Converting 2004 Boxster Power Steering to 12V

[PorscheFan5]

Team,

As part of my EV conversion I am driving my AC compressor from the back of my DC motor however I am converting the Power Steering system to 12V and not driving it from the drive train.

I have decided to use the MR2 Spyder Power Steering pump and cable it directly to the Power Steering rack.

I know the following fitting sizes for the MR2 pump:

• Pressure line - 16mm x 1.5
• Return side 3.8 mm nipple (plastic)

I need help from someone on this forum on dimensions for the following:

• Fitting for Pressure line on the PS rack side
• Fitting for Return line on the PS rack side

Would appreciate help from anyone who has the info. Thanks!

P.S. If you want to check out info on my build check out the link below that points to my WIP website...

EV Project: Converting my 2004 Boxster to Electric Vehicle

[BoxsterLS376]

Cool project.
I just bought the conversion kit from renegade but they simply use a Toyota pump like you are doing. Check out my build thread and you will find some info in there.

The easiest thing to do with the fittings is just cut them off of the factory lines and weld new fittings on the end, I never had to worry about dimensions. Or you could just cut the factory hoses and have them crimped onto new lines etc. Either way just cut up the factory stuff, it's the easiest thing to do.
Good luck
J

[PorscheFan5]

Hi John,
Thanks for the post. That is exactly what I am going to do, cut of the rubber lines and have a shop crimp new 'ferruls' using new lines. I am getting the Russel fittings and 6AN line from Summit racing.

How much was the kit from Renegade and what did it contain?

[BoxsterLS376]

It cost a lot but when I started I wanted to be able to easily replicate the project, certainly can be done for less...

Power Steering Kit

Billet custom power steering plate with mount

Electric power steering pump

Custom hose kit (customer supplied cores needed)

Plugs, harness, relays

Total
$1,295

[The Radium King]

go spec racing sells a kit as well, or you can buy just the parts you need, such as the two rack adaptors.

[PorscheFan5]

Thanks John.

Radium king,

I have everything I need except for the fittings on the rack side. I will check out go spec racing. BTW, is that same as GSR racing?

[PorscheFan5]

Go spec auto racing --> GSR --> Trinity Auto sport don't work on Porsche's now so they cannot help. I will have to figure some ways of using the existing Porsche line, cut it and have a shop crimp a 6AN line on it...

[Sassmatt72]

Just looking into this, what year pump are you sourcing??

thanks.

p.s. are you re-using the mounting bracket, upper resivior, is wiring an issue (i.e. do you need the controller module?), did you resue the oem fittings on the pump?

thx

[PorscheFan5]

Originally Posted by Sassmatt72

Just looking into this, what year pump are you sourcing??

thanks.

p.s. are you re-using the mounting bracket, upper resivior, is wiring an issue (i.e. do you need the controller module?), did you resue the oem fittings on the pump?

thx

Hi Matt,

I got the PS pump from 2001 MR2 Spyder. I am fabricating the mounting bracker myself, as you saw yesterday...:-). The pump has its own reservoir and I don't think I need another one. There are good articles on the wiring, in fact there is a sticky article. The controller is part of the pump assy. I got the fittings and high pressure hose from Summit racing. Mostly I am using Fragola fittings and hoses. I am getting the rack end fitting from Woody and will see if I can get 6AN tips welded to the ends. Will post pictures on my website's Power Steering section once done. You can check it out here:

boxsterev

[Deadeye]

Do you have a wiring diagram to connect the mr-2 pump?

[Deadeye]

Also, do you have a parts list with part #'s and source for the wire connectors, plugs & relay?

[PorscheFan5]

Originally Posted by Deadeye

Also, do you have a parts list with part #'s and source for the wire connectors, plugs & relay?

Deadeye,

Yes and yes. Will post later today. I got the connectors and wires for the pump from toyotapart.com, relay from eBay. Will post details and the 986 forum link for the diagram article...

[PorscheFan5]

Deadeye,

Here are the details you need:

Items for the MR2 Spyder pump purchased from Factory Toyota Parts and Toyota Accessories We are an OEM Parts Supplier.:


Code Item Qty Price/Ea. Total
90980-12068 HOUSING, CONNECTOR, FEMALE 1 $8.75 $8.75
90980-10897 HOUSING, CONNECTOR, FEMALE 1 $8.02 $8.02
90980-10942 HOUSING, CONNECTOR, FEMALE 1 $5.24 $5.24
82998-12440 TERMINAL, REPAIR W/ WIRE 3 $5.35 $16.05
82998-12500 TERMINAL, REPAIR W/ WIRE 2 $5.35 $10.70
Shipping: Small Flat Rate: $6.50
Sales Tax: $0.00
Total: $55.26
Toyotapart.com 5850 Stadium Dr Kalamazoo, Mi. 49009

80 Amp Relay from eBay - URL
Will use a new type resettable fuse - URL

Connection Diagram attached. The fuse goes between battery 12V (not key-switched 12V) and relay contact - left top corner of diagram.

Hope that helps. Let me know if you need anything else...

[Deadeye]

Perfect. Thanks!

[PorscheFan5]

Okay, was able to finish up the installation of the pump and wiring. Some pics attached.

I am taking the '12V Switched' from the fuse box D4 which is an unused spot. I read somewhere on this forum that one can take 12V Switched from there. Had to do some cutting etc to the side of the fuse box but it worked out. I was quite happy with my work... Routed the wire inside and above the steering column to bring it to the center console from where I have made a hole and added a plastic fitting to take it out from there. I am going to need 12V switched in many places and am thinking I will put a bus bar somewhere...

I am also thinking of changing the allen-head bolt, that goes on the pressure plate that keeps the pressure and return line pressed in, to a hex head bolt and be done with it once and for all...

Hope this helps someone else doing the project.

[PorscheFan5]

Quick update and a question...

One checking the 12v that I got from D4 at the footwell fuse box, I found that it shows 12V as soon as the battery is connected and remains 12v so far as the battery is connected

That would mean this is 12V Batt and not 12V Switched (12V On only if switch is turned to ON position). Am I missing something?

Need to find 12V SW if possible from fuse box. Or I will have to tap it from behind the radio?

Please help!

[jsceash]

Originally Posted by PorscheFan5

Quick update and a question...

One checking the 12v that I got from D4 at the footwell fuse box, I found that it shows 12V as soon as the battery is connected and remains 12v so far as the battery is connected

That would mean this is 12V Batt and not 12V Switched (12V On only if switch is turned to ON position). Am I missing something?

Need to find 12V SW if possible from fuse box. Or I will have to tap it from behind the radio?

Please help!

The bundle of wire that is right between your circuit breaker and firewall has a red wire with a black stripe I pulled and spliced into that wire to turn on my pump. Not the same brand as your but it starts my pump with the key.



Mine is mounted in the same location different mount.

[PorscheFan5]

Thanks for the prompt response. I see two bunches there, one a thick one another a thin one. Is this RD/BLK wire in the thin one?

BTW, mine is a 2004 Base Boxster. I checked both the bunches that run parallel to the black bar and neither of them have the RD/BLK wire in my case. I will have to find another way.

I would like to find the 12VSw in the cabin somewhere near the driver side dash. That will make it easy for me to route it since I have created a junction point for 12vSw there...

Any ideas?

[Escy]

Nice install. The pump isn't working, they aren't that quiet

[jsceash]

Mine is noticable when running there is a light whine. The sound increases as you turn.