How can I remove the AOS top with out cracking it?
 

I had to remove the air oil separator recently and found that an ancient fire had damaged it beyond repair. I picked up another one from the local Porsche recycler today and when I did a leak test it was leaking badly around the top cap. The top already has several cracks around the outer diameter where the small locking tabs are located. I'm afraid that when I try to pry it'll crack and be unusable.

Does anybody have any tips or tricks for removing this piece? Or maybe I should bite the bullet and buy a new one.

Thanks for your help.

'86 951 Stock with lots of miles.

If I remember, they're sonically sealed, or supposed to be. I don't think they're supposed to be removed.

no they're not supposed to be opened. but given a screwdriver or a chisel and an xacto knife, it can be done.

seal it back up with high temp RTV or jbweld. works just fine.

remember to buy new orings for it when u put it back into the car.

They can be opened.
 

I was able to snap the lid off the old one that I took off the car. It has small snaps on the inside of the lid, but the plastic has become brittle and "shed" a lot pf pieces. There is a small cross section o-ring under the cap to seal the two halves together.

I figured that it wasn't designed to be taken apart for servicing, especially after 23 years of service, but I can't see paying that much for what amounts to the failure of a two dollar part inside the assembly.

I have the o-rings that go onto the assembly already. It's funny how the parts catalog calls out for three o-rings and there are only two required.

I wonder how long that JB Weld will hold up? I really don't want to take that darned thing off again anytime soon.

i can't imagine jbweld giving way before the rest of the plastic housing decays.

I would like to see a step-by-step description of how to accomplish this if anyone has done this before. Pics would be great.

I'm in the midst of replacing all the vacuum lines, the ISV and fuel injectors. I took the AOS out cleaned it the best I could outside then in. Took a mini-mag flashlight to all the ports and shining the light in the bottom drain and looking through the top hose connection - there is absolutely no media whatsoever. looking into the top port, all you can see is what appears to be an inner wall of the canister.

Can anyone break this process down into 3 main areas?

1. Opening on the AOS
What tools and methods and sequence (in detail) were used to open the canister and minimize damage?

2. Servicing the AOS
Exactly what kind of media should be in there, & how much? Is it safe to assume the old-school white breather element media is OK to use?

3. Closing/resealing the AOS
I've seen the JB Weld recommendation. But this might make it difficult to service again in another 25k miles if required. Any thoughts on high-temp RTV?

Jim
1985.5 944 NA