Hydraulic Power Unit

REMOVAL
1. CONFIRM THAT GEAR IS IN N POSITION
2. REDUCE ACCUMULATOR PRESSURE
3. REMOVE SUSPENSION UPPER BRACE
Remove the 2 bolts, 2 nuts and suspension upper brace.
4. REMOVE AIR CLEANER CAP, AIR FILTER AND AIR CLEANER CASE
a. Disconnect the MAF meter connector, VSV connector for CCV and vacuum hose.
b. Disconnect the 2 clamps, and remove the air cleaner cap.
c. Remove the air filter.
d. Remove the 2 bolts and air cleaner case.
5. DISCONNECT SOT SYSTEM HOSES
6. REMOVE HPU ASSEMBLY
a. Remove the reservoir cap cover from the HPU assembly.
b. Install a reservoir cap seal.
Part the No.: Reservoir cap seal: 90080-30087





c. Disconnect the HPU connector from the HPU assembly.





d. Remove the 3 bolts and the HPU assembly.
7. REMOVE HPU BRACKET FROM HPU
Remove the 3 bolts and HPU bracket.

DISPOSAL
DISPOSAL ACCUMULATOR





a. Remove the accumulator from the HPU.
b. Place the accumulator in a vise.
c. Using a saw, discharge the gas inside by making a hole in the hatching area.

CAUTION:
^ The gas discharging is colorless, odorless and harmless.
^ Saw a hole while covering the saw with a shop rug be cause chips may fly up.

REPLACEMENT
1. REPLACE SUB-WIRE





a. Using small screwdrivers, pry out the terminal retainer.
b. Cut off the clamp which is attached to the sub-wire.





HINT: Place markings on each terminal before removing the terminals.





c. Release the locking lug of the 6 terminals when pull the 6 terminals out from the rearward.

NOTICE: Pull the 6 terminals put one by one with much care.

d. Disconnect the sub-wire connector from the accumulator pressure sensor.
e. Connect the sub-wire connector to the accumulator pressure sensor.
f. Connect the 6 terminals to the sub-wire connector.
g. Install the terminal retainer.
h. Attach the clamp to the sub-wire.
2. REPLACE RUBBERS





a. Remove the 3 rubbers and 3 spacer tubes from the HPU bracket.
b. Apply water to 3 new rubbers.
c. Install the 3 rubbers and 3 spacer tubes to the HPU bracket.

INSTALLATION
1. INSTALL HPU BRACKET TO HPU
Install the HPU bracket with the 3 bolts.
Torque: 22 Nm (224 kgf-cm, 16 ft. lbs.)
2. INSTALL HPU ASSEMBLY





a. Install the HPU assembly with the 3 bolts.
Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)





b. Connect the HPU connector to the HPU.
c. Remove the reservoir cap seal.
d. Install the reservoir cap cover to the HPU.
3. CONNECT SMT SYSTEM HOSES

NOTICE: Exchange the O-ring of 3 system hoses with new one.

4. CHECK SMT SYSTEM FLUID LEVEL
5. INSTALL AIR CLEANER CASE, AIR FILTER AND AIR CLEANER CAP
a. Install the air cleaner case with the 2 bolts.
b. Install the air filter.
c. Attach the air cleaner cap to the air cleaner case, and install the 2 clamps.
d. Connect the MAP meter connector, VSV connector for CCV and vacuum hose.
6. INSTALL SUSPENSION UPPER BRACE
Install the suspension upper brace with the 2 bolts and 2 nuts.
7. PERFORM INITIAL LEARNING OF SMT SYSTEM
8. CHECK FOR LEAK