[Scott Collins]

OK - is this why I am losing coolant, because this thing is not connected?

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[DaveN]

I think the hose you broke is just vacuum to the AOS? The coolant runs through the <acronym title='mass air flow'>MAF</acronym> on 2 large hoses and there are O-rings inside to stop the coolant from getting into the intake manifold.

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[Lear35A]

Scott. No. No. No. Do not spend $400 for this little faux pax. I too broke mine off. I tried JBWeld, but it just doesn't stick to the material Porsche has used on this separator.

I bought a pack of inflating needles for a whole dollar (see picture). I cut off the smaller diameter part of the tip. I drilled out the hole in the top of the separator (5/16" is perfect for the threads on the inflating needle.) I put some JB weld around the thread area and pushed the needle into my nice 5/16" hole. I flushed out the separator well, and the repair is done.

Yes, you do have to remove the separator, but once this pieces is broken off you have to remove it whether you do the $400 new part repair, the $200 used part repair or the $1 Lear repair.

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[Langley968]

[quote name='Lear35A' timestamp='1328039042' post='121233']

I bought a pack of inflating needles for a whole dollar (see picture). I cut off the smaller diameter part of the tip. I drilled out the hole in the top of the separator (5/16" is perfect for the threads on the inflating needle.) I put some JB weld around the thread area and pushed the needle into my nice 5/16" hole. I flushed out the separator well, and the repair is done.[/quote]

That sounds just like the repair I did many years ago on my first car, a VW Rabbit. I had broken a plastic nipple to which a small hose was fastened at the top end of the rad. I was told I would need to replace the whole rad. I drilled out both pieces, slid a plastic sleeve in, fastened with plastic cement, and proceeded to add over 30K to the odometer... <img src="/forum/images/smilies/968/clap.gif" class="smilie" alt="" />

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[kwikt]

Funny... I used a Kehein carburetor pilot jet and just screwed it into the broken nipple hole. Less than a 5 minute repair and better than original.

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[Scott Collins]

I love these fixes, particularly the 5-minute variety. As soon as it happened, I started thinking of possible solutions that did not involve removal of the intake.



Lance: thanks for those pics and description of hour "$1 Lear repair."



kwikt: what is the part you are referring to and did you have to remove everything?





-Scott

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[kwikt]

Scott, it is a slow speed pilot jet from a motorcycle carb that was in my carb parts bin. I think it was off my KX250 when I motocross-ed. I was looking for a vacuum nipple but everything I looked at had to be glued in. So the pilot jet is threaded and has a collar so it will bottom out and seal. Oh and I did have to drill the pilot jet so it had larger hole for the vacuum. If you ever notice these holes are the size of a small needle or smaller. I'll see if I have another and shoot you a pic of it. Oh..... and nothing to remove for this fix but the fuel injection cover plate.



Kevin

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[kwikt]

    Scott, I used the one on the left but you may also use a mig welding tip.

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