Why do people do it!

Decided to sort out some jobs on the car in time for summer and starting to regret it lol I had a few coolant leaks so have fitted a new centre rad, thermostat and housing, along with water pump (good job as the bearings are shot), and all went well. So I moved onto something I had been putting off and that’s the AOS. Started stripping it down to find the resonance tube jubilee clips facing the bulkhead, so had to cut them off! Then started on the manifold bolts to find them literally soaked in thread lock and massively over tightened Got 4 out and 2 to go but walked away before doing something stupid. I was told that the first owner had a crankshaft replaced under warranty, so I wonder if this was done with the engine out and the technician is responsible for my woes 25 years later!

Most likely OPC.........they've always been good at f***in stuff up.

yup, OPC's working to a timed job card like it's an episode of it's a knockout

They put the long bolts in the short holes and the short bolts in the long holes when bolting my gearbox on to the engine, thus snapping part of the casting off my engine. Wasn't until my mechanic did a clutch change for me years later we knew about it.

When I bought my car it had just had new radiators fitted by an OPC and when I removed the bumper the self tappers holding the air scoopy things on were screwed into the fins of the new rads!

I’m currently doing the AOS, check my thread out, it might help with parts etc. Thread '996 1999 C4 e-gas issue, not sorted hot start, cutting out at idle and rough idle' 20 Apr 2026 Car is a 1999 C4 e-gas. When cold It starts fine, however when hot catches idle briefly, then dips and stalls unless I hold a small amount of throttle. It feels like it’s trying to stabilise but can’t quite maintain idle. I carried out another smoke test and this time found a definite leak at the rear of the intake plenum around the breather connection from the AOS (behind the throttle body / T-piece area). There is also a noticeable amount of oil present in that area. What’s strange is there are no typical AOS failure symptoms: No white smoke No obvious oil consumption Oil... The Baron3 Replies: 30 Forum: Porsche 911 996 (1997-2005)

Will check it out. I have walked away for the weekend and will see if I can get the 2 remaining bolts out next week. I have soaked them in penetrating fluid in the small hope that it helps!

By way of update I have managed to remove the inlet manifold, old AOS, and fitted the new one this afternoon. What a faff! Looking at the old one it appears the bottom o-ring had failed as it all seems in tact.

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So the penetrating fluid and forcing a break from it helped?

I went out and purchased some thin wall sockets which seated better on one of the remaining bolts, and by removing the alternator & vacuum tank I was able to get the further most bolt from under the inlet! The penetrating fluid may have helped, but the main reason for taking a break was to ensure I didn't end up breaking something by making a poor decision when frustrated.

Did you not replace the breather pipes whilst you were in there?, it comes as a kit from Design911?

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I always do that particularly when things are going well I have a habit of packing up and leaving it on a high. I sleep better.

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No didn’t bother as there were no signs of damage or leaks, and nothing broke during removal (if it ain’t broke). Pretty sure the AOS on the car wasn’t original as the flexible rubber hose connector on the bottom was held in place by jubilee clips rather than spring clamps. In the end a new o-ring might have been all it needed.