Steering: Other Porsche Boxster 987

Preliminary work

1. Ignition key in position 1. Then ignition key in position 0 = (switch ignition off but do not remove key so that electronic steering wheel locking does not lock). Then disconnect battery.

2. Remove airbag unit for driver. Refer to 69 58 19 Removing and installing driver's airbag unit - as of MY 2005 (All Models) .

3. Turn steering wheel to a straight-ahead position and remove it > 481019 Removing and installing steering wheel .

Note. For better accessibility, move the height adjustment (steering wheel) of the steering column to the appropriate position and close the locking lever.

4. Remove main headlight switch. To do this, press in rotary knob on the light switch (not to the stop) and turn the switch clockwise. Pull out the light switch in this position. Release and remove connector.

Scheme 3

5. Remove trim panel (lower part of dashboard) --> 70 19 19 REMOVING AND INSTALLING TRIM UNDER DASHBOARD - AS OF MY 2005 (ALL MODELS). Unscrew the fastening screws -1- and swivel the cover under the dashboard on the driver's side -2- downwards -Arrow A-. (Scheme 3)

Scheme 4

6. Release plug connections -1, 2, 3- and remove -Arrows A-. (Scheme 4)

7. Remove clutch pedal on vehicles with manual transmission Refer to 30 05 19 Removing and installing the clutch pedal - as of MY 2005 (All Models) .

> Observe safety regulations for handling airbag modules.

Note. The height adjustment (steering wheel) of the steering column must be in the lower stop and the locking lever closed. The electronic locking unit (ELV) must be open (ignition key plugged in, then disconnect battery).

As a spare part, the steering column -A- is delivered complete with steering shaft. (Scheme 5)

Scheme 5

A - Steering column with steering shaft

1. Remove trim panel of steering column switch and remove steering column switch --> 94 50 19 REMOVING AND INSTALLING STEERING-COLUMN SWITCH - AS OF MY 2005 (ALL MODELS) .

Scheme 6

2. Loosen strut on retaining frame (arrow shows mount on steering column). --> Strut on steering column. (Scheme 6)

3. Remove KESSY/PAS control unit.

Scheme 7

4. Loosen lower steering column mount. To do this, loosen the lock nut -1- approx. 3 turns. Then unscrew the pedal bearing axle on the hexagon -2- approx. 2 turns (anti-clockwise). (Scheme 7)

5. Loosen upper steering column mount (loosen lock nut -3- /remove hexagon-head bolt -4- ) and extend the steering column. (Scheme 8), (Scheme 7).

6. Remove front underbody panel.

Scheme 8

7. Loosen fastening screw -Arrow- and pull off steering shaft (universal joint) on the steering gear. (Scheme 8)

> Observe safety regulations for handling airbag modules.

Note. Observe the tightening sequence on the mounting bracket. Once the battery is disconnected, perform the work required for full restoration of normal driving. Refer to 27 06 IN External power connection, jump lead starting - as of MY 2005 (All Models) . Calibrate steering-angle sensor. Refer to 45 60 Initializing and calibrating steering-angle sensor - as of MY 2005 (All Models) . If the steering column is replaced (new steering column), the electric steering column locking mechanism (ELV) must be taught with the PIWIS Tester in the PAS system, menu Learning functions >> Teach ELV << . You can get the necessary Teach Enable Code (TEC code) from IPAS or from your importer using the vehicle identification number. Always replace the fastening screw for the universal joint of the steering column. Replace locking screws and nuts. Replace the clamping washer (strut mount to steering column). Carry out a visual inspection of all parts. Observe correct tightening torques > 4800TW Tightening torques for steering .

Individual components cannot be disassembled and/or replaced.

1. Before installing the steering column, mount the strut -Arrow- without play on the steering column. see scheme 9

2. Put steering gear in center position. Make sure that the clip for steering gear pinion is present (steering shaft assembly aid). Mount the steering shaft (universal joint) to the steering gear in the correct position using new hexagon-head bolt -Arrow-. see scheme 10

Scheme 9

3. Insert the steering column and pay attention to the block teeth of the steering shaft (the steering shaft can only paired be in one position! 2. worker required). Tightening sequence for mounting

1. - Pedal bearing axle on a/f 10 mm hexagon -2- (tightening torque 8 + 2 Nm (6 + 1.5 ftlb.)). (Scheme 9)

2. - Lock nut right -1a- (tightening torque 10 Nm (7.5 ftlb.)). Then lock nut for steering column -1b- (tightening torque 46 Nm (34 ftlb.)). (Scheme 9)

3. - Lock nut of upper mount -3- (tightening torque 46 Nm (34 ftlb.)) (Scheme 9)

4. Install front underbody panel.

5. Install KESSY/PAS control unit.

6. Put steering column in the lowermost adjustment position and close the locking lever again. In this position, fasten the strut to the structure (this allows the adjustment range to move smoothly in all positions).

7. Install the steering-column switch and the trim panel from the steering-column switch --> 94 50 19 REMOVING AND INSTALLING STEERING-COLUMN SWITCH - AS OF MY 2005 (ALL MODELS) .

Subsequent work

1. Install clutch pedal on vehicles with manual transmission Refer to 30 05 19 Removing and installing the clutch pedal - as of MY 2005 (All Models) .

Scheme 10

2. Mount linings under dashboard --> 70 19 19 REMOVING AND INSTALLING TRIM UNDER DASHBOARD - AS OF MY 2005 (ALL MODELS) .

3. Install main headlight switch. To do this, insert the connector until it is felt to engage. Push in the light switch to the stop and turn the rotary switch anti-clockwise.

4. Install steering wheel --> 48 10 19 Removing and installing steering wheel - as of MY 2005 (All Models) .

5. Install airbag unit for driver --> 69 58 19 Removing and installing driver's airbag unit - as of MY 2005 (All Models) .

6. Connect the battery. Refer to 27 06 IN External power connection, jump lead starting - as of MY 2005 (All Models) .

Note. If the steering column is replaced (new steering column), the electric steering column locking mechanism (ELV) must be taught with the PIWIS Tester in the PAS system , menu Learning functions >> Teach ELV << . You can get the necessary Teach Enable Code (TEC code) from IPAS or from your importer using the vehicle identification number.

7. Read out all fault memories and delete them, if necessary.

8. Carry out suspension alignment.

9. After the suspension alignment, with the position of the wheels >> straight ahead << calibrate the steering-angle sensor on the measuring platform.

10. Carry out a test drive and check the operation (continuous easy steering movements, steering column adjustment, electronic steering column lock).

Tools

1. Raise the vehicle Refer to 40 Tightening torques for front axle - as of MY 2005 (All Models) .

2. Remove front wheels Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .

3. Remove front underbody panel Refer to 51 92 19 Removing and installing cover for front underbody - as of MY 2005 (All Models) .

General warning notes

> Multiple steering operations (maneuvering) with the engine switched off change the fluid level in the reservoir. In this case, the engine must be running immediately prior to the fluid level check.

> If coolant hoses come into contact with Pentosin, clean them thoroughly with water IMMEDIATELY.

> Replace visibly swollen coolant hoses.

Note. Before the feed and return lines are loosened, place a suitable container underneath to collect steering fluid. Wear protective goggles and gloves.

Removing

Note. Fix the steering wheel with the wheels in straight-ahead position or remove 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.

Scheme 11

1. Loosen universal joint (steering shaft) at steering gear -Arrow-. For this purpose, take out the clamping screw and slide the joint upwards. (Scheme 11)

2. Press tie-rod end out of steering arm. Use press-out tool P 9560 (ball-joint extractor). When loosening the lock nut, counter with a screwdriver P 9546 (Torx screwdriver).

3. Repeat procedure on the other side.

Scheme 12

4. Loosen feed and return lines at the steering gear. To do this, loosen the hexagon socket-head bolt -Arrow- and remove the retainer plate. Plug lines or use collecting container. Cover lines if necessary (danger of soiling). (Scheme 12)

5. Loosen the two steering-gear fastening screws (on the underside of the cross member).

Scheme 13

6. Loosen screws -1+2- on the two (front) diagonal braces. (Scheme 13)

Scheme 14

7. Lower vehicle to working height (lower platform lift) and support cross member with a hydraulic lift (use hard rubber base or wooden block: (Scheme 14)).

8. Loosen threaded connections -3+4- securing cross member to body (front) and threaded connections -5+6- securing cross member with diagonal arm to body (front) (screws -1+2- have already been removed). (Scheme 13)

9. Loosen threaded connections securing cross member to body (rear) -7+8- and screw out -9+10- by approx. 10 mm. (Scheme 13)

10. Lower front cross member slightly (approx. 50 to 60 mm).

11. Pull out steering gear to the left (to the right for right-hand drive vehicles).

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

Scheme 15

12. If necessary, loosen and remove right and left tie rods at steering gear.

Installing

Note. When topping up or filling in Pentosin, make sure that it does not come into contact with the coolant hoses. Observe the specifications in order to avoid overfilling, and thus overflowing. If coolant hoses come into contact with Pentosin, clean them thoroughly with water IMMEDIATELY. Replace visibly swollen coolant hoses. Tighten all threaded connections to the specified tightening torque.

Install in reverse order. It is essential to observe the following points while doing so

Replace steering-gear fastening screws, the fit bolt of the steering shaft and the steering-wheel fastening screw whenever they have been removed. Screw threads must be clean and free of grease.

Ensure that no damage (scoring) is caused to the steering rack.

Mount the tie rods on the steering gear. Then secure the respective bellows with new clamping rings --> Tie rod on steering gear. see scheme 19

Position red plastic clip on steering-gear pinion. The plastic clip ensures that the fastening screw between the universal joint and steering pinion sits into the groove on the steering pinion.

Push on universal joint (steering shaft) with the steering gear and steering wheel or airbag contact unit (spring) in center position. For ease of assembly, just insert steering-gear fastening screws.

Observe following notes for sliding piece and airbag contact unit!

Notes for sliding piece and airbag contact unit

Scheme 16

1. If sliding piece -1- was pulled off the steering shaft -4-, the notch -2- must point towards the tooth gap -3- during assembly. (Scheme 16)

2. If the steering wheel was not fixed before the steering gear was removed, the position of the contact unit (spring) may no longer be correct. In this case, remove steering wheel and move contact unit to center position because otherwise the spring will be damaged.

Contact unit in center position

Scheme 17

To position the airbag contact unit in center position, press the latch -D- and turn the rotor -A- carefully to the left as far as it will go. (Scheme 17)

Then (from the furthest left position) turn the rotor -A- carefully to the right, approx. 3.5 to 3.75 turns, until the band printed on one side is visible in the window. (Scheme 17)

3. Turn front wheels to straight-ahead position before fitting the steering wheel (steering shaft mounted on steering gear).

1. After fitting the pressure lines, fill steering hydraulics with Pentosin and bleed the steering system.

2. Fit front underbody panel Refer to 51 92 19 Removing and installing cover for front underbody - as of MY 2005 (All Models) .

3. Fit front wheels Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .

4. Adjust toe Refer to 44 95 03 Suspension alignment, complete - as of MY 2005 (All Models) . Calibrate steering-angle sensor if necessary.

Designation Type Number Explanation Disassembly tool, universal commercially available tool NR.21

Scheme 18

Scheme 19

1 - Throttle housing with distributor pipe

2 - Resonance tube

3 - Intake distributor cylinders 4-6

4 - Air-conditioning compressor

5 - Supply tank

6 - Sealing rings

7 - Pulley

8 - Screw

9 - Hydraulic pump

1. Remove left front seat. Refer to 72 01 19 Removing and installing front seat - as of MY 2005 (All LHD Models) . Refer to 72 01 19 Removing and installing front seat - as of MY 2005 (All RHD Models) .

2. Remove rear wall cover. Refer to 55 59 19 Removing and installing rear wall cover - as of MY 2005 (All Models) .

3. Remove engine compartment cover.

1 - Throttle housing with distributor pipe

2 - Resonance tube

3 - Intake distributor cylinders 4-6

4 - Air-conditioning compressor

5 - Supply tank

6 - Sealing rings

7 - Pulley

8 - Screw

9 - Hydraulic pump

1. Remove throttle housing and distributor pipe.

Refer to 24 42 19 Removing and installing throttle body - as of MY 2005 (All Models) .

2. Remove resonance tube.

Scheme 20

Loosen screw-type hose clamps, see -Arrows-, and remove resonance tube -2-. see scheme 24, (Scheme 19).

3. Remove left intake-air distributor.

Refer to 24 46 20 Removing and installing intake-air distributor - as of MY 2005 (All Models) .

4. Loosen belt pulley.

Loosen screws on pulley, see -Arrows-. (Scheme 20)

Scheme 21

5. Remove drive belt and pulley.

Refer to 13 78 19 Removing and installing drive belt - as of MY 2005 (All Models) .

Unscrew screws on pulley, see -Arrows-, and remove pulley. (Scheme 20)

6. Drain hydraulic fluid at underbody connection point.

The following steps must be completed in order to drain the hydraulic fluid

Scheme 22

6.1. Remove rear underbody panel.

Replace fastening nuts -2- following removal. (Scheme 21)

Scheme 23

6.2. Remove underbody panel at the left side.

Replace fastening nuts -3- following removal. (Scheme 22)

Scheme 24

6.3. Disconnect supply and return line at underbody.

Disconnect supply and return line and collect hydraulic fluid.

Scheme 25

7. Remove the supply tank.

Remove hydraulic fluid from supply tank by suction. Open bayonet lock and remove the supply tank.

Scheme 26

8. Disconnect return line at the supply tank/hydraulic pump.

Disassembly tool, universal NR.21, Tools .

If you do not have a special tool to hand, press the red circlip forward using two plastic spatulas and pull the return line out at the same time.

Scheme 27

9. Loosen air-conditioning compressor.

Unscrew screws -2- and move air-conditioning compressor -1- so that the screw -3- can be removed. (Scheme 26)

Scheme 28

10. Disconnect feed line at the hydraulic pump.

Loosen feed line -1- (a/f 16). Counter at the connection piece while doing so (a/f 24). (Scheme 27)

11. Remove hydraulic pump.

Note. When you remove the drive belt, the drive belt tensioner is lying on the hydraulic pump. The increased strain prevents the hydraulic pump from being removed and inserted, so the tensioner must be turned accordingly. Get another person to help you do this.

11.1. Unscrew the screw at the back of the hydraulic pump.

Remove screw -3-. (Scheme 28)

11.2. Unscrew the screws at the front of the hydraulic pump.

Remove screws -2- and press the drive belt tensioner back at the same time. Remove hydraulic pump. see scheme 34

1. Install hydraulic pump.

Press drive belt tensioner back with the help of another person and insert the hydraulic pump.

1.1. Screw in and tighten the screws at the front of the hydraulic pump.

Tighten screws -2- at the housing. see scheme 35

> Tightening torque: +23 (17 ftlb.) Nm

1.2. Screw in and tighten screw at the back of the hydraulic pump.

Tighten screw -3- at the housing. see scheme 36

> Tightening torque: +23 (17 ftlb.) Nm

2. Secure feed line at the hydraulic pump.

Secure feed line -1- (a/f 16). Counter at the connection piece while doing so (a/f 24). see scheme 37

3. Connect return line at the supply tank/hydraulic pump.

4. Secure air-conditioning compressor.

Tighten screws -2- on air-conditioning compressor. see scheme 39

> Tightening torque: 23 (17 ftlb.) Nm

5. Install supply tank.

Pay attention to markings on the catch and on the supply tank, see -Arrow-! see scheme 40

6. Connect supply and return line at underbody.

6.1. Connect supply and return line at underbody.

6.2. Install underbody panel at the left side.

Replace fastening nuts -3-. see scheme 42

6.3. Install rear underbody panel.

Replace fastening nuts -2-. see scheme 43

Tighten fastening screws -1-. see scheme 43

> Tightening torque: 2 (1.5 ftlb.) Nm +/-1 (0.5 ftlb.) Nm

Tighten fastening nuts -2-. see scheme 43

> Tightening torque: 1.5 (1 ftlb.) Nm +/-1 (0.5 ftlb.) Nm

Tighten fastening nuts -4-. see scheme 43

> Tightening torque: 5 (3.5 ftlb.) Nm +/-1 (0.5 ftlb.) Nm

7. Install drive belt.

Refer to 13 78 19 Removing and installing drive belt - as of MY 2005 (All Models) .

8. Secure belt pulley.

Tighten screws -Arrows-. see scheme 44

> Tightening torque: +23 (17 ftlb.) Nm

9. Install left intake-air distributor.

Refer to 24 46 20 Removing and installing intake-air distributor - as of MY 2005 (All Models) .

Scheme 29

10. Install resonance tube and throttle housing with distributor pipe.

Tighten screw-type hose clamps in correct position. Refer to 24 42 19 Removing and installing throttle body - as of MY 2005 (All Models) .

11. Fill in hydraulic fluid, bleed the power steering and check for leaks.

1. Install engine compartment cover.

2. Install rear wall cover. Refer to 55 59 19 Removing and installing rear wall cover - as of MY 2005 (All Models) .

3. Install left front seat. Refer to 72 01 19 Removing and installing front seat - as of MY 2005 (All LHD Models) . Refer to 72 01 19 Removing and installing front seat - as of MY 2005 (All RHD Models) .

Poses Online