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About BillyRay

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    996 C2

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  1. A recent AOS failure pitched me up here. Fairly handy under a car but this is easily the toughest task I've attempted & wouldn't have had a cat in hell's chance without your outstanding tutorial, Mr Hobbes. Probably took me a good 10hrs all told but the DIY was bang on the money - a thousand thanks! For what it's worth, here are the tricky bits I encountered: Alternator removal - no amount of prying was shifting mine so used a 1/2" drive extension piece, a hammer and a lot of tapping on the right side mount to slowly rotate the alternator clockwise. This requires A LOT of patience (I almost threw in the towel at this early stage) as you don't want to use too much force but it works. Fuel lines - when disconnecting each of these use 2 spanners, one to hold & brace the base of the connector while you use the other to turn the actual connector. They take a fair bit of torque to release and the thought of all that force transferring across made me sweat. Also worth draping a rag over each one as you disconnect to catch the little spurt of fuel when they pop apart. Coolant tank - had to remove the sensor underneath (1/4 turn anticlockwise, be gentle!) with the tank in situ as there was no way the tank was going past the fuel line connection with it in place. Also dropping the engine down to the limit of the motor mounts made tank removal a breeze. Spent a good hour trying to tease the tank out before this occurred to me. Throttle body and upper intake were straightforward but for the love of god, as soon as you take that intake off get those lower intake holes taped over with duct tape. Dropping anything down one of those doesn't bare thinking about! AOS - getting enough purchase on those **** squeeze fit hose connections was a true test of faith but they do come apart. The bottom one was the hardest and I could only do it reaching up from underneath the car. Took a while lining up the new AOS (found I needed to manoeuvre it both from the engine bay and underneath the car) but when you get it in the correct position I found it kinda dropped into place and felt 'right'. Things I broke - one of the little plastic vacuum line pipes (part no. 420mm) and a plastic coolant connector (part no. 996.106.226.52). This connector is bolted to the block directly above the tensioner pulley and connects the coolant hose from the AOS to another coolant hose and had become incredibly fragile. Breaking this screwed up my plan of just siphoning out the coolant tank and meant I had to drain the engine block instead. It's a hard job but doable. Just take your time, go slow. and most importantly be patient, patient and more patient. Ideally leave 2 clear days so you don't feel rushed by time. Only specialist tool I used that was a genuine help, bordering on invaluable, was a pair of flexible long reach hose clamp pliers.
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