Removal and Installation

HYDRAULIC CYLINDER

Removal and Installation


HYDRAULIC CYLINDER ASSEMBLY

Removal

CAUTION:
- Protect the rear fender with a fender protector.
- Never bend or twist hydraulic hoses sharply, or strongly pull them.
- After installation, hydraulic hoses must not move towards self- locking bands.
- Never let the ends of self-locking bands touch hydraulic hoses.
- Remove rear parcel board and set bracket to the straight up position for preventing interference from rear parcel board roof.
1.Remove trunk room trim. Refer to "Removal and Installation" Removal and Installation.
2.Remove rear cushion and seatback. Refer to "Removal and Installation" Removal and Installation.
3.Remove rear side finisher. Refer to "Removal and Installation" Removal and Installation.
4.Open relief valve of oil pump.
5.Set trunk lid to the backdrop status.
- Open trunk lid manually.





- Release trunk lid lock (1), (2) toward vehicle rear.

CAUTION:
Never move roof manually faster than with automatic operation to prevent hydraulic system from a damage.
- Lift trunk lid to the backdrop status.





- Support trunk lid (1) using a stand (2) as shown in the figure.

CAUTION:
- Always hold trunk lid, because trunk lid moves according to change in hydraulic pressure after removing cylinders.
- Two workers are required for manual operation.





6.Manually set retractable hard top (1) to the straight up position and hold using a lashing belt (2) as shown in the figure. Release front lock on "Work Support" using CONSULT-III.

CAUTION:
Always hold retractable hard top using lashing belt, because retractable hard top moves according to change in hydraulic pressure after removing cylinders.





7.Remove roof lock cylinder upper portion from roof link assembly (5).
- Remove clip (3) of roof lock cylinder.
- Remove roof lock cylinder (1).
8.Remove roof drive cylinder upper portion from roof link assembly (5).
- Remove retaining plate (4) of roof drive cylinder.
- Remove roof drive cylinder (2).










9.Remove roof lock cylinder lower portion from roof link assembly.
- Remove clip (2) of roof lock cylinder.
- Remove roof lock cylinder (1).
10.Remove roof drive cylinder lower portion from roof link assembly.
- Remove retaining plate (4) of roof drive cylinder.
- Remove roof drive cylinder (3).










11.Cut clip (1) of roof drive cylinder lower portion using nippers (2)
as shown in the figure.





12.Take out roof lock cylinder (1) and roof drive cylinder (2)
together in the direction as shown by the arrow in the figure.





13.Remove trunk lid drive cylinder (1) from trunk link (2).
- Remove hydraulic pump assembly.
- Remove clip of trunk lid cylinder. Remove trunk lid cylinder.
14.Remove hydraulic hose from hydraulic cylinder.
- Record the installation position of hydraulic cylinder and hydraulic hose.
- Put a paint mark showing the clip band position of hydraulic hose.
- Cut clip band using nippers.
- Remove hydraulic hose.

CAUTION:
Never damage hydraulic hose.

HYDRAULIC HOSE ASSEMBLY

Removal





1.Remove the hydraulic hose retaining clip (1) using a flat-bladed screwdriver as show in the figure.

CAUTION:
- Disengage the clip slowly and carefully.
- Place shop paper under the cylinder to catch any hydraulic fluid that may spill.





2.Remove the hydraulic hose (1) from cylinder (2).

INSTALLATION

Install in the reverse order of removal.

CAUTION:
- Prepare the service cylinder for fitting. Remove retaining clips and remove blind plugs.
- Check the connection bore profile if the O-rings are removed from the blind plugs.
- Remove O-ring, if not removed, using a pin that is not sharp.
- Normally, O-ring is attached to blind plugs.
- Check connections including O-ring for damage and cleanliness.





1.Slide retaining clip (1) of new hydraulic cylinder (2) toward outside as shown in the figure, remove blind plugs (4), and remove
O-ring (3).





2.Apply hydraulic oil to O-ring (1), and install it to hydraulic hose body.

CAUTION:
Never damage O-ring.





3.Install the hydraulic hose (1) to the cylinder (2).

CAUTION:
- Never damage O-ring.
- Install hydraulic hose slowly and carefully.





4.Slide the hydraulic hose retaining clip (1) using a flat-bladed screwdriver to the position (2) as show in the figure.
5.Install hydraulic hose to the paint mark position and fix using the specified clip band.
6.Install the hydraulic cylinder to the roof mechanism.
7.Work Support.
- Open relief valve of oil pump.
- Select roof open and close function on "Work Support" using CONSULT-III.
- Operate oil pump toward roof open for 5 seconds, and then toward roof close for 5 seconds.
- Close relief valve of oil pump.

CAUTION:
- Full open and fully close the roof 3 times and check for leakage from hydraulic cylinder.
- Always install component parts like clips and hoses to the original installed positions.
- Check oil level before and after each cycle. A lower level due to oil leakage may cause hydraulic pumps damage.
8.Install all of the removed component parts.

REFILLING

Fill and bleed of hydraulic system
Checking oil level
1.Close the roof completely.
2.Remove the trunk room trim. Refer to "Removal and Installation" Removal and Installation.
3.Lift the hydraulic unit pump carefully from the hydraulic unit assembly position.
4.Remove the foam cover.





5.Put the hydraulic unit pump in the horizontal position and check that the oil level is between "MIN" and "MAX" (A).
Filling oil
1.Remove the filling plug.
2.Fill with hydraulic oil to the max mark on the reservoir using a suitable and clean funnel.
3.Tighten filling plug to the specified torque. Torque: 2.0 Nm (0.2 kg-m, 18 in-lb)
NOTE:
- Approximately 250ml of 560ml of oil is drained from the system during removal and installation procedure.
- Be sure to refill oil to the specified level.

CAUTION:
- Never overtighten torque.
- Fully open and fully close the roof 3 times. Check for leakage and check oil level.
- Filler plug must be tightened to the specified torque for preventing oil leakage.