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YOUR RESEARCHAOS is stuck!!!
Leading reported evidence
Use chapstick in a pinch
Performed · outcome unconfirmed
No successful repair reported for this finding.
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Leading evidence: 'Use chapstick in a pinch' (no explicit attributable resolution; this is a reported action or suggestion). Across 1 matching discussions, the most frequently mentioned possible cause is 'only way i could get it' (1 discussions; 0 report identifying it and 1 suggest it). The most frequently discussed action is 'Disconnect )' (1 discussions). For that action, 0 discussions report a resolution and 0 report an unsuccessful attempt. No action has an explicit, attributable resolution report under the current rules. These are forum reports and suggestions, not a confirmed diagnosis.
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Performed · outcome unconfirmed
Cant remeber but i probably used a short extension too.
Use very light layer of extra motor oil (extra dt-40)
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Performed · outcome unconfirmed
I used a very light layer of extra motor oil (extra DT-40).
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Performed · outcome unconfirmed
Especially for you guys up North, the salt used will corrode metal and make everything harder to remove.It's not much the cost of the AOS, they are relatively cheap compared to the labor/time to replace them...
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Performed · outcome unconfirmed
Short Box wrench is what I used with the 10mm bolt...It's a slow process.
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41 eligible posts · 0 unverified posts · 1 discussions match the subject in their title or opening post.
Rennlist: 1 discussions
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Generation: 20261027T192637Z · outcome-qualification-6. Deterministic extraction; no AI model inference. How we use sources
I've been fighting with this thing for hours. Everything with the exception of one of the water lines has been disconnected. No matter how hard I pry or pull, I just can not seem to lift this thing out from the engine case either above or below the car. Any suggestions?
In order for us to better assist, take some clear photographs with your iPhone and repost.
Explain what you've done to gain access to the AOS (i.e. lowered the engine, transmission removed or not, etc.).
I had a similar issue. The AOS fitting that is inserted into the case gets stuck. And it�s hard to get access to pry that area. You will get it eventually. Try various prys and angles. Walk away and come back several times. Use some lithium grease or suitable agent on the AOS fitting when reinstalling. Or it may be a bear to install too. It�s not a fun project. You�ll get it!
This is one of the reasons I invented the UAOS, saving the expense and PITA of not ever having to do this again. Especially for you guys up North, the salt used will corrode metal and make everything harder to remove.It's not much the cost of the AOS, they are relatively cheap compared to the labor/time to replace them...
Maybe you've already done this, but you didn't say.
Did you unbolt two bolts holding it in, and remove the clamp holding the hose on the bottom? I had to do those three things from under the car (with a MT) apparently a Tip trans is harder.
My difficulties here, including a picture from the bottom:
https://rennlist.com/forums/996-foru...l#post17013135
Sorry if that's trivial, and that of course you did that, but I thought I'd offer my prior posts about the same issue.
they are two 5mm allen(socket head) screws correct? I just did this job on an 02 so it's fresh in my mind. At first I removed the a wrong screw (to the alum part of intake) and I couldn't get the AOS out.
also get some 35mm long, 6mm thread socket head(5mm) replacement screws for the manifold from Bel Metric. It will make installation of that back screw way easier. your new AOS will have more material right in the frickin way
Doug, You nailed it! There were two hex screws and I didnt get the one on the left. And finally got it out!! Many Thanks.
No idea how I am going to get this all back together....
Good.
I'll tell you.....the difficult AOS screw.... put in with a little pencil pocket extender magnet
insert the far back manifold screw (Bel Metric sourced 35mm long 5mm socket head) into the manifold before you slide the manifold in place
get the camera,
Amazon
Amazon
use the camera to help you get the ball driver on the far back socket. once it's in, it will pretty much stay in place
I taped that most rearward hex screw to the socket to reinstall, firm enough so it would not drop but loose enough so that once the threads caught the tape broke free and came out with the socket.
Thanks. Hope to start the reinstall today.
couple questions.
is it necessary to replace the green upper manifold gaskets?
is there an easy way to verify the AOS vac hoses are still ok?
I did not replace, obviously if there is any visible damage or deformation, replace. In my case, they looked perfect.
A smoke test before you button everything back up for good is not a bad idea. Smoke tester can be made for cheap dough with a hand transfer pump and a cigar.
I think this is where dropping the motor some really helps on a mk2. I had enough room on my mk1 to get a 1/4" drive and socket in there. Cant remeber but i probably used a short extension too.
Left outside by feel. You can't see **** while doing it. Think chopsticks holding the wrench with the fuel line under the wrench in the palm of your hand. It was the only way I could get it... I think someone found a stubby socket set (1/4 drive) and had luck.
You need to leave the AOS loose to get the socket between the manifold and AOS.
Loosen the AOS so it gives you the slightest wiggle. Also, I think I shaved my magnetic 1/4in 10MM socket down on a bench grinder to minimize the room I needed.
Almost there.
Took forever to get that foremost manifold bolt in. Would have been much easier to switch to a hex bolt, but was already halfway in when I understood the recommendation. Also a little impatient in having to wait for a bolt to arrive.
Also struggled with bolt 4, so had to loosen all others back up to get it to align.
Rear plenum is back in.
Today may finish up, but have a couple questions.
I have the IPD comp plenum and GT3 TB that I was going to put back in. I know the verdict is out on those but can�t hurt so was going to reinstall.
I also removed a K&N �CAI� that I think I am going to keep off.
Question is do I go to the factory airbox?
Factory airbox with resonator delete? Or source a 997 box?
thanks for all the help so far. Jeremy.
