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Join Date: Oct 2010
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I eliminated my AOS!!!

My AOS failed, causing my 01 996 to smoke badly. After partially dropping the engine I was able to remove the old AOS with LOTS of effort. I was going to install another AOS, but had concerns about the failure rate these seem to have and the difficulty of replacing it without damage. So, here's what I did (hope you find it useful)

1. Cut the top off the old AOS right above the lowest seam (seam from casting). This leaves the remaining AOS as two distinct cavitities with no crossover.
2. Plugged the oil inlet in the AOS with a threaded pipe plug.
3. Cut the bottom ring off of a PVC grommet. (valvecover style grommet)
4. Installed the grommet into the the modified AOS and a PVC valve into the grommet so that it was connected to the cam cover through the modified AOS.
5. This effectively plugs the oil hole in the block, and installs a PVC valve above the driver's side head. I used a PVC valve from an 84 blazer ($2), but should have opted for one with a straight outlet, instead of 90degree elbow.
6. Ran 3/8" vaccum line from the PVC valve to throttle body in place of the factory vent line. If I rework this, I'll try to use the factory vent line(s)
7. Added a valve cover style filter to the vent line on the passenger side. (I would like to add a 2nd PVC valve and T into the vaccum line.
8. Re-routed the coolant lines that go to the AOS together. (bypassing the AOS)

So far so good. No engine light, runs great with no smoke! FYI, I have been an automotive engineer for 13 years and worked through an ABET accredited college as a welding/fabricator then toolmaker/machinist. Can't guarantee the durability yet, but as I said it's worked great for me so far. I don't fear replacing a defective PVC valve as I can get to it from under the car and can replace it without tools. Good luck!
Old 10-22-2010, 12:03 PM
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Nice project! please keep us updated on how it works out.
Old 10-23-2010, 09:50 AM
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Sounds very interesting. Thank you for sharing this.
Old 10-23-2010, 11:33 AM
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Charles,

Any pics??
Would love to see them and build my own.

Thanks,
Kyle
Old 11-04-2010, 11:14 AM
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Wow. Ingenious, I must say. I just went through the hassle of a do-it-yourself AOS change.
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1984 911 Carrera Cab - track day and back road weapon
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Old 11-06-2010, 05:42 PM
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Wow. My question is how is the frothy oil reduced? You eliminated the AOS but did you redesign the purpose of it, while excluding the AOS?
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Old 11-12-2010, 09:41 PM
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