Accumulator Assemblies – Removal and Fitment

Applicable to SZ cars

Difficulties with the Low Pressure Return Hoses

Difficulties often arise particularly on SZ Vehicles with their accumulators located at the rear of the B-Bank Crankcase. This applies to all Turbocharged vehicles and to all vehicles from Chassis 30,000 onwards.

On removing an accumulator assembly from the vehicle, two common difficulties arise using the normal procedure.

1) The hose may be very difficult to slide from the return adaptor on the accumulator valve body. The adaptor is of a composite material and may be damaged or broken through excessive force when removing the hose. In this case, it is wise to cut the hose free from the accumulator assembly and to remove the remaining piece of hose on a bench.

2) Once removed, and after a few such operations over time, the hose end becomes damaged or weakened, therefore difficult to seal upon refitting

The original hose is of the exact length required, and fitting the hose to the accumulator is difficult in the confined space. Furthermore, if the hose has been shortened by cutting it free from the accumulator assembly, it will not be possible to refit the accumulator without replacing or extending the hose. The original hose is only about 30cm long, and clamps to a tube beneath the firewall. Replacing the hose without removing the engine is very difficult.

Action for Each Accumulator Assembly – fit a hose extension

1) Obtain a 40cm length of reinforced hose suitable for use with HSMO - LHM – Mineral Oil Hydraulic Fluid. A compatible hose is a reinforced Automatic Transmission Cooler hose. The internal hose diameter is 3/8”. Also source a two-way inline hose connector.

Suitable hose is 3/8” H514 automatic transmission cooler hose. This is a high-temperature hydraulic mineral oil hose rated at 60 bar and exceeds the requirements in every respect. H514 hose is available at Autopro, Supercheap or ENZED, as are suitable connectors. Autopro part number 06007-06 is the ideal connector. Quality generic hose clips are suitable. Obtain at least four hose clips for each accumulator.

2) Shorten the existing hose on the vehicle until the weakened or used section is removed.

3) Insert a two-way 3/8” brass hose connector, and connect the new hose length. Clamp with a pair of Jubilee or similar hose clips.

4) Place two more hose clips over the lower end of the hose. One is for immediate use and the other a spare in case any hose clip fails at any time.

5) With the hose hanging down beneath the chassis, it may readily and safely be fitted over the accumulator return adaptor and clamped with one of the remaining hose clips. Secure the remaining hose clip against moving or rattling.

6) Rotate the accumulator assembly and raise it to its final position, ensuring that the hose extension forms a smooth loop with no kinks. Typically, the loop will rest neatly between the two accumulator pressure tubes once secured. Secure the accumulator loosely on its mounting bracket.

7) Reconnect the accumulator pressure tubes (using new rubber sealing sleeves on early cars). Tighten the tubes, then tighten the accumulator assembly to its mounting bracket.

When removing the accumulator assembly for service at a later time, the assembly may safely be lowered beneath the chassis for the convenient removal of the hose from the accumulator. Should it at any time be necessary to cut the accumulator free from the hose, then there will likely still be adequate spare hose length after the hose has been so shortened.

rht 14-Feb-11