Power Steering Pump Removal & Installation

[itoy]

I would like to share my experience on working with my Boxster (Base & TIP) year 2002. But I would like you to know that I am not a mechanic. I am just a trying hard hobbyist on fixing cars. Last month, my car started creating a whining noise so I did check and found out that the noise is coming from the steering pump. I bought a new pump from autoparts warehouse for $327 brand new. So here we go.

1. Open the compartment engine as usual.

2. Remove both the trottle body tube and resonance tube by unscrewing the four screw type brackets. Be carefull because there are some wirings and vaccum hoses attached to the underside of these tubes. I actually broke one that is connected to the throttle tube and cost me $18 to buy from the dealler. Remove everything connected to it including a flex hose connected to the AOS.

3. Once cleared, disconnect the two sensor terminals on top of the engine block and behind the reservoir to make room.

4. Try to siphon or collect as much fluid as you can from the reservoir. What I did is I used a syringe with flexible tube attached to siphone some of the fluid from the reservoir. However, there is no way you can avoid leaks from the reservoir.

5. Now you will see the back of the steering fluid reservoir and the fluid's return line. "YOU HAVE TO DISCONNECT THIS METAL PIPE FIRST" before doing anything else. This is a PIA. The return line is connected through a compression fitting with a RED plastic compression ring and two rubber o-rings. My pump is seated on top of this reservoir. It took me two days and a broken knuckle to dislodge this pipe. It was so painfull and I start cursing out loud. What I did is use a block of wood as a lever and wedge it between the pipe and the back of the plastic reservoir. I used small crow bar to separate them.

6. Then, go inside the passenger side and loosen the 3 bolts holding the steering pump's flywheel. Then remove the serpentine belt. Remove the 3 loose bolts and the pump's flywheel.

7. Then remove the 3 bolts holding the pump in the front and the two bolts at the rear.

8. At the back of the pump, there is a half circle metal between the pump and the reservoir. Loosen the bolt that holding this half circle metal and temporary tie it up to clear up the area.

9. Loosen the compressor by loosening 3 bolts. Ther are 2 bolts in the front and 1 at the rear. You can use universal swivel socket through the gap in the intake manifold to reach these bolts. You have to do this because the compressor's plumbing is blocking the way.

10. Now, you can detach the filler tube reservoir by un-screwing. Once removed, the whole unit (pump & reservoir) can be maneuver and remove in one difficult way. It will takes time to remove the whole assembly.

The installation is the reverse. You will need some ties or wire to temporarily hold those things blocking your way. I totally forgot to take pictures and I am sorry about that. Well, thats all folks. I hope this explanation is clear to you.

[san rensho]

Thanks, good explanation. Now I'll try to avoid this repair. That hose sounded like a bear.

[john90290]

Thanks for the post! Can you describe the noise you heard?

Thanks,

John

[itoy]

The noise sounds like a jet engine but not that loud. Before, the noise will dissapear after a couple of minutes. Then last month, it became continous.

[GERMAN NUT]

THERE IS A 2 PINS ON LOWER TANK... SAVE FLUID AND EASE OF REMOVING THAT HARD TO REMOVE HOSE...REMOVE TWO PINS ,AFTER REMOVING FRONT PULLEY. LEAVE LOWER TANK IN PLACE.MUST REMOVE 2-REAR BOLTS AND SECURE RING TO SLIDE PINS OUT.SEE PICTURES.

[Verhag]

Originally Posted by itoy

The noise sounds like a jet engine but not that loud. Before, the noise will dissapear after a couple of minutes. Then last month, it became continous.

Sounds like my issue....I described it recently to a Porsche tech "as a nearby neighbor's string trimmer" running. High pitched whine, goes away as I back out of garage, seems noticible only on cold starts. He mentioned secondary air injector noise and normal, however this sound was not there during my 1st month of ownership. Does this sound like a power steering pump going bad?

[pedot99boxster]

Verhag, did you replace your power steering pump? was it easy?

[Jinster]

If the OP is still around, or anyone else who has done this, does moving the compressor require a regas of the aircon? How long did the whole process to replace the power steering pump take?

[BYprodriver]

Originally Posted by Jinster

If the OP is still around, or anyone else who has done this, does moving the compressor require a regas of the aircon? How long did the whole process to replace the power steering pump take?

You can remove the 3 bolts that secure the A/C to the engine & leaving the hoses connected move the A/C into the passenger compartment. My 2000 Box A/C is ice cold with zero maintenance even after moving the compressor as above.

[pjq]

I remember the pump was a PITA to remove even when I had the engine out of the car and infront of me. So maybe a few pic's to go along with the advice and instuctions in this thread will help.
A.C. has been removed.

[Jinster]

Thanks for the advice and the photos, guys. I started doing this today, but have some questions.

I don't understand why the two rear bolts need to come out. They just connect the plastic tank to the metal part of the power steering pump, right? So if I am replacing the whole thing, I can just remove the three bolts in the front, and not worry about detaching the air con compressor to access the two rear bolts?

Does the power steering pump eventually come out via the front or the back?

[pjq]

Yes the steering pump comes out via the back.
If I recall trying to get the unit out as a whole was the issue, due to its length. That may be why its suggested to remove the tank from the pump (back 2 bolts). I was able to continue removing parts from behind until it finally came out (if i recall I was getting close to the hammer stage).

Did you check out -101 projects for your porsche boxster- site?

[97-986]

I have PS fluid on the top of my motor. I can't find the source of the leak but think it may just be where the reservoir connects to the pump.
Do I need to go through all 10 of those steps or can i just detach the reservoir after I siphon it?
TIA

[18wheelerbob0642]

First I to thank ITOY for her version of the removal, and Yes it took me two days of fighting with that RED ring. My neighbor was wondering why I was in the same position (lying half into the motor the other half across the trunk and rear quarter) then he tells me "that RED compression fitting ; the more you pull out the tighter it gets. He suggested to push the pipe inwards towards the reservoir and push the RED ring into the pump and slowly pull out the metal tube. That took 5 minutes and it was out , every else just follow ITOY instructions.
Now on the third day trying to figure out how to install the new pump, in a two part installation, pump with lower half of the reservoir then the upper when it's in place. or try as one complete unit , but from where I'm standing thats going to be difficult . So I'll try my first option.if that works it's down hill from there.
If by any chance any follow members wants to give me tip please do . LOL

[Tommm]

Excellent thread with one addition.

I tried and tried to get the line out of the reservoir. I made the tool, got is about 1/2" out and that was it. I had the compressor loose, the pulley off and on and on.

Follow the line to the front (of the car) of the motor. Driver side, just under an to the right of the pump there is a clamp with the hose in a rubber grommet. I had to get the bolt out of that bracket which gave me enough slack to get the line out of the reservoir.

Also, once you loosen the plastic connection to get the upper reservoir off, is it just pull, or is there another twist needed? I am not sure what I did to disconnect it.