UAOS Benefits & FAQ

ULTIMATE AOS - USPTO Patent # 11,326,489

DESIGN THEORY

The Ultimate Air Oil Separator (UAOS) works by taking a systematic approach to the problems associated with the design of the Porshe Air Oil Separator (PAOS) and corrects them through engineering improvements.

 

The UAOS application has been expanded to fit not only the 996, but the 997.1 and 986 and 987.1 engines.

Porsche AOS Design Problems and UAOS Design Solutions

1. Diaphragm Failure

Problem - The PAOS is well known for failure of the flow control diaphragm which can lead to a number of problems including: (1) rough idling and fuel trim faults, (2) increased oil consumption, (3) excessive smoking at start-up and during spirited street and track driving, (4) catalytic converter and O2 sensor failure, as well as (5) catastrophic hydrolock.

Solution – As a design improvement, the UAOS mitigates the risk of diaphragm failure by doubling the thickness of the diaphragm from 0.020 inches in the PAOS to 0.040 inches in the UAOS.

2. Catastrophic Hydrolock

Problem - When the PAOS diaphragm fails, it’s unable to control the flow of air from within the crankcase to the intake. This results in an increased vacuum within the crankcase which then draws oil from the sump into the intake manifold of which the oil then passes the intake valves and accumulates in the cylinder. Hydrolock typically occurs when the amount of oil accumulates above 60cc creating an intense pressure in the cylinders that results in catastrophic engine failure from cracked cylinders and bent rods.

Solution - As a design improvement, the UAOS mitigates the risk of hydrolock by incorporating a specially designed Accumulator between the Vortex and the Flow Control Diaphragm regulator that works as a secondary oil separator to ensure no oil makes it to the intake manifold, plus copper mesh filters for extra efficiency. In addition, the UAOS also has a microprocessor controlled infra-red warning sensor in the Accumulator which is set to activate an in-dash warning if oil accumulation reaches a dangerous level. This indicates a fault in the Crankcase Vent System, allowing for operator intervention before the threat of hydrolock can occur. 

3. Oil Flow Limitations

Problem – 

· The M96/97 engines with the Porsche “Integrated Dry Sump” system has a very large oil pump that pumps a high volume of oil through the xxxx

· 40% of this oil ends up in the top end of the engine in the heads, IMS and chain area. 

· There are two return oil pumps (scavenge oil pumps), one in each head on Bank 1 and Bank 2. 

· When driving aggressively in high-G Force turns, all the oil in the top end goes to one side in one head, so only one return oil pump can return oil to the sump. 

· With the UAOS System, overfilling the oil level will provide more oil to be returned to the sump with the scavenge pumps. This cannot be done with the Factory AOS. 

· The UAOS system also has dual drains to drain back the oil faster to the sump so that it will not be overwhelmed by the overfilling of the oil level.

Solution - With the UAOS Street & Track, the Extreme Track Duty Drain Back can drain oil twice as fast as the Motorsport AOS back to the sump. The Motorsport AOS still uses the Factory drain to get the oil back down to the sump, The UAOS also uses the factory drain but includes a Second Drain to make the drain back twice as fast.

4. Oil Capacity Limitations

Problem – 

· Overfilling the oil level has shown through comprehensive data to be the best thing you can do to help stabilize oil pressure. But this cannot be done on the Factory AOS, it will overwhelm it….

· The Porsche Motorsports AOS has a larger body that holds more oil, but this lowers the oil level in the sump and contributes to oil pressure instability. 

· With the emission legal UAOS Street only version the oil level can be run at the “full mark” in contrast to run to the “half way mark” which was recommended by Porsche in (bulletin #).

· In addition, the emission legal UAOS Street and Track version can be run at .5 to .75qts “overfull” to help stabilize oil pressure when on the Track.

· Further, the non-emission legal UAOS Track Only version can be run at .75 to 1.25 qts “overfull” to further help stabilize oil pressure for Track Events.

· Where the Factory AOS and Porsche Motorsport AOS only use 1 element ( a Vortex) to control/keep out oil from the engine, the Emission legal UAOS Street version uses 4 elements to keep oil out of the engine making it many times more efficient.

· The Emission Legal Street and Track version adds another element making it 5 elements to keep the oil out of the engine, 

· The non-emission legal UAOS Track Only version adds yet another element making the total of 6 elements. 

· So you can see why the UAOS system is so efficient, it has had a lot of R & D gone into the development of it in just a few years.

Solution - Increases Oil Capacity - The UAOS is so efficient ,the engine can be ran "over-filled" with oil to help mitigate oil pressure instability on the Track. ( with Drain Back option or Track Only non-emission legal vesion).

5. Intermix

Problem - PAOS failure is also known to cause intermix issues on the 996/997.1 engines due to its design of running both oil and coolant through the PAOS. Plastic housing cracks appear internally due to the heat cycling resulting in coolant flowing into the oil thru the chamber at the back of the diaphragm. 

Solution – As a design improvement, the UAOS eliminates the need to run coolant thru the UAOS by relocating the diaphragm to a much warmer spot near the throttle. This design not only eliminates the risk of intermix, but it also eliminates the unnecessary line, connections and clamps that could cause additional external leaks. 

6. Replacement Costs

Problem - When the factory PAOS fails, the procedure is to drop the engine and replace the PAOS. Not only is the cost of the new PAOS expensive but the service procedure to replace it is extremely expensive in time and high labor costs. 

Solution - The UAOS eliminates the need to continually replace the PAOS, which is a costly and time-consuming job for most shops. Instead, the UAOS is designed to only replace the inexpensive flow control diaphragm regulator which is moved to an easy access location near the throttle body and can be replaced in a matter of minutes versus hours for the PAOS. The "Vortex" part of the air-oil-separator is left in its factory designed location and drains the separated oil back to the oil sump with the UAOS Street & Track, and into the Accumulator for draining with the UAOS Street. This makes any service easy and labor effective, saving substantial money in replacement parts and labor hours year over year.Looking for high-quality auto parts for your vehicle? Look no further than Ultimate AOS. We offer a wide selection of parts and accessories for all makes and models of cars, trucks, and SUVs. Our team of experts is always available to help you find the right parts for your needs, and we offer fast and affordable shipping to anywhere in the country.