DIY- 2.2l Turbo Modified Power Steering Pump for Under Manifold Inlet

[fattie92]

Here is a little DIY that I just did in order to save a few bucks on a new pump. This is on my 2.2l Turbo Legacy. We were thinking about getting a WRX pump to clear our under manifold turbo inlet, but why not just make the stocker work??

Stock pump right off of the car.
http://photos-f.ak.fbcdn.net/hphotos-ak-snc1/hs004.snc1/2795_79129833183_500753183_1679421_466207_n.jpg

Take the 2 10mm bolts off of the reservoir and remove it..
http://photos-g.ak.fbcdn.net/hphotos-ak-snc1/hs004.snc1/2795_79129838183_500753183_1679422_1033145_n.jpg

You can now see the pumps inlet hole and seal.
http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs004.snc1/2795_79129843183_500753183_1679423_3612672_n.jpg

Clamp the reservoir in a vise up-side-down and cut out the mount. It will not come out just yet after its cut.
http://photos-a.ak.fbcdn.net/hphotos-ak-snc1/hs004.snc1/2795_79129853183_500753183_1679424_2098752_n.jpg
http://photos-b.ak.fbcdn.net/hphotos-ak-snc1/hs004.snc1/2795_79129858183_500753183_1679425_6215145_n.jpg

You also need to grind down the two bosses that stick up on the top of the reservoir.
http://photos-a.ak.fbcdn.net/hphotos-ak-snc1/hs004.snc1/2795_79130838183_500753183_1679432_2843757_n.jpg

You can now remove this contraption!
http://photos-b.ak.fbcdn.net/hphotos-ak-snc1/hs004.snc1/2795_79130843183_500753183_1679433_7687486_n.jpg

Place in a vise and cut off the two tubes. DO NOT DISCARD!! You will need them later!
http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs004.snc1/2795_79130858183_500753183_1679434_3470969_n.jpg

You can now clean up the base with a grinder or sanding disk. Might as well try to make it look good! DO NOT grind the center down!!
http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs004.snc1/2795_79130863183_500753183_1679435_1283153_n.jpg
http://photos-e.ak.fbcdn.net/hphotos-ak-snc1/hs004.snc1/2795_79130873183_500753183_1679436_626889_n.jpg

Fits perfect!
http://photos-e.ak.fbcdn.net/hphotos-ak-snc1/hs004.snc1/2795_79132428183_500753183_1679452_464800_n.jpg

Take one of the tubes that you saved and cut it in half (or however long you feel fit)... Clean it up really nice. Place the rod on the mount and get ready to weld it up! This is going to be the nipple for the remote reservoir!
http://photos-f.ak.fbcdn.net/hphotos-ak-snc1/hs004.snc1/2795_79132433183_500753183_1679453_5713571_n.jpg
http://photos-g.ak.fbcdn.net/hphotos-ak-snc1/hs004.snc1/2795_79132443183_500753183_1679454_3362002_n.jpg

Mounted up! Dont forget to replace the O-Ring!
http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs004.snc1/2795_79132448183_500753183_1679455_5434308_n.jpg
http://photos-a.ak.fbcdn.net/hphotos-ak-snc1/hs004.snc1/2795_79132458183_500753183_1679456_4466210_n.jpg

I opted to weld a bead at the top and then smooth it down some for a ridge. That is to help the hose stay on. The bolts that I used are M8 x 1.50 at 1" long.

We have a remote reservoir off of a old Mercedes that will be mounted on the frame rail. We are hoping that this pump will create enough suction to work that way. If not, then we will have to get even more creative! Since the motor is still out of the car, this will have to wait a little bit to be tested out fully.

[kreitz3]

That is very creative Ryan and something I would never think of!

Thanks for the write up!

[kurt.]

Yes, I've been wanting to do something like this as well. My problem is overheating the PS fluid and boiling it over. I think that a remote mounted reservoir will help keep the fluid much cooler and you can have a larger reservoir too..

-Kurt

[fattie92]

I have a rather large all metal remote reservoir that will be used. Nice thing is that it has a internal reusable filter. I plan on mounting it over where my ABS unit used to be. Not exactly sure yet, we will figure it out as we do it... Should look pretty good, and hopefully work as good as it looks.

[biggreen96]

interesting... I hope it works as planned.

[fattie92]

So far so good! Here is a picture of the completed set up. The reservoir is in front of the passenger side strut tower.

http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs006.snc1/4164_85657458183_500753183_1763503_7725628_n.jpg

http://photos-f.ak.fbcdn.net/hphotos-ak-snc1/hs006.snc1/4164_85658853183_500753183_1763573_6294814_n.jpg

[kurt.]

Any idea if an aftermarket turbo inlet will fit under there?

-Kurt

[fattie92]

Any idea if an aftermarket turbo inlet will fit under there?

-Kurt

I would say as long as it is a silicone style inlet, then Yes. If it is a hard one like the APS inlet, I would have to say No. Never know for sure though until you try.



This power steering setup is working GREAT so far!

[kurt.]

I see you moved your coolant expansion tank too; is that necessary? I'm working on converting mine right now (EJ20G tho, not EJ22T), for a turbo upgrade.

-Kurt

[fattie92]

I see you moved your coolant expansion tank too; is that necessary? I'm working on converting mine right now (EJ20G tho, not EJ22T), for a turbo upgrade.

-Kurt

The coolant expansion tank had to be relocated for the intercooler to fit properly. Since we threw away the A/C compressor we just mounted the tank in its spot.