Just completed this and it took me about 2.5 full days; I have a lift which made getting at the AOS much easier but I couldn't get my rear tire off even with a breaker bar so I had to work in the small opening under the car. Biggest issues for me was 1. removing the fitting on the long line to the AOS and then getting it reconnected securely. Those squeeze fittings are a massive PITA. Messed around over and under the car for awhile trying to reconnect it. I finally held the bottom squeeze fitting in place with a long screwdriver and the handle on my chest while pressing on the top with my finger and pushing on the side of the line with a piece of wood about 2 feet long and an inch square to seat it. 2. Second biggest issue were the idiotic vacuum lines beside the front plenum fittings around the throttle body. Pulled out on both sides from their original seats (the ones in the far back) which required a pair of long forceps and a bright flashlight to re-seat. If you're a surgeon that's probably helpful. Then putting the throttle body in place I'd inevitably press one of the vacuum lines out the back on one side. Don't know how many times I had to re-do that. Also, either Hans in Stuttgart or one of the mechanics working on the car in the past (I'm the original owner) tightened the hose clamps of the right rear plenum so the adjustment screws are not visible and therefore impossible to get off. 3. Reseating the AOS takes some patience as you can't see and can barely feel the hole it sits in. In retrospect, it's not a hard job but loads of patience and really small hands would be a major benefit (I unfortunately, have neither). I could probably re-do it twice as fast now that I've done it once. FYI, I ordered the full replacement kit from FCP but it didn't include the green manifold gaskets. This instructional video is first rate and doesn't miss anything.
@fredbergeron79972 жыл бұрын
I'm loving the DIY videos on the 996 Porsche. This makes me way more likely to do it myself instead of paying hundreds to a shop. You have enough details which make the job more easy to tackle. Keep it coming!
@theLeftHandedDog2 жыл бұрын
I tackled this job myself, after reading a number of comments stating that it wasn't that hard to do - some had completed it in a couple of hours. I ordered a new AOS, set to work, and finished up the job yesterday. For anyone considering doing this replacement work yourself, here are my stats; The car was up on the jacks for about two weeks. I spent between 1 and 7 hours working on it nearly every day, since I first removed the air box. The major hang-ups for me were the alternator, the coolant tank, the gas line going to the fuel rail (I had to remove it to make room to get the coolant tank out) removing the center plenum (the second one) removing the sixth bolt at the back of the air intake plenum, loosening various coolant hoses and the rubber boot at the bottom of the old AOS, uninstalling the old AOS, installing the new AOS, reconnecting the various coolant hoses, tightening the sixth bolt on the air intake, reinstalling the coolant tank, reinstalling the alternator, and reinstalling the 2nd plenum. Everything else was easy. After all that, the car started... but is still emitting heavy white smoke. There are two possibilities here; either I screwed up the AOS during installation, somehow, or I should have gotten the problem diagnosed by a professional shop, because it now seems likely the problem wasn't the AOS at all, but score boring or something equally disastrous. I'm going to talk to the Porsche shop down the road tomorrow & get their opinion. My car is a 2001 996 .1, incidentally.
@fcpeuro2 жыл бұрын
It is certainly not a quick job, that is for sure. Perhaps just doing the actual valve may be okay, but doing the complete system is a whole different animal. We wish you the best of luck with your further investigations!
@shaazy Жыл бұрын
Would love to hear an update on this
@Stefan0207 ай бұрын
Any update?
@crubenbauer13 жыл бұрын
I'm proud to know FCPEuro's staff and Principals , and it's amazing growth over the years. Nick, Scot and Max... Y'all have come a long way from the humble beginnings in Groton. I'm excited to see continued growth and success of FCPEuro!! You folks ROCK!!!
@fcpeuro3 жыл бұрын
We really appreciate the kind words Christian, and its people like you who have supported the company and people along the way that helped make it a reality!
@crubenbauer13 жыл бұрын
@@fcpeuro In my initial comment, I forgot to mention Mike Rivera. He's been a phenomenal help to me from the beginning. Thanks Mike!!
@BCBlue8 ай бұрын
I have a 2001 996 and replaced the AOS at 99K. Several shops told me it is necessary to drop the engine to replace this part. I was able to find a mechanic that replaced it as you have. This cost me $400 instead of $1200.
@fcpeuro8 ай бұрын
Nice find!
@harrysewell5506 Жыл бұрын
I’m 21 years of age and managed to do this on my driveway with a couple of jack stands in 12 hours.
@samuelvakulich59432 жыл бұрын
This video makes me so happy that my engine is already out. This job would be so much easier having 360 degree access all around the engine.
@fcpeuro2 жыл бұрын
Mike tried to convince us to let him do it with the Engine out, but we figured not everyone has the time, space, or capability of necessarily dropping the engine. But you aren't wrong!
@billybudd34010 ай бұрын
Excellent video! Excellent camera shots. Excellent wrenching techniques.
@gwaddy47463 жыл бұрын
Thanks for the video. Brilliantly presented, and it helped me a lot. I changed one this week, tricky job, the hardest part was getting to the back 10mm on the intake manifold.
@flyderdecastro37882 жыл бұрын
Very talented detailed mechanic.
@DSC8002 жыл бұрын
Another nice FCP how to video. I did my AOS when I dropped the trans to do the clutch, etc. If I had to do the AOS again I think it still would be easier to just drop the trans again rather than go through all this.
@skcapture2 жыл бұрын
What a job. Well presented and filmed. Thanks
@franksegrov85394 ай бұрын
Excellent video, well narrated, what type of lighting are you using for this video, the blue box that you have under the bonnet
@Raguvian2 жыл бұрын
Thank you so much for the video! I just got a '99 and discovered this series. You got a subscriber here!
@luisruelas97635 ай бұрын
Excelent DIY!!!!💪💪💪👍👍👍
@fcpeuro5 ай бұрын
Thank you for watching! -Mike
@user-oy1re6vj8m9 ай бұрын
God bless you for doing this.
@fcpeuro9 ай бұрын
😎
@flyderdecastro37882 жыл бұрын
You are Awsome. And the camera guy did really good too
@nickosmond3 жыл бұрын
What happened to the 850 project??
@peterpaulhenze3 жыл бұрын
Sooo impressive! Indeed, massive work. Guess, it only makes sense to also do the oil cooler seals and replace the oil filler tube while in there. So, Michael, How long does it take--really? Kudos for a cool and calm guide that encourages. "Goes in like sin!"
@fcpeuro3 жыл бұрын
Thanks for following along peterpaulhenze , without shooting and editing this would have taken Mike about 8 hours
@pmgear2 жыл бұрын
great technician! very well filmed1
@1drwnd.porsche2 жыл бұрын
Great video. However, part numbers should be listed in the description box.
@fcpeuro2 жыл бұрын
Hello, we have a link in the description below for a listing on all the parts used, and each one lists all the OE part numbers as well!
@thetumanshow Жыл бұрын
Seems like a lot of extra items to remove VS what Pelican Parts suggests. I replaced mine with a Ultimate AOS
@richardowens6520 Жыл бұрын
Good job, thank you
@Mckorzi3 жыл бұрын
Did you have to drain the coolant before removing the hose in front of the plenum? I,m asking because that plastic connector brakes easily and I’m replacing it with a aluminum aftermarket part. So I,m wondering if you had to drain the coolant in order to remove that hose. Another great video, I,m more than impressed👍 Hopefully you work on a clutch change soon😉
@miketdavies2 жыл бұрын
Nice, thanks! Did I miss the part where you refilled the power steering fluid? :)
@porschelover356c Жыл бұрын
Thanks for the great videos FCP! Quick question - i have a 996.2 where the the AOS bolts are removed from the top. The bolts i removed are M30 allen bolts. Would you recommend replacing those bolts with a different style? I ordered your oil cooler kit and it came with replacement T30's - i'm wondering if I should use the same style bolt for the AOS
@peroukin2 жыл бұрын
hi Michael and thank you for works !! one question, by any change is it possible to have a video to fix P0491 & P0492 issues ? mostly related to leak pb. Kr.
@LordLauderdale3 жыл бұрын
Massive Job !
@timmychriss10 ай бұрын
Should I change the starter at the same time? What else could I do while I'm in there? 66000 miles
@bcapa217 Жыл бұрын
Had the dealership service this. Cost $1k
@marsogreen24113 жыл бұрын
Thank you for the informative video. Does a failing AOS also cause low oil pressure when warm? Thanks in advance
@Nick-hp8qr Жыл бұрын
Does anyone know if the new AOS is suppose to fit flush or is the orange rubber fitting suppose to protrude a bit? It seems like the new AOS design is a tad larger than the original design.
@flyderdecastro37882 жыл бұрын
Good job !!
@awdfabu568711 ай бұрын
Curious why y’all didn’t show the removal of the expansion tank
@fcpeuro11 ай бұрын
We have a video on that job on its own!
@awdfabu568711 ай бұрын
@@fcpeuro maybe, but making someone go watch a different video then have to come back to this one, seems a bit odd.
@daniel1967hkc Жыл бұрын
at 7 min, the engine mount was loosen. Why was it necessary to loosen the engine mount?
@fcpeuro Жыл бұрын
Hi Daniel, loosening the nut on the mounts allows you to drop the engine a bit to gain room to remove all of the components topside.
@tarekchbeir82993 жыл бұрын
Thank you for the thorough DIY demo. I want to point out that my '03 model has a different AO separator. The bolts go vertically into the block, not horizontally, and the device itself covers one of the bolts of the intake. Therefore after wrenching endlessly to remove the intake in order to access the AO separator, I'm finding that it's impossible to do so. It seems that one must remove the AO separator first, in order to remove the intake, and since access is impossible, one must drop the engine. Could you, or anyone else here, confirm this? Thank you very much in advance
@jasonherzog48982 жыл бұрын
Tarek you are right it is nearly impossible to do, however I just completed replacing mine. I have a 2003 Carrera 4 3.6L Tiptronic. It is possible but one of the most difficult job's I have ever done, I worked as a Nissan Mechanic back in the 90,s for 10 years, but oh boy did I feel the 20 years of rust build up since then. To get to the point the rear intake bolt and coolent tank were the most difficult to deal with. To remove the rear intake bolt I used a short 10mm flat wrench. It took me hours to remove as each turn barely turned the bolt. With that being said I did get it out. Then it looked impossible to get to the AOS bolts. I found removing the Vacuum reservoir helped with that, I broke the vacuum tit so had to replace it so be careful with that. Another tip is make sure you get a special tool to remove the hose clamps. I found one at my local auto parts store, it is an OEM part #25246 hose clamp pliers. It is impossible to remove the hose clamp off of the bottom of the AOS without this..... made a much easier job of reinstalling the clamps, I paid hell removing them without this, I got it after everything was disassembled. So the big tip I have on reassembly is do not reuse the back intake bolt. Replace it with a bolt that has a torx or allen head, It is impossible to get a wrench or socket on the head of the old bolt, I used an allen head bolt. Make sure to place the new bolt into the intake back hole before you slide the intake back into place, then I purchased a long allen wrench with a T handle to be able to turn the bolt, you may have to cut the tool to make it the right length so the T handle can be turned . This is not an easy job by any means, I do see why alot of people recommend removing the engine. But it is possible. I still can't figure out how to install the coolent take without removing the upper tank holder/bracket which is impossible to install after the tank is in place...ughhh.. Last but not least keep track of the vacuum line routing. Some pictures will save you alot of headaches.
@philippecharles50722 жыл бұрын
Le meilleur
@bimmergotup65843 жыл бұрын
+ 1 Hours ? Thank you so much ! I will take beer's :-)
@khestehave3 жыл бұрын
Awesome!!
@jamesmitchell22862 жыл бұрын
Great video, many thanks going to tackle my AOS this coming week. Can I ask how far you can drop the engine without disconnection? Greetings from the UK.
@fcpeuro2 жыл бұрын
Glad to be of help, James! You will see that you have about 2"-3" before you hit the cross member underneath. Just keep an eye on that and you will be set!
@jamesmitchell22862 жыл бұрын
@@fcpeuro Thanks for the reply I have the cross member out whilst underneath the car so 3 inches will be good. Love the videos keep them coming...
@RobertS-eq9yn2 жыл бұрын
I have a 2008 997.1 base I wonder if this is what my problem is. I have light smoke only on a morning cold start. For the rest of the day it doesn't smoke at all even if I get on the gas hard.
@fcpeuro2 жыл бұрын
Hi Robert, it would be worth doing some further investigation for sure. This car had no signs of failure, so we cannot compare it to that; we just changed it due to the age of the vehicle and the mileage. Hopefully, it's just condensation!
@ChrisMcPorsche2 жыл бұрын
Is the long one worth swapping out? Or is there any way to determine if it needs to be replaced?
@fcpeuro2 жыл бұрын
Hi Chris, that really depends on the vehicle itself. Ours specifically being a Southern Cali car, it lived in a warm environment its whole life, plus having 120k on it meant the ends were a bit brittle from heat cycles. The other thing with it is that it is so buried, so if you are going that deep to inspect it, may as well swap it out at that point.
@jeanpierrepichon2372 жыл бұрын
bonjour très bonne vidéo je possède une 996 4s de2004 boite tiptronic je n'ai pas d'acces en dessous avec la bv auto faut-il descendre le moteur merci pour votre reponse
@fcpeuro2 жыл бұрын
Hi Jean, if you are unable to reach it with the Auto in place, you can try lowering the engine down a bit, however you may find it easier to drop the transmission for this one.
@ericbengle2 жыл бұрын
Do you have a DIY for sealing valve covers?
@fcpeuro2 жыл бұрын
We have not done one yet! It is on the table for potential jobs.
@ericbengle2 жыл бұрын
@@fcpeuro if you all were close you could use my car for your video
@bugsy7912 жыл бұрын
Eff that...i would gladly pay for a pro to do this job...this seem intimidating af....ill tackle changing pads