How to REPLACE/INSTALL AIR OIL SEPARATOR (AOS) | Porsche Boxster 986 987 (Project 9)

[@garyl5128]

Great video as usual! I think your dog summed up the feeling of frustration pretty well too :) Apparently this part fails regularly (I believe the diaphragm inside eventually perishes/splits) so replacing it as a part of a preventative maintenance regime is a good idea, rather than waiting for it to fail, especially if you've just bought a Boxster and don't know if it has been replaced recently or not. Tough job though! Keep up the good work :)

[@HelpMeDIY]

+Gary L thanks Gary! I definitely went through the stages of grief during this one. Millie has sympathy sadness 😆

[@rfpriddy1951]

Yes, my mechanic said it was the rubber that wears out/fails. However, when my AOS failed, the vacuum it created sucked my RMS into the engine creating an oil leak and "disaster." It would seem prudent to replace the AOS perhaps every 20k miles or so...

[@nicotristan6119]

i dont mean to be offtopic but does anyone know of a method to log back into an Instagram account?? I was dumb lost my account password. I love any tips you can offer me!

[@londonkalel9492]

@Nico Tristan instablaster =)

[@nicotristan6119]

@London Kalel I really appreciate your reply. I found the site through google and Im in the hacking process now. Takes a while so I will reply here later with my results.

[@DanielJohnson-r7n]

Hi, HelpMEDIY! I found your video on replacing the AOS to be very helpful on my 1999 Boxster. I anticipated trouble removing the lower side breather tube (purple arrow in your video) so I gave it a shot of WD40 the night before... the following day, it removed within 15 seconds of my initial attempt. I did so by reaching in with my left hand past the oil fill hose and pressed the release with index finger on top and thumb on the bottom. Your video provided a nice DIY guide for the remaining replacement procedure. The replacement job was completed about 90 minutes after starting! Without your video, I am sure it would have taken me several hours. Thank you for your videos!

[@HelpMeDIY]

+@user-uc4wp9cx4q you’re welcome! Glad it helped. 🍻

[@markcash2]

Thanks for that WD-40 tip. I get to do this once the new AOS I ordered today arrives!

[@recon20671]

Just completed this job in just over an hour and a half using your instructions. Thank you so much. Semper Fi.

[@HelpMeDIY]

+recon20671 love it! 🍻

[@sirsmack]

Did I need to buy that brittle hose clamp… If so what’s it called? I only ordered the other hose clamp with the blue ring

[@ksheeh]

I'm impressed no cursing and no blood, at least not on camera

[@HelpMeDIY]

+ksheeh ahhh the magic of film and the power of editing 😂

[@ksheeh]

@@HelpMeDIY Great video keep them coming

[@HelpMeDIY]

@@ksheeh thanks!

[@Firirinchi]

This community is very pleased to have someone like you. I have seen many of your videos. Very helpful, by the way

[@HelpMeDIY]

+@Firirinchi appreciate the kind words 🍻

[@isidroalcantara9409]

Love the editing with the arrows to point out the bolts and the zooming in to point out the hose clamp!

[@HelpMeDIY]

+Isidro Alcantara haha thanks! Hope you’re a subscriber now 😉

[@isidroalcantara9409]

@@HelpMeDIY I have been since you painted your brakes! I used your video before painting mine!

[@HelpMeDIY]

+Isidro Alcantara awesome! How did they turn out?

[@isidroalcantara9409]

@@HelpMeDIY they turned out great! You can check them out on my instagram @redvancitycayman

[@rob12449]

so I saw your other video about starter, and yesterday I took on both the starter and AOS, I was more worried about the starter with the suggestion of two feet or so of extensions. So after gaining access to engine, first time seeing it on my used boxster I found a mouse apartment complex. For starter I removed the throttle body and air intake tube, then I realized the oil filler tube was in the way. After removing that, or disconnecting it I could see I had room to get starter bottom bolt, no need for socket and extensions. This made me happy. Next I began on the AOS and realized the two mounts were blind from the top, but I felt my way in with a 1/4" socket and got them out. The job was getting harder by the minute as I was almost complete at removing it. I resorted to cutting the rubber bellows, which you mentioned, and once aos removed it was easy to remove cut bottom rubber bellows with clamp. The part you showed of clamp with ring is amazing, but imagine I had not known about this. So it became impossible. Then I too resorted to removing rear tire and found the bugger in my sight, but a difficult reach away. Eventually I gave up and resorted to using a screw type radiator clamp which worked. Next time this job should be easier. However I learned that of all the jobs I've tried, auto mechanic is the least desirable. It sucks.

[@HelpMeDIY]

+rob12449 great job! Without the right tools and knowledge it can definitely suck! And even with them sometimes 😆

[@gunsandotherbadwords6030]

Thank you for a very instructive video. I just completed this job on my '98 Boxster and have the following observations: 1. The hose clamp pliers are a game changer. 2. As recommended by others, I sprayed a little WD-40 on the plastic vent hose pinch connectors. I found them to be still disagreeable after this, but manageable. 3. I did not need to separate the oil filler tube, but I did not try to access the AOS mounting bolts, the 2nd pinch connector, or the bottom hose clamp from above. Instead with the vehicle raised and the rear passenger wheel off, I kneeled on the floor with the brake rotor touching my chest. This allowed me to reach around the left side of the rotor with my left hand, removing the hose clamp with the hose clamp pliers, squeezing and removing the pinch connector for the lower vent line, and removing the 2 mounting bolts with a small ratchet. I also used a large screwdriver to gently pry the old AOS out of the block. 4. After wiggling/twisting the new AOS down into its rough location, my same sitting position allowed me to easily get the bolts threaded and position the bottom hose before pulling off the blue tab.

[@HelpMeDIY]

+@gunsandotherbadwords6030 well done! 🍻

[@kjohnston6498]

Thank you for this and all your videos! So much help with pain avoidance. My trick on the difficult hose was to detach everything else first. Then I was able to get the AOS loose and out enough to get a better grip on the disconnect. I am also lucky it has been previously replaced so the bottom clamp was a hose clamp and the top vacuum tube is already the longer style.

[@HelpMeDIY]

+@kjohnston6498 you’re welcome! 🍻

[@8bitaffiliate243]

Just wanted to let you know how much we appreciate you!

[@HelpMeDIY]

+8bitaffiliate ALWAYS means a lot to hear 🙏🍻

[@davey111359]

Just got done doing mine about 2 hours ago...I have the type that the disc up top sits sideways so the process was a little easier (I didn't have the hoses in the way, at least not as bad as your was)...the hardest part was putting the AOS back in! I also did the same thing you did, pulled the blue tab off the lower hose clamp and it missed its mark, unbelievably I was able to use channel locks and did it by hand...whew. Appreciate your efforts as I learned a couple things from you before I decided to tackle the job...next, replace pads, rotors and brake fluid flush

[@HelpMeDIY]

+davey111359 you’re welcome! Thanks for commenting and letting me know, I love hearing success (eventually at least) stories!!

[@jamesmiller9379]

EXCELLENT JOB AND VIDEO!! I need to change my AOS on my 1998 986 soon and your video has already put my on the right track. Keep up the EXCELLENT WORK!!

[@HelpMeDIY]

+James Miller thank you for the kind words. I appreciate them

[@jonathanmoore6365]

Thanks!

[@HelpMeDIY]

You’re welcome, thank you!

[@jonathanmoore6365]

@@HelpMeDIY No problem! 10 minutes ago i posted a fairly detailed comment with some tips that people may find useful but it is not there for some reason now. Could this be because i included an amazon link to some plastic part i found really useful? If so maybe i can find this my original comment and repost with out that link.

[@HelpMeDIY]

@@jonathanmoore6365 yes that would be why. Links aren’t allowed by default. I will look to see if I can find and approve it.

[@jonathanmoore6365]

@@HelpMeDIY Thanks - Appreciate that. Could remove that link, i just wqnted to illustrate a type of tweezer i used

[@HelpMeDIY]

@@jonathanmoore6365 not sure what’s up with comments recently. Can’t find it even under held for review, sorry

[@davidwilliamsmobile]

Great video 😊 Really helped me prepare for the job with the extra bits needed before I started. Also, in respect of showing you all the steps as if you were doing the job in person, the video is perfect. I really appreciate all the effort you went into editing the video.

[@HelpMeDIY]

+David Williams thank you! Glad it helped. Thanks for taking the time to comment 🍻

[@weejim48]

Good vid. I was going to have a go at replacing AOS myself, but having seen this I think I will just take it to my specialist. 👍👍👍

[@HelpMeDIY]

Haha I can’t say I blame you! It’s not one of the “fun” things to do with a Boxster that’s for sure.

[@myogui]

Same here!

[@maestrodevil9566]

Simply amazed by the attention to detail, and your devotion in pointing out the possible pitfalls. Great work my friend!

[@HelpMeDIY]

+Maestro Devil thanks so much! 🍻

[@turboacar]

Very nice that you took the time film and share this. 1 thing to consider is to clean all that dust dirt before you start. You don’t want any of that in ags or eventually in the engine.

[@HelpMeDIY]

+Greg Lietzke definitely can’t hurt! Good tip, thanks.

[@A1Absolut]

incredible your patience .... super didactic and the best thing is that you are just one of us !! Great

[@HelpMeDIY]

Thanks for the kind words. Yes, just a regular guy trying to figure out how to do stuff to my car :)

[@wildbillcarroll]

Great video when I did my AOS I used the wonderful tool you have for the clamp on the hose, rather than cutting. The extension clamp compressor.

[@HelpMeDIY]

+william carroll thanks! 🍻

[@sunset986S]

Another great video! When mine went the exhaust blew billows of white smoke like a giant reefer from a Cheech & Chong movie...I always figured these AOS had something magical inside of them because they're Porsche but after watching this I see it's just a 20 cent spring operating a diaphragm...thanks to you I've seen behind the curtain from the Wizard of Oz...lol

[@HelpMeDIY]

+Heidi 😂😂😂😂

[@emersonz849]

Sooo much work you have done especially with recording you put a lot of effort of the angles on the work I literally don’t know but keep it up I try recording and work and it’s very difficult

[@HelpMeDIY]

+Emersonz thanks man, I don’t know how I do it either sometimes 😂

[@ryanmillerick320]

I found that using a vice grips to hold open the clamp really helps. You can get the clamp lined up really nicely and then release the grip. Those blue pin things are cool too. You can even reset them afterwards onto the clamp with a vice grips.

[@HelpMeDIY]

+Ryan Millerick yeah I’m totally a fan of either the blue pin or just a hex head hose clamp. Vice grips are a good tip too!

[@kimmcaleer5652]

I found it interesting when you took the separator apart. What can break down are the springs and rubber diaphragm in the top it appears to me. If they would allow excess to the top you could replace those and not have to replace the entire unit. It being all sealed you can not do that. Of course you could have failure of the rubber connections as well. Did not find it easy to do especially if one has large hands. Thank you for showing it was very informative for me. The tips on the extra parts needed to reinstall were very helpful and a must.

[@HelpMeDIY]

+Kim McAleer you’re welcome! Glad it helped. 🍻

[@devinkarringten5702]

I just got my first Porsche baby! 2001 Boxster 986. Been maintained by a formula1 mechanic so it’s pretty good mechanically to say the least. But loving watching your whole process and failures and successes. Really love how in depth you go! I’ll be doing a few of these myself. Already ordered new headlights / orange delete / and the same 719 style rear tail lights! Can’t wait to throw those on. SUBSCRIBED !!! 😎❤️

[@HelpMeDIY]

+Devin Karringten thanks for watching man, and congrats on your newborn! 😆

[@FlyinFreek]

i guess i should have watched to the end to see that the oem breather hose is indeed too short vs finding out on the fly, 3/4 hose came to the rescue, another helpful vid

[@HelpMeDIY]

+@FlyinFreek haha right on. Hope you gave it a 👍 😉🍻

[@budhill8328]

Brother, for me personally, it's not the skill level I am worried about...It's the "PATIENCE LEVEL- Buddhist Monk" that intimidates me. Impressive journey...thank you for sharing!

[@HelpMeDIY]

+bud hill 😂 I love it. I may have to steal that one.

[@budhill8328]

@@HelpMeDIYConsider it yours! And TY again!

[@peterhaslam-brunt4154]

A great video as are your others, it has convinced me to let my Porsche garage do the job when it needs doing. I have worked on cars for 50 years and just don't fancy the struggle with this one,. No enjoyment that's for sure. But a great video.

[@HelpMeDIY]

+Peter Haslam-Brunt thanks! There is definitely no fun to be had in this one.

[@jonathanh.7470]

Did this before. 3 years later my AOS failed again! Just watched your video to reference the headache I went through again.... yeah... the ptsd is coming back to me. LOL

[@HelpMeDIY]

+@jonathanh.7470 if you know it you don’t forget 😂 🍻

[@jonathanh.7470]

@@HelpMeDIY I try to forget that one in hopes I didn't have to do it again 😅🤣🤣

[@ReveredTimmyB]

Duuudeee...super helpful. Sorry, it was a PITA for you. I was nervous about the lower tube. Using your buddy's idea of tipping it forward and pressing down worked like a charm. I used a large standard screwdriver to press down with my left hand (cause there is so much space :-p) while the right just gently pulled it away.

[@HelpMeDIY]

+Timothy Blackton that’s awesome! So glad to hear it was helpful.

[@sche10]

I just did the AOS yesterday - I think if I had to do it a second time it would be a lot easier. One point though - ON MY 2002 Boxster S the bolts securing the AOS to the block were 8mm, not 10mm

[@HelpMeDIY]

+sche10 congrats! You’re an AOS club member now 😂 And thanks for the additional info! 🍻

[@duanemariamarshall4469]

Thank you for creating and sharing this video. I ordered all the parts you linked. Huge help. I use all of these videos with the 101 Projects book. Winning combo to ease a new or seasoned Boxster owner into DIY repair.

[@HelpMeDIY]

+DuaneMaria Marshall glad to help 🍻

[@blakslee720]

Every time I think “maybe I should buy this boxster for sale nearby”, I watch a video like this which and change my mind

[@HelpMeDIY]

+@blakslee720 😂😂 Yeah, but what other car is so well documented now to help you fix whatever might go wrong? 😝🍻

[@briansturgill5905]

Love the video man. I went ahead and did my camshaft sensor while I was there cause it’s right behind that bottom plastic part. What a pain!!

[@HelpMeDIY]

+Brian Sturgill thank you sir 😎

[@stampedetrail2003]

Just finished this. Honestly this is the singular job that makes me wonder if this car (2000 2.7) is actually worth it. I've done the starter, coolant tank, coil packs, plugs, immobilizer, ignition switch, MAF sensor, in 2 years. None of those jobs are quite as annoying as this one, even with the entire kit of spring-clamp pliers. And I can't see why the engineers wouldn't have made it serviceable, the part that fails is the diaphragm at the top. I was not able to remove the bottom spring clip from the old part because it was rotated way over to the side so I just cut through the rubber hose to remove the old part, then got at it with the old AOS removed. Installation wasn't quite as bad but I did replace the spring clips with hose clamps. Appreciate your what's inside moment. I'll tell you I did attempt to circumvent the AOS by blocking off both the intake manifold side and the AOS side, and it doesn't work, doing that builds up a bunch of pressure in the crank case and causes a lot of oil to leak right away.

[@HelpMeDIY]

+Brian & Sylvia cutting the old one is definitely the way to go! Nothing is fun about this job for sure.

[@stampedetrail2003]

@@HelpMeDIY Ok it's been a week and I can give you an update. I also had to remove and work on the number 2 spark plug since it had been fouled by oil due to the AOS fail. I pulled that plug and torched it with a propane flame thrower, and that actually made a huge difference. This last week all kinds of problems with plug fouling and uneven running have kind of worked themselves out so, it must have been an AOS problem for the most part causing problems! So now I'm back on the *this is so cool I can never sell it* phase of the diagram. But hey I really appreciate your content you've been a huge help for me, thank you.

[@HelpMeDIY]

@@stampedetrail2003 you’re welcome! Thanks for the update

[@BikerBloke600]

Hi just watched your video an can absolutely say its the best AOS replacement video I have seen. I drive a 987.1 Caymen S and have done this job a couple of years ago myself and remember it was a real PITA but I'm lucky I can do most things on my car as don't trust anyone else to do it. One thing I noticed while watching your video is I don't think the rubber hose was correctly seated onto the engine when you removed the blue plastic ring, but I could be wrong. Anyway keep up the good work. Mick, Northern Ireland 👍🍻

[@HelpMeDIY]

+Michael Kane great eye! I caught that myself luckily and fixed it after editing the video :)

[@mickphillips3824]

Great video, just shows you where theirs a will theirs a way. Cheers, Mike from London Uk.

[@HelpMeDIY]

+Mick Phillips thank you sir! 🍻

[@TimC-986]

Thanks, you helped a lot. I had trouble getting the same hose you did. I don't have a helpful neighbor, so I checked other videos. One guy had no trouble at all, but his hose had oil on it. Then I thought maybe a little lube would help. A shot of WD40, and it popped off.

[@HelpMeDIY]

+Tim C ah great tip! Thanks 🍻

[@benedekpal6136]

Tanks for the vid! My suffering with the tube starts in a few hours. My AOS failed, the car didn't give out smoke yet but the idle was horrible and I could hear something like someone hitting an oil barrel.

[@HelpMeDIY]

+Benedek Pál how do you know the AOS failed? Just curious

[@benedekpal6136]

@@HelpMeDIY opened the throttle body, oil started to seep in but it didn't produce the white smoke, then disconnected the hose from the aos and pluggedt both ends, the idle went back to perfect no popping noise and stable, then started to look under the aos and discovered it was seeping oil at the bottom too.

[@HelpMeDIY]

@@benedekpal6136 that’s a pretty dead giveaway I suppose 😂

[@benedekpal6136]

@@HelpMeDIY 😅

[@markcash2]

Thanks for the video and the links in amazon. The AOS you linked to is no longer available, but there were other sellers for it.

[@HelpMeDIY]

+@markcash2 you’re welcome! Thanks for the heads up, I’ll update the link. 🍻

[@markcash2]

@@HelpMeDIY Getting that 2nd hose unclamped is really difficult. I have a sprained wrist so getting my hand in there ti squeeze and pull off at the same time is a pain! I gave up after 4 hours of trying. Will try again this weekend.

[@vernbell391]

Just got a 2002 booster and loveing all your videos keep up the great work

[@HelpMeDIY]

+Vern Bell thank you sir and thanks for subscribing!

[@MrERGUTI]

I really appreciate your videos help me save quite a bit of money

[@HelpMeDIY]

+Engels Gutierrez that’s awesome! 🍻

[@Simba-qi4gk]

Thanks for the great video 👍. Did you do a video on how to replace the canister purge valve including both hoses? Asking because it’s my next project on my 1997 Boxster and can’t find any instructions on how to get the new valve and hoses back in under the intake manifold. Thanks

[@HelpMeDIY]

+Simba you’re welcome! No I don’t have a video on that. If you want to make one while you do it I’ll be happy to post it for helping the next person 😉

[@peterbrown216]

Another very useful video. Apparently replacing the AOS is much less stressful if the gearbox is out. About to drop the gearbox on my TIP to replace a leaking RMS. Will try and replace the AOS at the same time. Has to be easier on the skin than going in from the top.

[@HelpMeDIY]

+Peter Brown I’m sure the more stuff ifs out of the way the better 🙂

[@tabberacci8541]

Did the same last week and used three nights to try to get the whole red seal on the AOS in the engine case. Could not do it despite all my efforts. Good to see that your AOS also left a mm of seal visible. Now I can let that go, it should be fine I guess.

[@HelpMeDIY]

Yeah I noticed the same! Once the two bolts are tightened it’s not going in any further!

[@tabberacci8541]

I even tried to shrink the seal with a heat gun to get it to fit but it didn’t work. I’ll drive and keep an eye on it to see if it leaks.

[@HelpMeDIY]

Tabberacci report back!

[@jonedgar5996]

If it's of any reasurrance, mine did not go in to the block entirely either so it's more than likely by design rather than a fitting error.

[@HelpMeDIY]

@@jonedgar5996 Happy to hear multiple confirmations :D

[@christophersmithsonian3350]

Thank you I just bought a 986 last week and I'm a DO IT YOURSELF. TYPE OF GUY I have 2 951 Turbos one 944 and now a 986 also

[@HelpMeDIY]

+Christopher Smithsonian congrats! This is the channel for you then. Might even want to consider becoming a member or supporting the channel through the purchase of a shirt 😉

[@georgelouie5330]

Another excellent video. I love watching them, even if I'm not prepping for that specific job. They're very informative for future reference. Your commentary and camera work is among the best, if not the best I've seen, especially for Boxster related repairs. Keep up the Great Work. Have u ever considered doing a behind the scenes video? I'd love to see how you manage to position the camera so well. What camera are you using and are you using a tripod or other type of mount system. Oh yeah, I loved the bonus ending where u cut open the AOS. Always interested in looking inside things to see how they work. :)

[@HelpMeDIY]

+george louie thanks so much! Means a lot for people to take that much time responding so positively to my work :) I just use my iPhone 11 Pro for filming and sometimes use a small tripod, but usually just hold the phone. I hate to admit it for these videos, but I’m also a cinematographer on the side and shoot short (horror) films, so I guess that helps. But honestly I’m just tired of crap, grainy, poorly lit car videos that are only partially helpful. If I’m going to take the time to film it, I might as well put enough effort in to let you see what is happening!

[@georgelouie5330]

@@HelpMeDIY - short horror films? That's pretty cool. Anything available that I can check out online?

[@HelpMeDIY]

+george louie actually one is on my channel here. “Psycho Path”. Another one, “Tethered”, is available to rent on iTunes, Amazon, etc as part of an anthology called “The Source of Shadows”. We are making that one into a feature length soon ;)

[@georgelouie5330]

@@HelpMeDIY - Just watched Psycho Path this morning. It was really good. I shared it to my Facebook Page. :)

[@HelpMeDIY]

@@georgelouie5330 thanks! It's been fun making them. Our group (4 Leagues Media) is looking forward to our first feature!

[@chipgotay]

If my crankcase vent valve goes bad is it possible my AOS also went bad? And have you done a video of crankcase vent valve removal?

[@HelpMeDIY]

+chipgotay sorry, no experience with (or video for) that yet

[@SGliderGuy]

Done this. It was a pain in the Frickin' Wazoo! Instead of using the blue pin to hold the "pinch type" hose clamp open for installing, I purchased a regular hose clamp and was able to use a ratchet to tighten it. So how do you know when you need to replace it? With mine, I started to hear a loud noise, like a whistle or a squeal. It was difficult to diagnose the noise because it would come and go as it pleased, regardless of throttle, brake, gear, speed or anything. Also, there was also a much more frequent puff of smoke from the exhaust than normal. I believe I had a leak in the membrane that you revealed in the bonus video. That leak was causing the noise.

[@HelpMeDIY]

Yes I’m going to have to use the same type hose clamp that you did after screwing up the installation of it as shown in the video. I was able to remove it pretty easily with those hose clamp pliers and realized that reinstalling at this point would be difficult. Smoke is usually the tell tale sign, but it my case I just replaced it as preventative maintenance. Seems like they all go bad after a while, and it’s been 22 years! :)

[@SGliderGuy]

@@HelpMeDIY Hey. If you have some overheating problems or notice your fans fail to turn on when you turn on the AC, let me know. I can save you over $300 in repair parts. There is a KZbin DIY video on this, but they do it wrong!

[@HelpMeDIY]

Guy Spaulding if that happens I’ll get together with you and we will make a correct DIY 😉

[@vatoisimo]

The lower hose was indeed a pita. I ended up threading a string over and around the hose elbow from under the side of the car at the back of the valve cover. That way i could squeeze the release with my left hand, and pull on the hose with string/right hand. With a little wiggling it finally came off

[@HelpMeDIY]

+@vatoisimo very creative! 🍻

[@leanderball2568]

Yet another great video well presented I’ve got a facelift 2.7 986 and thanks to your vid I will definitely swap out that bottom clamp and at the same time my girlfriend because your helper is stunning 😂👍

[@HelpMeDIY]

Haha thanks! I like her 😁

[@IttNeverTooLateToRace-qz2gn]

I reaslly appreciate this and all your videos. They've been a tremendous help to me with my '99 Boxster base. I do have a question for you (and anyone else that would like to chime in on it): Could you use a small radiator type hose clamp on the lower hose instead of having to mess with the clamp and releasing the blue ring? It seemed that it might be easier to do that and get the clamp on the mark better. Would there be any problem with doing that?

[@HelpMeDIY]

+@IttNeverTooLateToRace-qz2gn you’re welcome! And yes you can do that. 🍻

[@paulhastler9318]

How did you know that the AOS needed changing, what were the symptoms? Great video btw . many thanks

[@HelpMeDIY]

+Paul Hastler I have a video for that 😉

[@philippelouisderivalzpiat6561]

This is going to be my next project on my 2001 Boxster 986! Rather scared to do it!

[@HelpMeDIY]

+Philippe Louis De Rivalz Piat it’s definitely not the most enjoyable job, but you’ve got this!

[@IttNeverTooLateToRace-qz2gn]

As always, your videos are great and a super help. A problem I'm having with the job: I cannot for the life of me get the new AOS bolt holes to line up properly so I can start to screw by hand the bolts back in. I've been trying for days to maneuver the AOS around and align the bolt holes, but just can't seem to do it. I also tried just for fun to see if I could get the old AOS bolt holes to line up, and not able to do that either. Anybody had the same problem and have any ideas on how to fix? Also, the "nipple" on the new AOS that goes into the block seems to be slightly larger than the old one. The old one fits into the block nicely about 1/16 to 1/4 inch in. But the new one doesn't seem to want to go in much at all. Is that just because it's new, and it will "wear in" once you bolt it down?

[@HelpMeDIY]

+@IttNeverTooLateToRace-qz2gn hmm never had those problems. Maybe someone else can chime in. Let us know if you figure something out!

[@blakechesbro3602]

Once again thank you to start, seemed a huge hassel. Did you change it for any specific reason ? also, if you did it again can you take the time to remove some of the other items in the way that made it so hard to accomplish the task or what that be counter productive ? again, thanks for your time.

[@HelpMeDIY]

+Blake Chesbro it was a huge hassle. Did it as preventative maintenance as it was the original from what I could tell

[@dion9146]

Thank you sir. I’m tackling this tomorrow,

[@HelpMeDIY]

+dion9146 good luck to you sir!

[@dion9146]

@@HelpMeDIY I have a 2002S, so the wire and hose design allowed me to get the old one out in about 45 minutes. The bad news is whoever changed this one attached the flexible hose with a damn zip tie! I even have the dealer records to show that they’re the ones who did it.

[@HelpMeDIY]

@@dion9146 ouch 😓

[@aryaniknami6532]

Great video! Just wondering the hose clamp with the blue tab could I just use a standard zip tie? Also where do I find the parts with the part numbers?

[@HelpMeDIY]

+Arya Niknami no I wouldn’t use a zip tie. You could use a standard hose clamp though. Part numbers should be in the description. Let me know if not. Also, I have another video on how to find Porsche part numbers. Please subscribe!

[@thepigllc]

At 7:24, what is that part that needed to be replaced?

[@HelpMeDIY]

Some clip… not sure the part number though. I have a video on finding Porsche part numbers that may help find it

[@iainmcglynn833]

I heard this was a tricky job to do. I wonder if WD40 penetrating fluid would help any of it to slip off Was it white smoke that you saw to highlight this and is it a case of the moment this fails it’s best to stop soon ish or oil will get into the pipes ? Very helpful video , I don’t have a gorgeous dog or wife ( ones in heaven and one ran off , I’ll let you guess which is which but I miss that dog 😂)

[@HelpMeDIY]

+Iain Mcglynn it’s definitely not the easiest job! I didn’t really have reason to believe it had failed, just did it as preventative maintenance based on age and lots of them seeming to fail. RIP dog 😂

[@iainmcglynn833]

Help me DIY it’s refreshing to see how difficult and long things can be , we’ve all been there and this job was as fiddly as it comes. Having all the parts / tools is very good advice and once finished you’d be very happy , the time and effort get forgotten quickly . Well done

[@HelpMeDIY]

Iain Mcglynn one of the goals of my channel is to not just tell people what has to be done but also show them HOW to do it, and that includes the time and the hard parts. As you know, reading the steps online vs SEEING it being done are completely different.

[@iainmcglynn833]

Help me DIY I’d recommend you to all and appreciate your efforts I must look at your other videos later , gate BMW so will skip those 😂🙏

[@HelpMeDIY]

Iain Mcglynn hahaha to each their own 😉😎. But seriously thanks for your support!

[@ralphsantaana7303]

Been watching you vlogs, thanks so much. It’s been very helpful

[@HelpMeDIY]

Love to hear that, thanks!

[@zupperm]

So the only moving bits are in the diaphragm at the top and if could be opened from the top it would be trivial to repair rather than replace?

[@HelpMeDIY]

+zupperm I suppose so

[@nunyabusiness2294]

Thank you for the great video!

[@HelpMeDIY]

+nunya business you’re welcome!

[@MyGuise]

Thanks this helped me a lot with my 987 Boxter.. Appreciate!!

[@HelpMeDIY]

+Chase Place that’s great! Hope you’re a subscriber now 😉

[@MyGuise]

@@HelpMeDIY I am now 🤪 But my ‘05 boxters new AOS part doesn’t come with a hose or any new clamps.. Would you still recommend cutting that hose and just ordering a replacement?? I’ve been cursing at it for an hour now and decided to take a break lol

[@HelpMeDIY]

@@MyGuise ahhh the memories… 😝 The part I remember cutting was part of the old AOS and I definitely recommend that clamp I linked to

[@allenhsu869]

Been there and done that. The hose clamp would definitely help. Thanks for the video!

[@HelpMeDIY]

+Allen Hsu you’re welcome, thanks for watching!

[@jeffs4760]

Wow. I cant wait till I have to do this.....and I thought the oil separator valve on my X3 was hard and it is! Ugh....did you just do it because it hasnt been done in a long time? Did you have the yellow like goop under the oil cap from condensation? Research on my X3 this condensation was from short trips to the store or so and not letting the car get up to full temp.

[@HelpMeDIY]

+Jeff S no goop on mine, just as regular maintenance.

[@zguy95135]

That looks like a pain... Thanks for posting the video now I know which hoses to remove to save a bunch of time. I gotta go in and replace all my SAI hoses and parts, and since the intake manifold will be off I might as well do the AOS too... I'll have a lot of clearance to get at those hoses you were having trouble with. Plus it does fart smoke every once in a while during startup and its a 21year old part. It would have been nice if Porsche would have made the top part with the bellows a modular part... Since that's really the only part in that entire plastic assembly that would wear.

[@HelpMeDIY]

+Joseph Delgadillo you’re welcome. Hope it helps! And yes, modular would be nice 👍

[@michaelwelschmidt9338]

For the hose you had difficulty with on the side, can you first unbolt the AOS and pull it up a bit to access that hose to remove it?

[@HelpMeDIY]

I actually tried that! But I found that the AOS being loose just made it even harder to pull it off.

[@scaresounds]

No, it's not just you on the difficulty level of getting that hose loose. I struggled with it too when doing the AOS.

[@HelpMeDIY]

+Marty Lane always nice to know you’re not alone! 😂

[@samuelseager6785]

I felt like a incompetent fool because I could not get mine off. It is so nice to see others struggled with it too.

[@philliplynch646]

Awesome Video👍

[@HelpMeDIY]

+Phillip Lynch thank you! 🍻

[@stevenpumford6506]

What book are you using? Could do with one myself.

[@HelpMeDIY]

+Steven Pumford check the video description

[@miraclefilmsnet]

Quick question… I recently purchased a 2000 Boxter that from looking has had an AOS already replaced several years ago. Do you think replacing this newer design would be easier than the original factory unit? My car has one just like the new one in your video.

[@HelpMeDIY]

+Jason Blackburn If it’s still working correctly I would not replace it. Watch my video on how to test the AOS and replace if it’s bad.

[@miraclefilmsnet]

Sorry I didn't explain earlier. It seems to be loosing pressure and squealing like crazy. Smoking some also upon startup.@@HelpMeDIY

[@lindaparker3140]

You made it look soooo EZ. "Hello Porsche...When can I bring in my 986 for an AOS replacement??".

[@HelpMeDIY]

+Linda Parker 😂

[@fredherb4805]

I need to do this to mine.How much did you pay for the hose clamps and for the longer pipe.Thanks and great video

[@HelpMeDIY]

+Fred Herb thanks! I have links to all the parts and tools in the video description.

[@davidpreston775]

Hi - really appreciate the video. Couple of questions please: in your opinion, is this easier done from completely under the car - at least the two bolts and the bottom accordion type hose (with the blue clamp)? Also, would the second hose, that you had so much trouble with also have been easier from below?

[@HelpMeDIY]

The two bolts, yes from below for sure. Everything else from the top (assuming you are removing an old AOS and can just cut the rubber accordion (bellows) hose from below. And the one I had trouble with was impossible for me to reach from below

[@seandenny2412]

Maybe it’s me but it looks like the hose that you put at the bottom with the blue clip it looks like it was folded back on itself like it wasn’t all the way on hopefully I’m not right so if it’s leaking oil it look like the hose did he got wrinkled as you were shoving it on thanks for the video look like a tough job

[@HelpMeDIY]

+Sean Denny no it wasn’t you! I saw it and fixed it right after I did it while I was editing the video, so it not only helped others but me too 😂 Thanks for pointing it out though!

[@1877DISH313dotCOM]

Thanks for the video! How did you know yours was bad? What goes wrong with them? It doesn't look like anything wearable in there, except maybe the diaphragm.

[@HelpMeDIY]

Yes that diaphragm goes bad and oil starts getting in through the top tube. I don’t think mine was bad yet, just preventative maintenance since it’s 22 years old and they are known to go bad.

[@MrJbipes]

When you start up a cold engine, you'll get a decent puff of blue smoke from the exhaust. small, but noticeable. It goes away quickly but it's annoying

[@joef2593]

thank you! great tips and very detailed

[@HelpMeDIY]

+Joseph Farley you’re welcome! 🍻

[@bryson-hx8hp]

I am still liking the vids

[@HelpMeDIY]

Thanks buddy!

[@treyfary5289]

So did anyone actually reverse engineer this part? Could we put a vacuum valve in between two of the hoses to suffice? Seems a little bit redundant.

[@HelpMeDIY]

+Trey Fary 🤷‍♂️

[@DarkTouch]

what is the symptom that would lead to a person knowing that this part has failed?

[@HelpMeDIY]

+@DarkTouch usually smoke from the exhaust

[@jonedgar5996]

Hi good video. Are you going bro reseat the rubber bellows on the bottom?....they look rather distorted.

[@HelpMeDIY]

+jon edgar yes the next morning I fixed it! Ended up removing that hose clamp with the hose clamp pliers and replace it with a new 8mm screw type hose clamp. I could have used some vice grips and reloaded the it into the blue pin, but I was tired of working on it 😆

[@jonedgar5996]

@@HelpMeDIY Ahhh that's good news. I replaced mine last week as well....not a job Id like to do again in a hurry! I also used a screw type hose clamp which is definitely a better solution. All the best Jon

[@danielferraro59]

brilliant love your videos Thankyou !!

[@HelpMeDIY]

+Daniel Ferraro 😁🙏🍻

[@Sank1982]

Do they do that book for a Cayman 987.1S ?

[@HelpMeDIY]

+Photo Sankey not that I’m aware of, but there are probably a lot of similarities and things to learn!

[@omm8701]

Same process for the 987.1 cayman right?

[@HelpMeDIY]

+Sandy Wong I have never seen one but I assume it would be very similar.

[@jeffreysalzman1497]

The AOS is slightly different, but the process is the same.

[@TheScottishCorsaBGuy]

where did you get that book from???

[@HelpMeDIY]

+Dale Mcgarry 101 projects… link is in the description

[@TheScottishCorsaBGuy]

@@HelpMeDIY cheers 😎

[@cescoral]

What is the blue pin tool called? I can’t find it anywhere… thanks!

[@HelpMeDIY]

+cescoral blue pin tool… what time in the video do I use it?

[@lamboguy188]

What year is his Boxster?

[@HelpMeDIY]

+Lamboguy188 1998

[@andrewwalling7522]

which book are you using for this job

[@HelpMeDIY]

+andrew walling 101 Projects. Link in the description.

[@andrewwalling7522]

@@HelpMeDIY perfect thanks Great video's may the way

[@HelpMeDIY]

@@andrewwalling7522 thanks! 🍻

[@stevehoward3981]

Excellent

[@HelpMeDIY]

+steve howard 🍻 Hope you’re a subscriber 😉

[@stevehoward3981]

Yes I am. Thanks

[@HelpMeDIY]

@@stevehoward3981 awesome. Thank you!

[@markriley8404]

the book says you have to take that off to change the cam sensor that's under it and it says 2 hrs to take off the air oil separator and only 1.7 to change the cam sensor if anyone knows a quick way to change the cam sensor let me know

[@rhysdavies305]

Right, now I know which project NOT to attempt. It'll be of to my local specialist when the time comes!

[@HelpMeDIY]

+Rhys Davies yes, this isn’t the easiest one to do yourself. I don’t blame you!

[@IvanGarcia-ft3zb]

Thank just bought my first 1999 Porsche 911

[@HelpMeDIY]

+@IvanGarcia-ft3zb congrats! 🍻

[@fernandosanchez4742]

That last hose it didn't went down the hose clamp did hose is not clamp 100%

[@HelpMeDIY]

+Fernando Sanchez yes, thanks to editing this video I saw that too 😉

[@Sank1982]

Think I’ll leave this for my specialist to do 😂

[@HelpMeDIY]

+Photo Sankey it’s not a job for everyone I admit 😝

[@glenngeelhoed9012]

I had it done by a brake and suspension guy who had never seen one before. I just told him lift it up a few feet, remove right rear tire and go for it. He did it in less than an hour. $50 cash :)

[@HelpMeDIY]

@@glenngeelhoed9012 he’s a better man than I 😂

[@rfpriddy1951]

Mine cost $550 for a new one installed.

[@zacharydahan4806]

I wish you made that video when mine died, I would have saved $300!

[@HelpMeDIY]

+Zachary Dahan haha maybe. But paying $300 for this one isn’t a bad deal either 😂

[@jimgraley8519]

It looks like a big PVC valve!

[@HelpMeDIY]

+Jim Graley 😆

[@johnmorgan7262]

The job is somewhat easier on a 2.5 liter. On the 2.7, there is another harness in the way. This is possibly the most unrewarding job I ever did on a car.

[@HelpMeDIY]

😂 I believe it!

[@timetravler3arewethereyet639]

LOL DUDE!!!! lol when i saw those legs i said dam bro why does he shave his legs like that lmao then i herd a females voice i said woeeee is that his wife lol i was gonna say man lol i never seen a dude with facial hair but smooth ass shaved legs! that was funny we all over here is crackin up bro. we seriously thought that was u 4 a sec.14:47

[@HelpMeDIY]

+time travler 3 are we there yet hahaha that’s great! Totally forgot about that and I can see how you thought that looking back. When the wife got under the car I couldn’t pass up getting a bit on film.

[@jeffjeff4477]

Not a fun job, but rewarding

[@HelpMeDIY]

+Jeff Jeff very true!

[@marceloigorra9155]

Hi Try to clean your engine, have a red dust from the paint.