Test Note 1-11
Fig.4:
Test Note 1. Depressurise the power hydraulics system:
To depressurize the power hydraulics system, pump the brake pedal until it gives a hard feel. The total number of brake applications should be a minimum of 18.
Test Note 2. Fit the power booster unit adaptor:
A. Disconnect the power hydraulics pipe at the booster unit.
B. Fit adaptor JAO (10 mm thread) and seal washer to the power booster (2, Fig 4).
C. Reconnect the feed pipe to the adaptor.
D. Remove the most accessible blanking plug from the adaptor.
E. Fit and tighten the P & M. C test point 04 (6 mm thread) and-seal washer (1 and 3, Fig 4).
Fig.5:
Test Note 3
The pipe must always be connected to the gauge first since the test point has a one-way valve fitted and incorrect fitment could result in loss of fluid at high pressure.
CAUTION: ALWAYS CONNECT THE FLEXIBLE PIPE TO THE GAUGE BEFORE CONNECTING TO THE TEST POINT.
Test Note 4. Fit the valve block adaptor:
A. Disconnect the power hydraulics pump feed pipe at the valve block.
B. Fit the relief valve adaptor JRVO (12 mm thread) and washer to (1, Fig 5) in the direction of fitment indicated by the
C. Reconnect the power hydraulics pump feed pipe to the adaptor.
D. Remove the most accessible blanking plug from the adaptor.
E. Fit and tighten the P & M. C test. point 04 (6 mm thread) and seal washer (2 and 3, Fig 5).
Test Note 5. Remove the valve block adaptor:
A. Switch off the engine.
B. Remove pipe and gauge assembly from valve block adaptor. Use a cloth to absorb spillage from residual pressure in the pipe.
Test Note 6. Remove the booster unit adaptor:
A. Switch off the engine.
B. Pump the brake pedal until it gives a hard feel.
C. Remove the pipe and gauge assembly from booster unit.
D. Remove the adaptor.
E. Reconnect the power hydraulics pipe to the booster unit.
Fig. 6:
Test Note 7. Bleed the power hydraulic system:
CAUTION: Use only CASTROL HYDRAULIC SYSTEMS MINERAL OIL (HSMO) when filling the system.
Drive the vehicle on to a ramp. Open the bonnet. Check/top up the power hydraulic system reservoir with new (HSMO) oil. Firmly apply the handbrake. Ensure that the vehicle is in "P" (AUTO ONLY). Ensure that the vehicle is in Neutral (MANUAL ONLY). Start the engine. Raise the ramp. Disconnect the ride height sensor link rod (1 Fig 6) from the RH wishbone, and raise the ride height sensor link arm (2 Fig 6) 2-3 cm. The rear of the vehicle will rise. Stop the engine when "pulsing" is felt in the strut feed pipe. Remove the dust cover from the bleed screw, located at the top of the LH strut assembly. Using a suitable pipe and container, bleed out 1/2 - 3/4 pint of hydraulic fluid.
Note: The vehicle will return to its normal height during the bleeding operation. lower the ramp. Check/top up the power hydraulics system reservoir. Start the engine. Raise the ramp. Raise the ride height sensor link arm 2"-3 cm. Stop the engine when "pulsing" is felt in the strut feed pipe. Repeat the bleeding procedure. Refit the bleed screw dust cover. Lower the ramp. Check/top up the power hydraulics system reservoir. Start the engine. Raise the ramp.
Fig. 7:
Using the ride height sensor link arm, raise the rear of the car. When "pulsing" can be felt in the strut feed pipe, reconnect the link arm to the RH wishbone. The vehicle will return to its normal ride height.
Lower the ramp and switch off the engine. Check/top up the powet hydraulics system reservoir. Finally, perform the steering system bleed procedure as follows:
Remove the steering system reservoir cap. Top up to the correct level, between the "ADD" and "H" marks. Run the engine and after 30 seconds running, perform three lock-to-lock maneuvers. Allow to run for a further 60 seconds then turn off and allow to stand for 5 minutes. Check reservoir and, if necessary, top up to the correct level.
Test Note 8. Fit the ride levelling strut adaptor:
A. Remove the ride levelling bleed screw.
B. Fit and tighten test point 05 (12 mm thread) and seal washer (1, Fig 7).
Test Note 9. Remove ride levelling strut adaptor:
A. Suspend the rear wheels.
B. Remove the pipe and gauge assembly.
C. Remove the adaptor.
D. Refit the bleed nipple.
E. Carry out the strut bleeding procedure - refer to Test Note 7.
Test Note 10.
As a normal occurance, the relief valve in the valve block may be heard operating when the
Test Note 11.
Vehicles within the VIN. range 594576 to 617978 may be modified by fitting ride height sensor DBC 6170 provided PHB high pressure hose CCC 2625 is fitted to the vehicle.
Vehicles within the VIN range 594576 may be modified by fitting ride height sensor DBC 6170 provided:
1. PHB high pressure hose CCC 2627 is fitted to the vehicle.
2. The pressure relief valve in the valve block is replaced with revised relief valve CCC 3832 using Service Tool JD 176.
Fig. 8 identifies the revised pressure relief valve.