Jump to content
×
×

Welcome to RennTech.org Community, Guest

There are many great features available to you once you register at RennTech.org
You are free to view posts here, but you must log in to reply to existing posts, or to start your own new topic. Like most online communities, there are costs involved to maintain a site like this - so we encourage our members to donate. All donations go to the costs operating and maintaining this site. We prefer that guests take part in our community and we offer a lot in return to those willing to join our corner of the Porsche world. This site is 99 percent member supported (less than 1 percent comes from advertising) - so please consider an annual donation to keep this site running.

Here are some of the features available - once you register at RennTech.org

  • View Classified Ads
  • DIY Tutorials
  • Porsche TSB Listings (limited)
  • VIN Decoder
  • Special Offers
  • OBD II P-Codes
  • Paint Codes
  • Registry
  • Videos System
  • View Reviews
  • and get rid of this welcome message

It takes just a few minutes to register, and it's FREE

Contributing Members also get these additional benefits:
(you become a Contributing Member by donating money to the operation of this site)

  • No ads - advertisements are removed
  • Access the Contributors Only Forum
  • Contributing Members Only Downloads
  • Send attachments with PMs
  • All image/file storage limits are substantially increased for all Contributing Members
  • Option Codes Lookup
  • VIN Option Lookups (limited)

997.2 3.6l AOS (Air Oil / Oil Mist Separator) DIY


Description

How to replace the AOS on 2009+ Carrera (997.2)

I replaced my AOS back in late September this year, and just haven't had a chance until now to compile the DIY.

The car was running great and consuming an average amount of oil according to Porsche guidelines, so this was purely a preventative step. 
Although the car ran great before, it did actually feel a bit better/smoother after the AOS install (particularly at idle and in the lower rev range)

At the time the car had about 72k miles on the clock.
Please excuse all the pollen & dust in the part of the engine bay where the AOS is installed (I don't think it's avoidable :)


I installed the OEM AOS with p/n 9A1 107 040 02 (note this is revision 3 of the part. I do not know what (if anything) has changed since prior versions.

The trickiest part of the job was actually replacing the plenum (air distributor pipe). It's the kind of thing that will always be easier the 2nd time around. Just pay very close attention to how the rubber sleeves are fitted when you first remove the half moon clamps, and you should be fine. This is really key as you do not want this part incorrectly installed and allowing dirty and unmetered air into the system.

Hopefully the pictures below make the steps clear. I borrowed some pics from the web in order to superimpose/highlight key areas.

80-porsche_911_carrera_997_3787_15_7fbb8


Step 1: Remove the airbox (there are many posts/DIY's on this step so I won't repeat it here)

Step 2:

80-img_6118_fc25bb6a1bc40ef22e804153f493

 

Step 3:

80-997_2_throttle_boy_removal_4bdd8a7672

 


Step 4:

80-img_6121_37067350486750484932308e3e58

 

Step 5: 
Loosening this harness will provide a lot more flexibility when installing the AOS and also when reinstalling the half moon clamps which connect and hinge from the rear.

80-997_engine_3_d00648a3b8cf06669fdea69c

 


Step 6:

80-997_engine_5_44c79704f2e09533367d70db

 

Step 7:

80-img_6126_b91228d880f562054acf31ea53d8

 

Step 8:

80-img_6127_4e594e252f0a292d1488843fe631

 

Step 9:

80-img_6128_fdd8eaa0319a0fb5361e078627a8

For the o-rings I used the following as it was the closest in specs and operating temp to what Porsche recommends and you can actually find the stuff:
https://www.amazon.com/gp/product/B000XBH9HI/ref=oh_aui_detailpage_o01_s01?ie=UTF8&psc=1

80-71ei_q45ecl_sy679__aa5c61dbf4c75a3eb2

 

Step 10:

80-img_6134_8e1380e9b87ac4423b2413e15f07


80-img_6137_8606b80813fae2ce09fc67c1354a


80-img_6136_62cd5edca21c1acf987d990419b4


Note the left side connector on the AOS is a real pain to get well seated. Also the design I think is flawed in that it will never sit 100% flush. This can also be seen when comparing the 2 ports on the old AOS. You can see that the left side port has some dust above the o-ring, whereas the right side port does not.
I think this really comes down to the design of the part and that the area where it seats has a conical opening.

80-img_6131_ccc93d530afe9cf7eaa228fe3daf

 

For reassembly - mount the air distributor/plenum and secure the half moon clamps before replacing the wiring harness conduit mounting screws to ensure more wiggle room back there.

I posted my findings about the change (increase) in the vacuum level after the new AOS install in the thread linked below:
http://rennlist.com/forums/997-forum/956371-997-2-vacuum-level-at-oil-filler-neck-let-s-build-a-data-resource.html

If anyone is doing this DIY or has an opportunity to add their data to the abovementioned mentioned thread on vacuum levels, that would be most appreciated.


It's been over 3 months since the new AOS install and the car still runs beautifully. It is too soon to determine if oil consumption has changed at all, but that was never a concern to start with. 

Today I changed out the air filters and took the opportunity to inspect the throttle body which I'm pleased to say was spotless inside.

 

80-img_0702_af0aa5d75ab12e48e37096ccd856

80-img_0712_cdcb0acfe4c933ce1e39fd6facc1

80-img_0715_5fcce22969e24ac77efba6b13b44

80-img_0721_699a4c79aa43a354807e32ef457b



×

Important Information

We have placed cookies on your device to help make this website better. You can adjust your cookie settings, otherwise we'll assume you're okay to continue.