Hydraulic System, Removal/Fitting

Hydraulic system

To remove

1. Remove the rear-seat cushion.
2. Remove the rear-seat backrest.
3. Remove the side trim.
4. Release the handbrake (to put slack in the cable over the servo pump).




5. Open the bypass valve, accessible behind the flap on the RH side at the back of the luggage compartment.




6. Release the clips securing the hydraulic hoses to the rear side panel on either side.




7. Remove the pin-retaining clip (split pin) from the piston rod on either side. Note the positions of the washers and spacers and withdraw the device pin on either side.




8. Close the bypass valve. Switch on the ignition and, by means of the switch for the top, fully retract the pistons. Switch off the ignition.




9. Undo the securing bolts for the servo cylinders.




10. Lift the servo pump off its seating and unplug the connectors from the relays.




11. Label the connectors and disconnect the leads from the pump.




12 Remove the moisture barrier on either side.




13. Lift the servo cylinders and feed them out through the apertures in the side panels.




14. Pass the cylinder on the RH side underneath the fuel lines and handbrake cable.
Lift out the hydraulic system complete.
Label the bracket for each cylinder (right & left) and put them to one side.


To fit

1. Bleed the hydraulic system to expel all air. This must be done before the system is installed in the car.




2. Ensure that the pistons are fully retracted.




3. Pass the RH servo cylinder and bypass valve under the handbrake cable and fuel lines.




4. Plug in the pump connectors, noting the markings to ensure that the right connectors are plugged together.




5. Plug the connectors onto the relays. Pass the pump underneath the handbrake cable and press the rubber bushes on the pump into the mounting plate.




6. Mount the bracket for the RH cylinder onto the cylinder, ensuring that the hose connections are towards the rear of the car.




7. Pass the cylinder through the aperture in the side panel.




8. Put the cylinder into position and tighten the securing bolts, gaining access through the aperture in the panel.
9. Mount the bracket on the other cylinder, again ensuring that the hose connections are towards the rear of the car.
10. Pass the cylinder through the rear aperture in the side panel.
Note that the hydraulic hoses should not go underneath the handbrake cable.
11. Put the cylinder into position and tighten the securing bolts, gaining access through the aperture in the panel.




12. Put back the moisture barriers on either side.




13. Pass the bypass valve through the aperture in the rear side panel and secure it in its clips.
14. Secure the hydraulic hoses in their clips.
15. Release the latching handles for the top, to facilitate adjustment of the servo cylinder piston rods.




16. Operate the pump to bring the pistons into the fully extended position.
Reconnect the rods by inserting the device pin and securing with the split pin. Work on one piston at a time.
17. Refit the side trim.
18. Fit the backrest.
19. Fit the seat cushion.
20. Close the latching handles for the top