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The Radium King · 04-23-2013, 07:35 PM

slowly putting the gear together:

- Vauxhall astra/zafira electric PS pump c/w mounting bracket ($200; used on ebay uk):

Vauxhall Astra MK5 H 2004 2010 1 3L Diesel Cdti Electric Power Steering Pump | eBay

- two GSR PS rack to 6AN male fittings ($110; to convert PS rack to AN fittings):

GSR Power Steering Rack Fittings - 6AN - Porsche 986, 987 Boxster, 996, 997 911

- Pending: Russell 16mmx1.5 o-ring seal to 6AN male fitting ($8; to convert electric PS pump pressure side to AN fitting):

Russell 648060 Russell Power Steering Adapter Fittings

- Pending: two 6AN female/female hoses ($?; depending on length).

notes:

- PS pump bracket can be easily bent to mount on flat surface, and comes with three rubber vibration isolation mounts between pump and bracket
- if mounted on upper tray of front trunk will clear hood (mounting on upper tray will also give good access to battery and keep main trunk free for helmets)
- original PS pump can be gutted to serve as dummy pulley if you have deleted AC (thanks eric) otherwise all required is a shorter belt; suncoast and bgb also sell AC delete pulleys (marketed for the 987.2, but will fit the 986 as the AC compressor part number hasn’t changed)
- PS pump wiring is as follows:
red - battery +12V
brown - ground
black - ignition +12V (i.e., only runs when key is on)
blue/white - alternator dash light (to turn it off if the key is on but car not running)
brown/white - not required (for diagnostics)

need to confirm:

- 6AN hose will fit over reservoir return spigot (presume not a big deal)
- source for Bosch 4P weatherproof male electrical connector to connect to PS pump electrical connector (for clean install, otherwise i can splice the wires)
- that i got the proper Russell fitting (presume metric, but could be 5/8”)
- hose length and routing from PS rack to proposed mounting location
- appropriate grommets to give bulkhead penetrations a finished look (got a box of them; something should work)
- source for switched +12v and alternator wires (under the dash somewhere; just need some time with the wiring schematic to get a colour code)

almost there; cost will be around $400 all in.

04-23-2013, 07:35 PM	#1
The Radium King Registered User Join Date: Apr 2010 Location: Canada Posts: 3,128	electric power steering project slowly putting the gear together: - Vauxhall astra/zafira electric PS pump c/w mounting bracket ($200; used on ebay uk): Vauxhall Astra MK5 H 2004 2010 1 3L Diesel Cdti Electric Power Steering Pump \| eBay - two GSR PS rack to 6AN male fittings ($110; to convert PS rack to AN fittings): GSR Power Steering Rack Fittings - 6AN - Porsche 986, 987 Boxster, 996, 997 911 - Pending: Russell 16mmx1.5 o-ring seal to 6AN male fitting ($8; to convert electric PS pump pressure side to AN fitting): Russell 648060 Russell Power Steering Adapter Fittings - Pending: two 6AN female/female hoses ($?; depending on length). notes: - PS pump bracket can be easily bent to mount on flat surface, and comes with three rubber vibration isolation mounts between pump and bracket - if mounted on upper tray of front trunk will clear hood (mounting on upper tray will also give good access to battery and keep main trunk free for helmets) - original PS pump can be gutted to serve as dummy pulley if you have deleted AC (thanks eric) otherwise all required is a shorter belt; suncoast and bgb also sell AC delete pulleys (marketed for the 987.2, but will fit the 986 as the AC compressor part number hasn’t changed) - PS pump wiring is as follows: red - battery +12V brown - ground black - ignition +12V (i.e., only runs when key is on) blue/white - alternator dash light (to turn it off if the key is on but car not running) brown/white - not required (for diagnostics) need to confirm: - 6AN hose will fit over reservoir return spigot (presume not a big deal) - source for Bosch 4P weatherproof male electrical connector to connect to PS pump electrical connector (for clean install, otherwise i can splice the wires) - that i got the proper Russell fitting (presume metric, but could be 5/8”) - hose length and routing from PS rack to proposed mounting location - appropriate grommets to give bulkhead penetrations a finished look (got a box of them; something should work) - source for switched +12v and alternator wires (under the dash somewhere; just need some time with the wiring schematic to get a colour code) almost there; cost will be around $400 all in. Last edited by The Radium King; 04-24-2013 at 05:03 AM.