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Old 04-23-2013, 07:35 PM   #1
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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.
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Old 04-24-2013, 04:03 AM   #2
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psp

Thanks for the info, I'm getting ready to do this mod on my car and all the info on the process would be appreciated
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Old 04-24-2013, 10:40 AM   #3
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there are those that talk and then those that do! I respect your quest and all the work you are doing Radium King. And thanks for sharing the fruits of your labour!!
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Old 04-24-2013, 04:34 PM   #4
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Very nifty and skillful you can do this. Am subscribed to this thread.
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Old 04-24-2013, 07:15 PM   #5
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thanks; hopefully not too much skill involved - drill a few holes, connect two hoses.

i'll have the front underbody panels off the car in a week or so and can confirm hose routing/length, at which point I can order hoses and the Russell fitting (I live in the boonies so have to order stuff in batches to save on shipping). that should let me know I have the proper fitting for my pump. after that I have to find some time to test, clean and paint the pump (it's used and has spent some quality time under the hood of some diesel british people mover). then I expect a day (or two) of actual install.
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Old 04-25-2013, 06:33 AM   #6
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Sounds good. Why did you choose this particular pump? What is the output with respect to the stocker? It's probably much more stable and will give the ps control valve less work.... but output pressure range?

It would be really handy if the ps control valve was right in the frunk somewhere....are you drilling to get to it??? Perhaps it's modularized with the rack....bummer

Are you removing all the ps lines from the back?

Will the gutted ps pump require some fluid to keep its bearings cool and lubed while idling? Will you still have to service this fluid?
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Old 04-25-2013, 06:45 AM   #7
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oil and transmission coolers
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Old 04-26-2013, 07:22 AM   #8
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Ahhh you have to get right to the rack....that means big holes for the hydraulic lines!

Who would have thought that a Porsche cup car pump would be a Vauxhall Astra piece...crazy!

Where do you plan to grab switched power for it?
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Old 04-26-2013, 07:54 AM   #9
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smallish holes - 6AN (AN/16 = 6/16 = 3/8").

switched power under dash - stereo, etc.

ill try to get some pics up of proposed placement this weekend.
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Old 05-03-2013, 08:26 AM   #10
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Here's a shot of the pump. You can see the opening for the pressure out, as well as the barbed return to the reservoir. You can see two of the three rubber isolation mounts on the oem bracket, and that with a bit of bending you can make the bracket mount to any surface you want. For wiring you see the main + and -, as well as the three-wire control connector.

A clean and a shot with a spray bomb (black plastic paint for the reservoir and some black high temp for the motor) and its ready to go in.

On another note, a quick peek of a Ruf 3600 clone coupe (zeintop):

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Old 05-20-2013, 12:27 PM   #11
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electric P/S

Just finished the install and tried it this week end at an autocross event, It worked like a charm, the steering is a little tighter but the feel is better than before. I ended up running a switch instead of the alternator light because it's more practical since it is a race car.

It was an easy project with all the info that I got out of this post

Thanks for all the research RK
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