rockhouse66

Answers in red above.

dan_189

Awesome thanks!

I'll keep everyone posted on my progress.

I wonder if anyone has used the 997 part and routed the hose ontop of the engine rather than through it (so to speak)??

dan_189

Here are the images of how the 3.6 997 engine routs that hose, which goes up behind and back to 4-6 crankcase side:

dan_189

Any thoughts on attempting to use the 997 hose and clips?

I'm thinking hopefully it might be easier to route and it would stay cooler as its routed on top rather than through the engine? Also there might be less effort routing it as it can be done from the top.

From checking all the part numbers it looks like the AOS end would be fine as the 997.1 AOS has a 996 part number. Also the 997.1 3.6L crankcase also has a 996 part number too, so from both sides of the hose they should theoretically fit.

dan_189

Okay so im going to answer this one myself, unfortunately the 997 hose is cost prohibitive at $189aud for the 997 vs $68aud for the 996.

​​​​​​So that answers that question...

dan_189

Any torque specs available for the end of the hose with the two bolts?

I couldnt find any information on the AOS or the hoses in the factory manual

dan_189

Okay! Got this done today, steps I followed were:

1. Remove air box
2. Remove throttle body
3. Remove 1st T plenum
4. Un-do 2 10mm bolts on the bank 4-6 side
5. Reach around the back of the engine (AOS side) unplug hose, its tricky but it comes off
6. Cut cable tie holding the cable in place (under the right side of the 2nd plenum)
7. Pull out old hose
8. Route new hose start with bank 4-6 side first
9. Route AOS hose side through 2nd intake runners (back between 4-5) then across through 2-3
10. Route hose down past coolant tank
11. Reach in and plug AOS side in
12. Cable tie hose to 2nd plenum (factory is 6mm x 500mm cable tie)
13. Re assemble - T plenum, throttle, airbox
14. Test drive

Only thing that would have been useful to know was that there is a 6mm x 500mm cable tie holding it in place. Hopefully someone else finds this useful in the future!

Only one thing forgot to connect my MAF for a few mins so turned off plugged it in, does this affect the maps? Also do I need to perform the throttle rest procedure (car is 04' drive by wire/e-gas).

Thanks!!

rockhouse66

I didn't mention the zip tie because I wasn't 100% sure that this was a factory installed thing or something someone added to my car. I also struggled to route the hose in such a way as to be able to replace that zip tie, so I must have gone underneath something that I should have gone over the top of. I did not replace it, but the hose just sort of stays there supported by the other hoses around it.

I don't think unplugging the MAF sensor messes anything up that needs resetting.

Good job getting to that AOS connection w/o removing the coolant tank. I don't know if I could have reached through there with any dexterity left to actually manipulate the hose connector.

dan_189

Thanks, yeah it wasn't an easy job by any means. Reaching behind and un hooking the hose was the hardest part.

I tried to get the new hose back through the existing cable tie but it wouldn't go through. Ended up cutting it using some smaller ones. I​ve ordered some larger ones so ill eventually replace it.

Hose is still sitting close to the coolant sensor though :/

dan_189

As it would seem 6mm is not a standard zip tie size! Whyyyy?!

Anyone have a part number for the zip tie or is that being too pedantic?

dan_189

Just to confirm this was indeed the hose, filled the old hose with water and watched it very slowly drip out from a section.

Ahsai

Nice. Glad you got it sorted.

dan_189

Thanks for everyone's help

dan_189

Ahsai, quick question for you, do you know what this cable tie/zip tie holds onto:



The second zip tie on that intake runner/resonator is the one that holds the vent line in place. Hopefully this helps someone in the future!

Ahsai

Interesting, I don't have that zip tie on either of my MkII engines ('02 and '03). The AOS hose is a hard line in the middle section that rests on top of the engine case. It's supported by a plastic bracket that's bolted to the engine case top.