P/N 8E1422891AK "Return hose"
P/N WHT000507 for "Pressure hose Bolt" (banjo bolt)
P/N N0138487 for "Steering gear and linkage Pump and hoses Seal Type 1 Type 1" (crush washers)
22mm offset wrench (I used 2 of them)
I bought my kit with all required items from ECS for $130 bucks but I had my own oetiker clamp. https://www.ecstuning.com/ES2771229/
The return hose is #12 and it's once piece even though the picture shows it as 2 separate hoses.
1) Jack up the car and remove the wheel. Noticed the outter tie rod end, upper control arms, knuckle, and strut/spring. I thought about removing the strut/spring and knuckle to get more room but found a way to get to the hose at the rack without removing any of that stuff. There's a plastic cover around the outter/inner tie rod end, you'll have to remove to get access to the hose/rack connection.
2)Remove the connector that's currently in front of the plastic cover. Mine was zip-tied together and I was able to simple pull it away from the plastic cover after snipping it. Disconnect the connectors and move it aside
3)Remove the acorn nut (10mm) and 2 plastic push-pin that's holding the plastic cover to the car. The acorn nut is on the right hand side of the plastic cover and the 2 push-pin are on the left side hiding behind the springs.
4)Pleasantly surprised that the cover doesn't have a slit where you can slide it off the tie rods, it's a once piece cover and I wiggled it out and slid it out/around the upper control arms. I thought about cutting a tiny slit at the bottom but I had plenty of clearance by just moving it so didn't see any benefits in cutting it
5)Now you see the two lines attached to the rack. The one with the loop is the high pressure and the gold/copper color below it is the return hose that we need to remove. I put my bottle jack below the rotor and push it up a few inches to create some more room for myself. That way the tie rods would be slightly higher and allow a tiny bit more room for my offset wrench. I had to used 2 different 22mm offset wrenches to loosen the bolt a few turns. After that, I just hand twisted the rest of the way. I'm not going to lie, I'm pretty sure the birth canal is bigger that the room you have to play with so be patient and don't get frustrated.
6)Now that you have the banjo bolt off the rack, there are 3 places where the hose is clipped to the car. There are two netting clip things in the engine bay and the 3rd place you'll have to get from underneath the car. After undoing all 3 clips, pull the hose up in the engine bay as much as possible. Then wiggle the hard connection out and around the tie rod and the rest of the hose will follow.
7)The rest of it is now doing everything in the reverse order. I slid the hose through the same opening near the tie rod and wiggle it as far as I could. Go up into the engine bay and pull up as much as you can. Be patient, it's not a straight line so it's going to take a bit of time.
8)Putting the banjo bolt back on the rack is loads of fun. Don't forget your crush washers. Put the washer on the banjo bolt and slide it into hose opening. The washer on top of the hose always has a way of slipping off for me so I put a little bit of coconut butter (whatever you have to make it stick to the hose) on it and slide it through the banjo bolt. You're pretty much doing it blink so keep sticking it in the hole and I'm sure a thread will catch. Don't tighten it all the way just yet, leave some room so you can wiggle the hose the rest of the way down to the cooler line.
9) I routed the hose the exact same way that I took it out and found it much easier to remove the little plastic clip holding the two connectors behind the headlight.
10) Connect the hose to the cooler line and make sure you clamp at the correct location, ask 924Carrera why. The hard line has a bulge at the end so make sure you push the hose all the way in and clamp as close as you can to the end.
I overfilled the reservoir and started the car. Shouldn't look like a waterfall in there so if it does, add more fluid. While the wheels are off the ground, turn it lock to lock to remove as much air from the system. Take it for a ride and wait for the next thing to break because you know it will.
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Originally Posted by AllroadMass
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