Work Preparation: Hose (Shop-Made)

Return line extension, for draining steering fluid.

Length of hose (shop-made) for return line extension

• → Inner diameter: +12 mm+3 mm 
• → Length: +1, 700 mm+300 mm 

1. Remove underbody protection and place a suitable container underneath for collecting steering fluid, e.g. a 10-litre canister. → 519319 REMOVING AND INSTALLING COVER FOR CENTRE UNDERBODY
2. Disconnect return line -1-  at the steering fluid cooler and drain steering fluid.

   Fit return line again after draining the steering fluid.

   Fig 1: Identifying Fluid Cooler Lines (Return And Supply)

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Disconnect the return line at the reservoir -4-  .
   Fig 2: Identifying Reservoir Suction And Return Line

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Remove single-lug clamp between the short rubber hose and rigid line. Then pull off the short rubber hose.
   Fig 3: Removing Short Rubber Hose From Rigid Line

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Fit the hose (shop-made) onto the rigid end of the return line.
   Fig 4: Fitting Hose (Shop-Made)

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Information 

   Use a sufficiently large container to collect steering fluid, e.g. a 10-litre canister.

   • Secure the free end of the hose (shop-made) in the collection container (strong flow of fluid). 

   Guide the other end of the hose (shop-made) into the steering fluid collection container.

   Fig 5: Identifying Hose (Shop-Made) 1

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Replace and fit suction hose -3-  and reservoir -1-  .
   Fig 6: Identifying Reservoir, Suction Hose And Return Line

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. Close off connection piece for the return line -4-  at the reservoir.
8. Fill the reservoir up to the MAX marking until the fluid level no longer drops.

   Engine is not started! 

9. Raise the vehicle until the wheels are no longer touching the floor. Turn the steering fully to the left and right and hold it at full lock for approx. 30 seconds on each side until the level no longer drops. Continually check the fluid level and fill to the MAX marking again.
10. Procedure for flushing the steering system 

    Vehicle must be standing on its wheels.

    1. 10.1.
       • Have a can containing approx. 3 - 4 liters of steering fluid ready. First mechanic  continually checks the fluid level in the reservoir and checks that Pentosin flows safely into the container.

       The reservoir must not run dry! 

    2. 10.2.
       • Second mechanic  sits in the vehicle and starts the engine for max. 1 second following consultation with the first mechanic  .
    3. 10.3.
       • Second mechanic  must also start turning the steering to the left and right at full lock on either side.
    4. 10.4.
       • Stop the engine IMMEDIATELY after flushing the system for 1 second! Fill the can with steering fluid if necessary and check the flow in the collection container (secure it to prevent it from slipping out!).
    5. 10.5.
       • Check the fluid level in the reservoir and continually top it up each time the engine is started. Then restart the engine several times following consultation with the first mechanic  until the steering fluid (3 - 4 liters) you are using to flush out the system has been flushed through.

       Then stop the engine IMMEDIATELY.

11. Once the flushing process is complete, remove the hose (shop-made).
12. Fit new return line.
13. Bleed the steering system and correct the fluid level in the reservoir. → 4890IN TEST AND ASSEMBLY WORK ON POWER STEERING 
14. By shining a torch in the reservoir, check for shimmering metal particles (like metallic paint) in the steering fluid. Don't confuse these with air bubbles! If metal particles are visible, flush the system again.
15. Fit underbody protection. → 519319 REMOVING AND INSTALLING COVER FOR CENTRE UNDERBODY