RPMulli

So I decided to jump into the AOS replacement today.. Whats the trick for the last intake manifold bolt again? It seems that the old AOS is directly on top of the bolt.... limiting access.. everything else has been easy though... I found something pretty interesting underneath the manifold. I will post pics later.

fpena944

I don't know if you've seen this before but I've been studying this PDF in anticipation of what I have to do for mine:

http://www.renntech.org/forums/index...placement-aos/

450knotOffice

Fernando, that's an excellent How-to. I could've used that when I took this job on myself last winter. The only thing I would add to the discussion is that it's so easy to lower the engine down a few inches that it should be done to gain that much more room up top.

Here's my documented experience with the job:
https://rennlist.com/forums/996-foru...separator.html

redridge

you should be able to move that AOS out of the way by now.... just take the 2 bolts that holds the AOS off and move the aos... this should make enough room for the intake bolts.

Or are maybe its the vac tank your are talking about... the trick is, the more you clear, the easiser to take out.



here is where the bolts are located....

RPMulli

Got the bolt out.. Look here my alternator harness is fried....



Another $100 down the drain...

redridge

how did that happened?

ivangene

awe... put some rags down those intake holes


what the hell happened to that wire

RPMulli

I have no idea. I saw the corroded wire while I was fulling the intake manifold off and its the main wire coming from alternator and starter... fun.fun

RPMulli

Don't worry rags are in the holes.. I just finished replacing the AOS and oil filler tube. That AOS job was sooo easy compared to my fuel pump. Oil filler tube was a matter of removing two bolts and thats it.

RPMulli

By the way... Is there a way to bench test the AOS? Mine looked in good shape. No leaks or torn boot.

9 lives

Just how long should one plan on for doing a job like this ? A day...a weekend ? Mine looks to be pooched too and if the job is a 5 out 10...then I might give it a go if it could be done in a day (2 tops).

RPMulli

I started 4 hours ago and I'm done (minus the wire harness replacement).....

redridge

what symptoms did you have that prompted to R&R the AOS?

Only way to tell really is to tear the AOS apart, if the diaphragm inside crumbles in you hand, its done.

RPMulli

Well, I've had some oil consumption and traces of oil behind the throttle body. Seepage around the intake manifolds (at the clamps) Also, I pulled the oil cap off while running and had excessive vacuum at the opening of the fill tube. My idle was also erratic sometimes and a experience a slight howling from the engine during certain RPM's after start up (sounded like an air leak or air blowing by a valve) I also needed a new Oil filler tube so I figured it was time...

Plus its a good thing I pulled of the intake manifold otherwise I would not of found that burn wire from the alternator.

For the record.. I simply removed the air intake, throttle body, air pump, alternator and the driver's side intake manifold to access the AOS. I did not lower the engine or remove the coolant reservoir. The hardest part was attaching the rubber boot to the block from the AOS with the clamp.

RPMulli

Oh yea I forgot to ask. Does anyone know if they have alternator rebuild kits out there?