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Old May 3rd, 2009, 08:28 PM   #1
cas951
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AOS Removal and installation steps. Revised

The first time I replaced the AOS on my wifes car it took me about 3 hrs to finish. Most of the 3 hrs was spent removing and reading instruction and struggling with removing the lower vacuum line that you barely have access to. After I removed the AOS I felt the instructions could be improved.

We did an AOS replacement yesterday and I reversed the steps from the instructions you normally find in the internet. This is what we did.

After removing the engine cover and had the car on jack stands and wheel removed.
1. Remove the two 10mm bolts mounting the AOS.
2. Cut the lower vacuum hose from the AOS mounting point.
3. Slide the AOS out of the engine block.

move to the top of the Engine Compartment
4. Remove the upper vacuum line.
5. Slide and maneuver the AOS and remove the lower vacuum line.
6. Remove the AOS......

I think we had the AOS out of the car in less than 30 minutes.

Before installing.
  • Make sure you replace the lower accordian hose clamp with a regular clamp.
  • Lubricate the AOS tube that slides into the engine block with oil
  • Lubricate the lower hose with oil

Place the AOS in the Eng compartment but do not lower all the way. The first item to connect is as follows from the top of the Engine.
1.Position the AOS and Connect the lower Vacuum line (Item #5 above).
2. Slide the AOS tube into the engine and align the mounting bolts.
3. From the bottom, install the two 10mm bolts.
4. Install the lower hose and tighten the clamp.
5. Bact to the top of the engine, Connect the upper vacuum line.

Doublecheck all your connections. We failed on this one.... The throttle cable was not on the CAM so when Jeremy tried to move the car he had no tension on the gas pedal.

Thanks to Bigb (Varun)and RaisedonPorsche (Jeremy) for assisting.

Cheers. I hope this helps the next person.
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Old May 3rd, 2009, 10:48 PM   #2
RaisedOnPorsches
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I took a few photos once the AOS was out of the car. You can see them in my new Flickr account here:

http://www.flickr.com/photos/[email protected]/?saved=1

The newer AOS design has three O-rings instead of one. Make sure all three of them are pressed into the engine port. This proved a little difficult for us given the tight space. We were able to push the first two O-rings in, line up the bolts, and tighten the two bolts evenly to help guide the last O-ring in.

Definitely worth having a few extra pairs of hands to help, but replacing the AOS really wasn't all that frightening. Saturday was a great day of Boxster DIYing.
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Old May 13th, 2009, 06:55 AM   #3
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Aos?

I'm a new Boxster owner and would like to know what is a AOS and what does it do? Thanks!
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Old May 15th, 2009, 11:11 AM   #4
The Voxster
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Quote:
Originally Posted by cas951 View Post
The throttle cable was not on the CAM so when Jeremy tried to move the car he had no tension on the gas pedal.
Procedure is awesome... thanks for sharing! I may be using it soon, depending on what the warranty company says about my AOS.

HOWEVER... I didn't see any instructions on the first half of your procedure that specified when to (or even that you need to) remove the throttle cable.

Might wanna use EDIT on your instructions and add it into the procedure...?
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Old May 15th, 2009, 11:45 AM   #5
BoxsterBob - San Carlos
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Quote:
Originally Posted by flexstar View Post
I'm a new Boxster owner and would like to know what is a AOS and what does it do? Thanks!
Similar to the PCV on most other vehicles. It basically allows blow by gases to be re ingested by the engine and burned off. I'm not a techie, so that's the best I can do

http://en.wikipedia.org/wiki/PCV_valve
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Old May 15th, 2009, 11:49 AM   #6
BoxsterBob - San Carlos
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Quote:
Originally Posted by The Voxster View Post
Procedure is awesome... thanks for sharing! I may be using it soon, depending on what the warranty company says about my AOS.

HOWEVER... I didn't see any instructions on the first half of your procedure that specified when to (or even that you need to) remove the throttle cable.

Might wanna use EDIT on your instructions and add it into the procedure...?
When I did my '99, I didn't have any throttle cable issues. Maybe I had eGas before it's time. (please, no burrito jokes)
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Old May 15th, 2009, 12:13 PM   #7
cas951
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Quote:
Originally Posted by The Voxster View Post
Procedure is awesome... thanks for sharing! I may be using it soon, depending on what the warranty company says about my AOS.

HOWEVER... I didn't see any instructions on the first half of your procedure that specified when to (or even that you need to) remove the throttle cable.

Might wanna use EDIT on your instructions and add it into the procedure...?
You're right. It wasn't covered because we didn't intentionally remove it. We must have accidently knocked it off the cam. My point was to make sure everything is operational before buttoning down the eng comp lid and conv top.

One thing to note: When I did a Tip tranny there was hardly any room to get my arm in there from the bottom. A car with manual trans is a lot easier. Has more room to access the AOS from the bottom.
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1988 944 turbo S
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The rest of the stable:
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Old July 4th, 2021, 01:23 AM   #8
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Make sure all three of them are pressed into the engine port. This proved a little difficult for us given the tight space.

- Lot Clearing
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Old September 7th, 2021, 02:13 AM   #9
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I really loved it here but are there any recent updates? Thanks https://hairextensionslincolnne.com
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Old April 26th, 2022, 11:36 PM   #10
Otto Osborn
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An AOS is required if your engine has direct injection. When you increase your horsepower, you should invest in a good AOS. Even if your car is essentially stock, AOS can enhance performance and fuel efficiency significantly over time. When fitted correctly, they operate effectively, and they are the ideal product for your engine. If you're done changing your AOS, why don't you try pubg mobile or Kiss of War. These are the best mobile games to play today.

Check out my Kiss of War - Gameplay Tips and Download
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