Steering: Overview Porsche Boxster 986 рестайлинг

STEERING TIGHTENING TORQUE SPECIFICATIONS

REMOVAL OVERVIEW OF COMPONENTS

1. Removing rear wall lining and rear wall cover
2. Loosening belt pulley of the hydraulic pump
3. Relieving and removing drive belt
4. Removing hinge lever retainer on convertible top compartment lid
5. Setting up and securing convertible top compartment lid
6. Removing throttle body with intake distributor
7. Removing supply tank of the power steering system
8. Separating steering pressure line and steering return line on the underbody
9. Separating steering return line from supply tank (without tools)
10. Separating steering return line from supply tank (with tool)
11. Detaching hydraulic pump and steering supply line in the engine compartment

HYDRAULIC PUMP REMOVING PROCEDURE INSTRUCTIONS

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HYDRAULIC PUMP INSTALLING INSTRUCTIONS

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1. Steering column switch with the associated covers
2. Instrument cluster (instrument mount)
3. Steering column cover

Note. The steering wheel must be removed before components 1 - 3 can be removed. Refer to REMOVING AND INSTALLING STEERING WHEEL (AIRBAG) .

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1. Remove ignition key. Disconnect the battery ground cable and cover terminal or battery.
2. Remove steering wheel. Refer to «REMOVING AND INSTALLING STEERING WHEEL (AIRBAG)»(ref-199516-S30652381882005101900000). Observe the safety regulations for handling airbag units.
3. Undo and remove the trim elements.
4. Remove steering column switch. To do this, undo the central screw on the clamp of the steering column switch. Disconnect electrical plug connection and remove steering column switch with airbag contact unit.
5. Remove instrument cluster (instrument mount). To do this: Switch on the hazard warning light switch (button comes out). There are small openings on the sides of the button which now project over the instrument cowl. Insert two small screwdrivers into the openings and use them to pull off the button (A) toward the front. The hazard warning light switch (B) is held in the instrument bridge by two locking hooks. Press the right locking hook toward the switch, grip the button holder with a pair of pliers and pull out the switch toward the front. Pull off plug on the left side and undo the 5.0 x 22 Torx screws. Lift the instrument cluster at the left and right and unclip; disconnect electrical plug connections. If the vehicle is equipped with a "handsfree telephone", disconnect the microphone plug connection instead of the dummy plug.
6. Pull cover (collar) off the steering lock.
7. Remove steering column cover (undo Torx screws, unclip the cover and lift it off).
8. Detach support of steering lock on the assembly (arrow). (Scheme 8) The support is fastened with a screw. The side nozzle must be removed to allow access to this screw. This procedure is almost identical to the procedure «REMOVING AND INSTALLING MAIN LIGHT SWITCH»(ref-199826-S00983113522005102000000). The difference here is that the electrical plug connection of the main light switch does not need to be disconnected.
9. Undo steering lock fastening screw A. Unlock steering lock on the steering column (press spring-loaded pin B with a scriber) and simultaneously pull the steering lock out of the steering column.
10. On Tiptronic vehicles, remove (disengage) the keylock cable from the steering lock housing. First turn ignition key to position "1" (ignition on).
11. Pull plug off ignition switch. Carefully unlock and disconnect the plug connection on the lock barrel (at the induction coil for the immobilizer).
12. Unlock the electrical plug connection on the signal converter from above and disconnect. Unclip the electrical wire on the steering lock housing.
13. Remove steering lock from the vehicle.

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1. Fit the steering lock in the vehicle with the locking pin in unlocked position (ignition steering lock position 1) NOTE: If necessary, first modify the lock barrel (use previous lock barrel) or modify the key head (handheld transmitter). This makes it unnecessary to teach the transponder (refer to «INSTALLATION»(ref-199516-S03547331732005101900000) ).
2. Align steering lock housing; the peg of the steering lock must engage easily. Tighten fastening screws.
3. On Tiptronic vehicles, join the keylock cable with the steering lock (in steering lock position 1). To do this, line up the pusher on the keylock cable with the steering lock and insert (press in) in this position until the connection nipple engages on the steering lock housing. (Selector lever not in position "P".) Then select position "P" and subsequently turn steering lock to position "0". (Scheme 12) NOTE: If the steering lock cannot be turned to position "0", this may be due to the following: Pusher of keylock cable not correctly fitted on the steering lock Keylock cable not correctly fitted on the selector console Defective parts (replace if necessary). The keylock cable is not adjustable. However, the following procedure (mounting instructions) must be followed when mounting on the selector console. Instructions for mounting keylock cable on the selector lever Turn ignition key to position "1" (ignition on) and move selector lever to position "D". (Scheme 13) Engage nipple (1) of the cable in the keylock lever (2) of the selector console. (Scheme 13) Insert housing adjustment device (3) in the selector console housing until the clip (4) engages. (Scheme 13) Press cable sleeve (5) toward the selector console (6). (Scheme 13) Release cable and press locking button (7) until it engages. (Scheme 13) Check keylock function: Insert ignition key and turn to position 1 (ignition on). Move selector lever from "P" to "D". Turn ignition key counter-clockwise. It must not be possible to reach the pull-out position. Then release key again and move selector lever to position "P". In this position, it must be possible to remove the ignition key and the selector lever button must be locked. (Scheme 13)
4. Push plugs onto induction coil, lock barrel, ignition starting switch and onto the signal converter.
5. Steering lock function (perform locking pin function and keylock function tests).
6. Insert steering column cover from below, position and fasten (with Torx screws).
7. Install steering column switch and airbag contact unit with the associated covers. Position the steering column switch before tightening the fastening screw. To do this, measure with a depth gauge between the end of the steering shaft and the sheetmetal cover of the steering column switch (Scheme 16) Adjusting dimension 55 +/- 0.5 mm The adjusting dimension 55 +/- 0.5 mm can also be adjusted or measured with the airbag contact unit fitted.
8. Install the instrument cluster. Connect the electrical plug connection on the instrument cluster. Push in the instrument cluster at the left and right and clip into place; fasten it with the Torx screws 5.0 x 22. Press in the hazard warning light switch and fit the plug on the left side. In the version with "telephone with handsfree unit", plug in the microphone plug instead and engage the microphone in position.
9. Install side nozzle and main light switch. Refer to «REMOVING AND INSTALLING MAIN LIGHT SWITCH»(ref-199826-S00983113522005102000000).
10. Install steering wheel and airbag unit, Refer to «REMOVING AND INSTALLING STEERING WHEEL (AIRBAG)»(ref-199516-S30652381882005101900000). Observe the safety regulations for handling airbag units.
11. Connect battery ground cable. Perform function test.
12. If a new transponder (new lock barrel with new key) is used, the new key must be taught. See «WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY»(ref-199821-S29795769282005102000000).

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

The transponder does not have to be taught if

1. The previous key head A (handheld transmitter) is fitted on the new key C. (Disassembling and assembling handheld transmitter.)
2. A new lock barrel with defined locking is installed (the entire previous key can thus be used).
3. The previous lock barrel with key is used. Removing and installing lock barrel. Refer to «REMOVING AND INSTALLING LOCK BARREL»(ref-199516-S11956262052005101900000) .

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There are 2 steering column variants - V1 and V2 - installed in the Boxster. - V1 - for vehicles without PSM and - V2 - for vehicles with PSM. (Scheme 19)

For the - V2 - variant, (vehicles with PSM), the lower steering shaft can be separated from the upper steering shaft, as there is an (exchangable) steering angle sensor - C - located there. (Scheme 19)

For the - V1 - variant, (vehicles without PSM), the lower steering shaft is permanently connected with the upper steering shaft up to the 1999 model- arrow -. For the - V1 - variant as of the 2000 model, the steering shafts in this area can also be separated/unscrewed (like vehicles with PSM). This version is not depicted. (Scheme 19)

Note. The -V2- variant (for vehicles with PSM) is supplied as a spare part ready for installation (complete with steering angle sensor and lower steering shaft)! The -V1- variant is also supplied as a spare part ready for installation (complete with lower steering shaft)!

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STEERING COLUMN REMOVING INSTRUCTIONS (1 OF 3)

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STEERING COLUMN REMOVING PROCEDURE INSTRUCTIONS (2 OF 3)

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STEERING COLUMN REMOVING PROCEDURE INSTRUCTIONS (3 OF 3)

1. Before installing the steering column, give all parts a close visual check. When installing the steering column, make sure all components function perfectly!
2. If the specified tightening torque is not observed or exceeded (tightened too tightly) when tightening the lock nut on the pedal bearing axle, the brake pedal could be difficult to move and could stick.
3. Observe the installation requirements and safety regulations for airbag systems!
4. After installing the steering column on vehicles with PSM, calibrate the steering angle sensor!

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STEERING COLUMN INSTALLING PROCEDURE INSTRUCTIONS (1 OF 3)

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STEERING COLUMN INSTALLING INSTRUCTIONS (2 OF 3)

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STEERING COLUMN INSTALLING PROCEDURE INSTRUCTIONS (3 OF 3)

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1. Connect battery ground cable.
2. Perform the work which is necessary due to disconnecting the battery. Refer to «WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY»(ref-199821-S29795769282005102000000) . Work instruction after disconnecting the battery.
3. Check the operation of all electrical loads and control lamps.
4. Check all built-in systems using the Porsche System Tester 2 to make sure they are fault free. Rectify any faults present and delete the fault memory of the respective system.
5. For vehicles with PSM, and using the Porsche System Tester 2, calibrate the steering angle sensor Refer to «CALBRATING (ADJUSTING) THE STEERING ANGLE SEN»(ref-199513-S07707133632005101900000) . Calibrating steering angle sensor.
6. Then perform a short test drive and perform at least one ABS control operation, taking the road conditions into consideration. The fault memories of all systems built in the vehicle should be read out again after the test drive. There must not be any stored faults.

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