, then consider
- brake lines (as they go over the gearbox)
- clutch
- IMS, if you are minded to inspect/change
- any other leaky seals

Apparently for a C2 you can get at it without dropping the engine.
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noblebenn
Newbie


Joined: 10 Jul 2018
Posts: 8



PostPosted: Thu Nov 15, 2018 4:48 pm    Post subject: Reply with quote

It’s 99’ C4. I think we should be able to do it with engine in place so was thinking more along the lines of clips, pipes, connections etc but if we do drop the engine then will look at the bigger items.
 
  
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Marky911
Kyalami


Joined: 04 Jun 2009
Posts: 1919



PostPosted: Thu Nov 15, 2018 4:58 pm    Post subject: Reply with quote

Wasz covered this on his.

You're working blind and its an utter pig. He got it done though.
If you've got a ramp it can only help. Thumb
 
  
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Robertb
Long Beach


Joined: 01 Sep 2003
Posts: 6721
Location: South Oxfordshire

2002 Porsche 996 Carrera 4S

PostPosted: Thu Nov 15, 2018 4:58 pm    Post subject: Reply with quote

Good luck!

I still feel a burning resentment at my AOS failing... so many more interesting mods and improvements I could have spent that money on. Sad
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noblebenn
Newbie


Joined: 10 Jul 2018
Posts: 8



PostPosted: Thu Nov 15, 2018 5:06 pm    Post subject: Reply with quote

Yes Ive got a full garage with ramps available and some very handy mechanics on hand.

If I can ask, what was the cost of having a third party do the swap for you?

I work on my cars because I enjoy it but I’ve no problem having recognised garages doing the works. I kind of go with the thinking that if they can do it why can’t I but know it’s not always this simple!
 
  
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Marky911
Kyalami


Joined: 04 Jun 2009
Posts: 1919



PostPosted: Thu Nov 15, 2018 5:10 pm    Post subject: Reply with quote

Cost will range depending on your Indy and location etc but you're looking at the thick end of a grand easy, because an Indy will drop the whole motor out.

So definitely worth some skinned knuckles if you can do it yourself. The part is only £100.
 
  
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alex yates
Brands Hatch
Brands Hatch


Joined: 06 Mar 2014
Posts: 14473
Location: The Ribble Valley, Lancashire

2000 Porsche 996 Carrera 4

PostPosted: Thu Nov 15, 2018 5:38 pm    Post subject: Reply with quote

Changing the AOS in situ is the equivalent of decorating your hallway through your letterbox whilst stood outside..........but it's doable Grin
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wasz
Magny-Cours


Joined: 28 Dec 2012
Posts: 2639


1999 Porsche 996 Carrera 2

PostPosted: Thu Nov 15, 2018 5:52 pm    Post subject: Reply with quote

Good luck!

I swapped mine while I had the gearbox out, even with good access it was awkward getting the connections off the old, getting the old out and the new into position and fitting the hoses onto the new.

Mine is a '99 with 130k, I only replaced it because I heard horror stories and thought I should replace while I had access. There was oil in every port so probably the old was probably failing - that reminds me I still have it to cut open and look at the diaphragm on the old one.

The vacuum lines are a little fragile (aged rigid plastic), and the o rings inside them had hardened making them a total pig get off and then back on. The force required to pull them off whilst trying not to snap them is a lot.

I replaced the o rings after a while of struggling then when I ran the engine there was an air leak from one (identified using a home made smoke machine). The o ring had got damaged when I pushed it on (almost impossible to vget it on straight and push it in the correct plane, so I had to get in there and swap the o ring again.

The online guides make it sound easy, and it might well be if your car is a lot younger.


noblebenn wrote:
I work on my cars because I enjoy it


So do I but this was not much fun. I wouldn't contemplate doing it again without either A) dropping the engine or b) dropping the gearbox and having replacement rigid vacuum lines on hand.

It would be a doddle if the engine was dropped. I reckon I could do it blindfolded with the engine dropped.

If you car has never had the over gearbox brake line changed it might be worth dropping the gearbox at least. Its not that hard.
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wasz
Magny-Cours


Joined: 28 Dec 2012
Posts: 2639


1999 Porsche 996 Carrera 2

PostPosted: Thu Nov 15, 2018 6:06 pm    Post subject: Reply with quote

Dropping the engine doesn't look too hard. Theres a great guide here:

http://kellyanneporsche.com/enginedrop.htm
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noblebenn
Newbie


Joined: 10 Jul 2018
Posts: 8



PostPosted: Thu Nov 15, 2018 6:23 pm    Post subject: Reply with quote

Thank you for the replies.

I use the car a lot and like things maintained properly so an engine drop it is. Will be good to have a look around and change other things for piece of mind.
 
  
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Halcyon
Imola


Joined: 02 Nov 2015
Posts: 777
Location: Somerset


PostPosted: Thu Nov 15, 2018 7:30 pm    Post subject: Reply with quote

My Mechanic did mine without dripping the engine. saves time & money. My total bill was less than £500

Lots of indys will tell you that you HAVE to drop the engine.
You do not.
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deMort
Zolder


Joined: 21 Mar 2015
Posts: 5533
Location: Brighton


PostPosted: Thu Nov 15, 2018 7:54 pm    Post subject: Reply with quote

Manual and in theory it can be done in situe .. Tip and it cant .

Now .. my thoughts .. ive tryed to do a few in situe over the last year or so .. these cars are not new anymore .. things just dont come undone .. pipes snap ..

You have very limited access to do it in situe .. on a new car you have a chance .. from my experience then i would say drop the engine ..

Ill put it this way .. im never attempting to do one in situe again and if the customer wants to go elswere he can .. that is how bad this job can be .

Times and its about 8 hrs to remove and refit a manual engine .. tip is something like 12 hours .

Its perfectly possible to do as a diy job .. Porsche designed these engines to come out pretty easily .. you basically have x4 bolts and a lot of pipes !

You also get to see the brake lines which are normally worth doing and the coolant pipes which are starting to show their age and corrode.

Hence my advice .. just drop it .. save your self a lot of grief and replace the pipes as needed while your there ..

You only really do this job once so get it all done in one hit .

My 2 pennys anyways .
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Armagreggon85
Trainee


Joined: 04 Jan 2017
Posts: 82



PostPosted: Thu Nov 15, 2018 9:41 pm    Post subject: Reply with quote

Just replaced mine while engine was dropped for a rebuild. Gotta say I can only imagine it would be a nightmare if the engine wasn't out of the car. Dropping / refitting the engine was actually pretty straight forwards
 
  
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Martin996RSR
Spa-Francorchamps


Joined: 08 Dec 2016
Posts: 284



PostPosted: Fri Nov 16, 2018 9:37 am    Post subject: Reply with quote

I did mine a couple of years ago ('98 C2) and it was a horrific job. I didn't drop the engine or the gearbox and I wish I had. If it ever needs doing again then I'll be taking it to an indy. I still wake up in a cold sweat thinking about that job.
 
  
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wasz
Magny-Cours


Joined: 28 Dec 2012
Posts: 2639


1999 Porsche 996 Carrera 2

PostPosted: Fri Nov 16, 2018 11:02 am    Post subject: Reply with quote

Martin996RSR wrote:
I did mine a couple of years ago ('98 C2) and it was a horrific job. I didn't drop the engine or the gearbox and I wish I had. If it ever needs doing again then I'll be taking it to an indy. I still wake up in a cold sweat thinking about that job.


Floor we should start an AOS survivors support group.

Better to spend a weekend dropping and refitting the engine then 8 solid hours of pure frustration trying to get those $£@% %^&@ pipes back on cursing the day you bought a 911. I've only ever considered setting the thing on fire once in my life and that is when I found I had an air leak from one of the pipes after stitching it all back up.

At least you feel will like you achieved something. Theres LOADs of other stuff you have access to with the engine dropped that you can inspect / attend to if you plan to keep the car long term.
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peterg1955
Trainee


Joined: 09 Apr 2017
Posts: 82
Location: Berkshire


PostPosted: Fri Nov 16, 2018 12:23 pm    Post subject: Reply with quote

My AOS was replaced at Northway just about a year ago, as it's a 2002 manual C2 they just had to drop the gearbox and it gave them a chance to check the clutch etc which was all fine, the cost from memory was a little under £500 all in

For a Tip the engine and box all have to come out, for manuals just the gearbox as the AOS is positioned at the front of the engine and 'easily' accessed one the box is out.
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