HYDRAULIC HOSE REPAIR REMOVAL PROCEDURE

1. Open door.

2. Turn ignition 'ON'.

3. Power the convertible top to the fully lowered position.

4. Turn ignition 'OFF'.

5. Refer to GTR Workshop Manual, section: 414-01 and disconnect battery ground

cable.

6. Refer to GTR Workshop Manual, section: 418-00 and remove the left-hand central

junction box (CJB) for access.

7. Refer to GTR Workshop Manual section 501-12 and remove the overhead console.

8. Where installed, disconnect the microphone harness electrical connector. (Figure 1)

9. Refer to GTR Workshop Manual section 501-05 and remove the sun visors.

10. Remove the sun visor retaining clips.

11. Remove the header rail retaining clip, and remove the trim finisher from the header

rail. (Figure 2)

12. Remove the retaining studs from the header seal. (Figure 3)

13. Lift the rear edge of the header seal for access and remove the latch cover retaining

screws. (Figure 4)

14. Remove the remaining latch cover retaining screws and remove the latch cover

from header rail. (Figure 5)

15. Disconnect the convertible top electrical connector. (Figure 6)

16. Detach the hydraulic hose retaining clips from the lefthand upper A-pillar. (Figure

7)

17. Detach the sun visor electrical connectors from the latch assembly bracket. (Figure

8)

18. Slacken and remove the seven latch assembly to header rail lower retaining bolts.

(Figure 9)

19. Slacken and remove the latch assembly to header rail upper retaining bolts. (Figure

10)

CAUTION:

When carrying out the following step 20, the retaining bolts installed in the open-

ended slots MUST NOT BE DISTURBED.

20. Remove the latch assembly rear retaining bolts. (Figure 11)

21. Support the latch assembly and loosen but do not remove the retaining bolts

installed in the rear slotted holes. (Figure 12)

22. Lower the latch assembly.

23. Mark the hydraulic hoses with locations and disconnect the hoses from the cylinder

assembly. (Figure 13)

24. Remove the latch assembly.

25. Install suitable blanking plugs to the convertible top latch cylinder and hydraulic

hoses.

26. Remove the tie strap retaining hydraulic hoses to the latch assembly. (Figure 14)

27. Remove and discard the cloth tape retaining the hydraulic hoses to the A-pillar at

the top edge of the instrument panel.

28. Detach the hoses from retaining clips in left-hand fuse box (CJB) opening. (Figure

15)

CAUTION:

The hydraulic hoses must be marked so the new hydraulic feed and return hoses are

connected correctly.

29. Mark the hoses ready to be cut, approximately in the middle of the left-hand CJB

opening, between the two retaining clips.

30. Route the hoses from behind the instrument panel to the lower A-pillar.

31. Cut both hydraulic hoses, and clean away any spilled fluid. (Figure 16)

..

HYDRAULIC HOSE REPAIR INSTALLATION PROCEDURE

CAUTION: 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.