Steering: Other Porsche Boxster 986 рестайлинг

GENERAL

Damage to power-assisted steering results from lack of oil in the hydraulic system. Because of the high oil pressure in the hydraulic circuit, even small leaks can cause loss of fluid and damage the servo pump.

Grinding noises when the steering is on lock or the formation of foam in the reservoir indicates lack of oil and/or the sucking in of air. Before filling the reservoir, any existing leaks must be eliminated on the suction side. Alternatively, the defective part on the pressure side should be replaced.

Only Pentosin CHF 11 S may be filled into the reservoir. Pentosin CHF 11 S can be ordered with the following part number: Quantity supplied 1 liter = 000.043.203.33.

SERVO-PUMP DRIVE BELT

The drive-belt pretension cannot be adjusted.

With engine idling, turn steering wheel as far as the stop and hold still. The maximum possible line pressure results in this way.

In this position, check all pipe connections for leaks and retighten if necessary.

Perform the check for a maximum of ten seconds. A longer check should always be interrupted by a brief pause after approximately ten seconds.

The reservoir is located in the engine compartment. There are two marks on the dipstick located on the reservoir cap. One side bears the mark "Cold" for a cold engine (approximately 20°C) and the other "Hot" for a hot engine (approximately 80°C).

Scheme 25

Check the fluid level (Pentosin CHF 11 S) with the engine stationary and cold (approximately 20°C).

1. Open engine compartment lid. Open reservoir cap.
2. Wipe dipstick. Close reservoir cap and open it again. The fluid level should lie in the hatched area beneath the "Cold" mark (mark = maximum level at 20°C). Top up with Pentosin if necessary. The upper "Hot" mark is intended for a fluid temperature of 80°C.

In no case add too much Pentosin. The respective marks are for the maximum fluid level at the "COLD" or "HOT" temperature.

Note. If assembly work was performed previously, check the fluid level with the engine idling and without operating the steering.

1. To fill the whole system after the installation of new steering components or lines or after a substantial loss of hydraulic fluid, briefly start the engine a few times and, when it fires, switch it off again immediately. This procedure causes the fluid level in the reservoir to fall rapidly, so constantly add Pentosin CHF 11 S. The reservoir must not be sucked dry.
2. If the fluid level in the reservoir does not fall any further when the engine is briefly turned over, start the engine and let it to run at idling speed.
3. Rapidly turn the steering wheel from stop to stop several times so that the air can escape from the cylinders. At the end positions of the piston, do not pull the steering wheel with more force than is necessary in order to turn the steering (to prevent unnecessary build-up of pressure).
4. Observe fluid level during this procedure. If it continues to fall, add fluid until the level in the reservoir remains constant and no more air bubbles rise in the reservoir when the steering wheel is turned. NOTE: If the fluid levels with the engine stationary and running differ by more than 10 mm, in the hydraulic fluid still contains too much air.
5. Correct the fluid level with the engine at idling speed - without operating the steering.

Scheme 26

Scheme 27

1. Disconnect battery and cover terminal or battery.
2. Remove driver's airbag unit. For this purpose, loosen the two fastening screws with a screwdriver for internal Torx T 30. Disconnect plug connection at airbag unit and at steering wheel (for horn). NOTE: Replace fastening screws whenever they have been loosened. The airbag unit must always be set down so that the cushioned side faces upward. If removed for a lengthy period, the airbag unit must be stored under lock and key. Observe safety regulations.
3. Loosen hexagon nut and remove together with spring washer.
4. Turn wheels to straight-ahead position. Then mark the position of the steering wheel with respect to the steering shaft (for refitting). Remove steering wheel (in straight-ahead position).

Note. To prevent unintended rotation of the contact unit (KE) when the steering wheel has been removed, the contact unit locks itself when the steering wheel is pulled back. Likewise, the contact unit unlocks automatically when the steering wheel is refitted.

FUNDAMENTALS

Various kinds of damage can be caused to the steering gear in the event of accidents or driving conditions resembling accidents. In cases where the steering gear shows no external damage it can be difficult and costly to detect damage. Nevertheless, this damage represents an unacceptable risk for the vehicle, since it could lead to failure of the steering system.

Since a comprehensive check on all individual parts of the steering gear would not make sense, as a rule, and is not possible using the ordinary means of a workshop, instead the condition of other components that are easier to check should be considered.

The following guidelines (section B) serve for a decision on whether the steering gear of a vehicle involved in an accident should be replaced or may continue to be used.

The steering gear can remain in the vehicle if all the following conditions are met

No visible damage to such front-axle parts as wheel rims, spring struts, wheel carriers, control arms, steering arms, track rods, front-axle cross member, front-axle side members, the steering shaft or to the points on the body where wheel suspension parts are bolted on.

No impermissible rise in torque and no jamming or catching when the steering gear is turned from stop to stop. When the steering is turned, the front wheels must be free (front axle raised) and, in addition, the engine must be switched off (pump of power steering undriven).

The permissible tolerances for wheel alignment must not be exceeded.

The steering gear must be repaired or replaced if one of the following points applies

Visible or detectable damage to the steering gear.

Fire damage (for example, steering bellows burnt).

Permanent deformation or breakage of

Steering-gear mounts

Track rods

Steering arms

Spring struts

Wheel carriers

Control arms

Front-axle side members

Front-axle cross members

If the listed criteria are insufficient for a decision, we recommend that the steering gear be repaired or replaced.

EXCEPTIONAL REGULATION/ORDER HANDLING

If a workshop's intended exchange of steering gear is refused by a customer or insurer for reasons of costs, an expert or if this is impossible abroad, the importer should be called in at the cost of the refusing party. If the decision contradicts the guideline, we recommend that a memorandum be drawn up on the point and that it be countersigned by the expert.

Externally undamaged power-assisted steering gear that has to be exchanged will be obtainable as an exchange part at a later time (as far as is known in March 1996).

Scheme 28

Scheme 29

Scheme 30

1. Remove underside panel.
2. Loosen universal joint (steering shaft) at steering gear. For this purpose, take out the clamping screw and slide the joint upwards. NOTE: First fix the steering wheel with the wheels in straight-ahead position or removes the steering wheel with the wheels in straight-ahead position. If this is not done, the airbag contact unit will have to be put in center position after installation of the steering gear. Refer to «INSTALLATION»(ref-199516-S34318832402005101900000).
3. Press out track-rod ball joint from steering arm. Use special tool 9560 (ball-joint extractor). When loosening the locknut, hold it with special tool 9546 (Torx screwdriver).
4. Repeat procedure on the other side.
5. Loosen feed and return pipe at steering gear. For this purpose, loosen the hexagon socket head bolt (arrow) and remove the retainer plate. Seal pipes or use collection containers. If necessary, cover pipes to prevent contamination. (Scheme 30)
6. Loosen the two steering-gear fastening screws (on the underside of the cross member).
7. Extend steering gear to the left (to the right for right-hand drive vehicles).
8. If necessary, loosen and remove right and left track rod at steering gear (arrow). (Scheme 30)

Note. Ensure that no damage (scoring) is caused to the steering rack. To loosen and tighten the track rods, secure the steering gear on a suitable plate.

Scheme 31

NOTES FOR SLIDING PIECE AND AIRBAG CONTACT UNIT

1. If sliding piece No. 1 was pulled off steering shaft No. 4, notch No. 2 must point to the tooth gap (No. 3) on assembly.
2. If the steering wheel was not fixed before the steering gear was removed, the position of the contact unit (spiral spring) may no longer be correct. In this event, remove steering wheel and move contact unit to center position.

If this is not done, the spiral spring may be damaged.

Center position: First move contact unit against the end stop. Turn contact unit two revolutions back from the end stop and then continue turning as far as the center position mark. The exact center position is indicated by the two arrows (No. 1). (Scheme 33) Turn front wheels to straight-ahead position before fitting the steering wheel (steering shaft mounted on steering gear).

Scheme 32

1. Center position mark (arrows) (Scheme 33)
2. Drivers that engage in the steering wheel
3. Locking (securing against turning), which becomes effective after removal of the steering wheel

Scheme 33

PLUG-IN COUPLING TOOL EXPLANATION

Note. Pressure and return lines have different dimensions. Pressure line = nominal diameter 6, return line = nominal diameter 10. The plug-in coupling is opened by unscrewing. It is joined by plugging together. Join the plug-in connection only in a straight line. Never use excess force. After separating the plug and socket piece, carefully protect them against dirt and scratches with caps. Pull slightly to make sure the connection is locked properly. Use special tool 9623 for this purpose.

STEERING HYDRAULIC SYSTEM PROCEDURE

PLUG-IN COUPLINGS FOR PIPELINES

Different plug-in couplings are used for various applications. (Scheme 35)

Scheme 34

Note. All listed plug-in couplings are used at various installation locations and on different components, e.g. on the carbon canister and on the oil dipstick guide tube.

IMPORTANT

1. Plug-in couplings are components that permit simple, fast and precise connection of pipelines.
2. These precision components must be handled carefully during repairs. Excess force during assembly work, damage to the sealing surface and soiling can cause leakage.
3. Perform preparations carefully when handling plug-in couplings - e.g. cleaning and fitting the plugs - as repairs are possible only by replacing the affected line in most cases.
4. After separating the plug and socket piece, carefully protect them against dirt and scratches with caps.
5. Join the plug-in connection only in a straight line. Never use excess force. Pull slightly to make sure the connection is locked properly.

FUEL LINES

Operate unlocking button(s) (press) and simultaneously separate the pipelines by pulling them apart (Scheme 36)

Scheme 35

Join the connection by plugging together in a straight line. The plug (the plug-in part) must audibly engage in the plug-in coupling. Then pull the connection slightly to check whether it was locked properly.

VACUUM LINE

In order to undo the vacuum line, press the black unlocking ring (arrow) and simultaneously pull the lines apart. (Scheme 37)

Join the connection by plugging together in a straight line. Then pull the connection slightly to check whether it was locked properly.

Scheme 36

The plug-in couplings are opened by unscrewing. They are joined by plugging together. See OPENING AND JOINING PLUG-IN COUPLINGS .

Scheme 37

CLUTCH LINE

Note. The plug-in coupling is opened by unscrewing.

Pipelines that were fitted once before are joined by screwing together (as opposed to new lines and steering lines, which are plugged together). This is necessary because holder C is located very deep in the threaded part of the plug-in coupling and cannot be removed with conventional workshop equipment.

CLUTCH LINE PROCEDURE INSTRUCTIONS

To release the return line, press the red unlocking ring (arrows) and simultaneously pull the line out of the hydraulic pump. (Scheme 39)

To unlock the return line, it is practical to use a commercially available removal tool - for example, Snap-on, order No. A177A. (Scheme 46).

Join by plugging together in a straight line. Then pull slightly to ensure that the connection is properly locked.

Scheme 38

Scheme 39

Scheme 40

1. Disconnect battery ground cable.
2. Turn ignition key to position 0 and remove.
3. Remove air duct (A). The air duct is plugged in. (Scheme 41)
4. Pull connecting plug off ignition switch.
5. Remove screw locking paint in the threaded bores of the two fastening screws (short arrows). Slightly loosen both fastening screws (short arrows) using special tool 9631 and pull the ignition switch out of the housing (direction arrow). (Scheme 42)

Scheme 41

Scheme 42

1. Move ignition switch to position 0 (same position as lock barrel).
2. Insert ignition switch into the housing. Tighten fastening screws using special tool 9263 and subsequently secure with screw locking paint.
3. Push plug onto ignition switch and fit air duct.
4. Connect battery ground cable. Perform function test.

Scheme 43

1. Disconnect battery ground cable.
2. Pull cover (rosette) off the steering lock.
3. Insert ignition key to and turn to position 1 (ignition on). Insert a steel wire (C) with a diameter of approx. 1.3 mm (max 1.5 mm 0) into the bore next to the ignition key (arrow) as far as it will go. (Scheme 44) Pull the lock barrel with induction coil out of the steering lock housing. NOTE: Inserting the steel wire (C) unlocks the lock barrel in the steering lock housing.
4. Carefully unlock and separate the plug connection on the lock barrel (at the induction coil for the immobilizer).

Scheme 44

1. Ignition lock must be in position 1 (ignition on). (Scheme 45)
2. Press on the pawl of the lock barrel (locking pawl). Press the pawl, insert the ignition key and turn the key as far as it will go to (ignition on). In this position, insert the steel wire (C) that was used for removal. (Scheme 45)
3. Plug connector onto the ignition coil (B). Position the induction coil (B) and push the lock barrel all the way into the housing. Turn the ignition key correspondingly, if necessary, until the lock barrel has been pushed in fully. Pull out the steel wire (C) in this position so that lock engages. (Scheme 45)
4. Connect battery ground cable. Perform function test.
5. If a new transponder (new lock barrel with new key) is used, the new key must be taught. Refer to «WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY»(ref-199821-S29795769282005102000000).

Note. The transponder is located in the key. The new transponder is taught with the Porsche System Tester 2. A new transponder can be taught to the vehicle in the system "Alarm system", menu "Teaching functions"/submenu "Transponder key". Access to IPAS is necessary in order to teach the transponder.

Scheme 45

Scheme 46

HYDRAULIC PUMP REMOVING AND INSTALLING TOOL EXPLANATION

Scheme 47

Scheme 48