I purchased my 2002 Boxster almost two years ago. It had been in an accident, and the PO had bought it with the intention of fixing it, but never finished. I am done with nearly everything, with the power steering the last fix needed.
It has never worked. The car smoked for the first few months, evidently burning off some leaked PS fluid from the top of the engine. I knew that the pump, being dry, was most likely bad, so I got a used pump to replace it. When I removed the pump and took off the lower reservoir I noticed that the intake connection hole to the pump was melted and fused closed.
So this was obviously the source of my leak. I ordered a used lower tank to replace the melted one. With everything installed, I refilled with Pentosin and started the engine. Immediately, the pump began making a loud noise. I thought that maybe the fluid was not circulating so I turned the wheels left and right in an effort to bleed the system. I did this a few times, letting the engine run 10-15 seconds at most each time. The pump got a little hot, and I figure that this is what happened to the last pump/reservoir.
I disconnected the lines below the drivers seat to see what if anything would come out. Supply line: brownish fluid from pump side and then eventually my blue/green pentosin, nothing from rack side. Return line, brownish fluid from rack side and blue/green Pentosin from pump side.
So has anyone had the issue of the melted tank? It seems that something is blocking the fluid from entering the rack and circulating back to the pump. Has anyone had that issue? My next option is to remove the rack and attempt to see where any blockage may be. I have the return line off the rack, still working on the supply line. Also, where is the pressure switch and could this be the issue? Or is it a bad rack? Is there any way to flush the rack to troubleshoot where the blockage may be? Any help is appreciated, thanks!
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