Hydraulic Hose Repair Installation Procedure
HYDRAULIC HOSE REPAIR INSTALLATION PROCEDURECAUTION:
The unions must be turned counter clockwise to be installed on the hoses.
1. Install the outer unions to the ends of the hydraulic hoses. (Figure 17)
CAUTION:
When inserting the inner union and starting to screw it into the outer, there is a tapered lead on its clamp tube. This must be located into the hose inner diameter. If it is not mounted properly the hose will be pushed out of the outer union as the inner union is screwed in. If this happens then the hose will not be successfully clamped between the inner and outer parts of the union.
2. Install and fully tighten the inner unions to the hoses, and install blanking plugs to the unions. (Figure 18)
3. Route the new hydraulic hoses up the left-hand A-pillar behind the instrument panel.
4. Remove the blanking plugs from the unions.
5. Connect the hydraulic hose unions and fully tighten.
6. Attach the hoses to the retaining clips in left-hand CJB aperture. (Figure 19)
7. Install new cloth tape to retain the hoses to the A-pillar, at the top edge of the instrument panel.
8. Align the latch assembly to the vehicle.
9. Remove the blanking plugs and connect the hoses to the cylinder assembly. (Figure 20)
10. Secure hydraulic hoses to latch assembly with new tie straps.
CAUTION:
The hydraulic hoses must not be trapped or pinched during the latch installation procedure.
11. Align the latch assembly to the rear bolts, and install the latch assembly. (Figure 21)
12. Support the latch assembly and install but do not tighten the two top retaining bolts. (Figure 22)
13. Install but do not tighten the remaining retaining bolts.
14. Tighten the two top retaining bolts.
15. Tighten all remaining retaining bolts.
16. Attach the sun visor electrical connectors to the latch assembly bracket. (Figure 23)
17. Attach the hydraulic hose retaining clips to the left-hand upper A-pillar. (Figure 24)
18. Connect the convertible top electrical connector. (Figure 25)
19. Install the latch cover, and tighten the retaining screws. (Figure 26)
20. Lift the rear edge of the header seal for access and install the latch cover retaining screws. (Figure 27)
21. Install the retaining studs to the header seal. (Figure 28)
22. Loosely install the left-hand CJB as follows: (Figure 29)
^ Attach the battery positive cable.
^ Tighten the retaining nut.
23. Connect the two left-hand CJB electrical connectors.
24. Refer to GTR Workshop Manual, section: 414-01 and connect battery ground cable.
25. Turn the ignition to the 'ON' position.
26. Power the convertible top to the fully raised position.
27. Power the convertible top to the fully lowered position.
28. Turn the ignition to the 'OFF' position.
29. Refer to GTR Workshop Manual, section: 414-01 and disconnect the battery ground cable.
30. Disconnect the two left-hand CJB electrical connectors.
31. Remove the left-hand CJB as follows: (Figure 29)
^ Remove the retaining nut.
^ Detach the battery positive cable.
32. Inspect the hydraulic hose unions for leaks.
CAUTION
Suitable foam padding must be installed around the unions to protect against Noise, Vibration and Harshness (NVH) concerns.
33. If no leaks are evident, install insulation padding.
34. Install the trim finisher to the header rail, and install the retaining clip. (Figure 30)
35. Refer to GTR Workshop Manual, section: 501-05 and perform the following:
^ Install the A-pillar trim panel.
^ Install the sun visor retaining clips
^ Install the sun visors
^ Where installed, connect the microphone harness electrical connector. (Figure 31)
36. Refer to GTR Workshop Manual, section: 501-12 and install the overhead console.
37. Refer to GTR Workshop Manual, section: 418-00 and install the left-hand central junction box (CJB).
38. Refer to GTR Workshop Manual, section: 414-01 and connect the battery ground cable.
39. Power the convertible top to the fully raised position.
40. Refer to GTR Workshop Manual, section: 501-05 and remove the right-hand luggage compartment side trim panel.
CAUTION:
Two fluid levels are marked on the pump reservoir body. The upper mark denotes the fluid level when the convertible top is fully lowered and the lower mark denotes the level when the convertible top is fully raised.
41. Check the convertible top hydraulic fluid level.
42. If the hydraulic fluid level is low perform the following:
^ Remove the hydraulic fluid reservoir filler plug.
^ Remove and discard the O-ring seal.
^ Using a suitable syringe, top-up the fluid until the correct level is achieved.
^ Install a new O-ring seal.
^ Install the hydraulic fluid reservoir filler plug.
43. Refer to GTR Workshop Manual, section: 501-05 and install the right-hand luggage compartment side trim panel.