AOS Replaced but I have some residual smoke

[jcb986]

Replaced the AOS, the top tube and the boot. Definitely fixed my problem. I still have some smoke on startup for about 15 seconds. How long does it take to clear up.

[mikefocke]

Depends on how much oil got into the intake. Clean the throttle body, you'll be glad you did.

[Wayne 962]

Give it a few weeks and a few hundred miles - you probably still have a bunch of oil residue trapped in the intake manifold.

Here's a link to my air-oil separator replacement article:

Pelican Technical Article: Air / Oil Separator - 986 Boxster (1997-04) - 987 Boxster (2005-08)

-Wayne

[syncspeedinc]

I found that the original top breather tube is just a hair too short when updating the AOS on my car so just a heads up to others. I guess that the change in the orientation of the diaphragm on the new AOS must have moved the relationship of the connector just enough.

[Wayne 962]

Originally Posted by syncspeedinc

I found that the original top breather tube is just a hair too short when updating the AOS on my car so just a heads up to others. I guess that the change in the orientation of the diaphragm on the new AOS must have moved the relationship of the connector just enough.

Hmm, I wasn't aware that the air-oil separator external dimensions have changed? Perhaps your original hose (plastic) shrunk slightly over the years? Seems like it may be a good idea to purchase a new attachment hose with the new air-oil separator. The hose is a plastic flexible one, and I imagine will get brittle over the years from the heat cycles in the engine compartment.

-Wayne

[syncspeedinc]

I did put them side by side and the angle of the top connection is different on the new AOS unit (version04) than the original unit that I took out, when they rotated the diaphragm on the top of the unit to a vertical orientation instead of the older horizontal it must have moved a tiny bit. I got the new OEM hose today and it is a tiny bit different on that end with a tiny bit of an angle and a 1/2 an inch longer now on the AOS end.

[Wayne 962]

Good info, I will add that to the book:

There have been many updates to the unit over the years. The later-style units are a direct bolt-on replacement, but the hose that connects the air-oil separator to the throttle body has been updated as well (the old one is too short). If you are replacing your air-oil separator with a new one, be sure to install the updated connecting hose as well.

-Wayne

[syncspeedinc]

Here is a poor phone photo to show the difference, the new unit is on the top.

[Wayne 962]

Cool - I ran into a similar problem with my 3.4 conversion - the hose fit, but just not quite and probably would have caused some major vacuum leaks.

-Wayne

[Zeke]

Originally Posted by Wayne at Pelican Parts

Yes, that was a late addition to the book. I didn't include the PN in the book because it may change in the future.

-Wayne

That was from a newer thread.

Just a note since I am doing this job right now. The PN's for the 2 parts are
AOS 996-107-023-04
Vent Line 996-107-145-06

[Wayne 962]

How did this turn out for you Milt?

-Wayne