XPartMGF Hydragas Suspension Replacement Kit - XPT006310

Fitting Instructions

Contents Page1. Before you start Safety Advice ................................................. 1 General Advice .............................................. 1 Advisory Notes ............................................... 1 Check the Kit contents ................................... 2

2. Fitting Instructions Vehicle Preparation ........................................ 3 Right Front - removing the old hydrolastic suspension .................................................... 4 RightFront-fittingthenewsuspension replacement kit ............................................. 7 Right Fear - removing the old hydrolastic suspension .................................................... 8 RightRear-fittingthenewsuspension replacement kit ............................................. 9 Left side of the car - preparation ................... 10 Left front - removing the old hydrolastic suspensionandfittingnewreplacement suspension kit ............................................... 10 Left rear - removing the old hydrolastic suspensionandfittingnewreplacement suspension kit ............................................... 11 Finetuningthenewsuspension .................... 13 Removal of the hydragas system pipes ........ 14

3. Vehicle Insurance Vehicle insurance declaration ........................ 15

Vehicle InsurancePleasebeawarethatthemajorityofmotorvehicleinsurerswillrequireyou,theowner,toadvisethemofchangesmadetoyourvehicle.OwnersofcarsfittedwiththeXPartHydragasSystemReplacementKitshouldadvisetheirinsurersthattheconversionhasbeencarriedout.Shouldyourinsurancecompanyrequestit,XParthaspre-preparedadeclarationthatyoucansendtothem,itcanbefoundinSection3,Page15oftheseFittingInstructions.Please note that XPart cannot guarantee that your vehicle insurance company will provide insurance as a result of the declaration.

Credit and Thanks CreditandthanksfromXPartgotoRogerParkerforhisoriginalwords,photographyandtestfittingthatprovidesthebasisofthispublication.

Thispublicationoranypartofitmaynotbereproducedwithoutpriorconsentoftheauthor.Thispublicationiscopyright©XPart2017.

Ifyouhaveanyqueriespleasecontact:xpart.communications@neovialogistics.com

Safety AdviceThisMGFHydragasSuspensionReplacementKithasbeendesignedandmanufacturedtobefittedasacom- pletesystem,replacingtheoriginalhydragasdisplacersANDoriginaldampers.Undernocircumstancesshouldany attempt be made to combine the use of original and MGF Hydragas Suspension Replacement Kit parts. Additionally under no circumstances should any attempt be made to open or dismantle a Hydragas Suspension Replacement Unit. The coil spring inside is under considerable tension and unauthorised dismantling without the special equipment needed poses the real risk of serious injury or even death!FittingtheMGFHydragasSuspensionReplacementKittoanMGFiswithinthecapabilityofanownerwhoiscompetentandfamiliarwithworkingonmanyaspectsoftheircarbeyondsimpleservicing,andwhohasacomprehensiveselectionoftoolsandgoodworkingfacilities.However,XPartrecommendthatitisfittedbycompetentmotorengineersandthatthefittinginstructionsarestrictlyadheredto.Ifinanydoubt,seekprofessional assistance.AsaguidetoprofessionalfittingcostsitisworthnotingthattheMGRovertimeallocatedforthereplacementof standard displacers and dampers is listed at 2 hours per side. Fitting the MGF Hydragas Suspension Replacement Kit should occupy a similar time frame. Note! Any seized nuts, bolts or other fixings, which is a quite reasonable expectation on a car made before 2002, will lengthen that time.Thehydragassuspensionsystemoperatesatveryhighpressures,nominally400psi,sohastobegivenrespectifinjuryistobeavoided.Thissystemneedstobedepressurisedbeforethehydragascomponentsareremovedandwecanonlyadvisetheuseofthespecifichydrolasticsuspensionpumptocompletethisprocess. Obviously one of the huge advantages of the MGF Hydragas Suspension Replacement Kit is that the hydrolastic pump is never needed again.TheinstructionsthatfollowareintendedtobereadinconjunctionwiththeWorkshopManual,copiesofwhicharewidelyavailable.Note! There is only the factory Workshop Manual, no Haynes or other aftermarket manual has been published.ThefittingoftheMGFHydragasSuspensionReplacementKitshouldbecompletedonahardandlevelsurface,e.g.concreteanddueconsiderationgiventothenormalsafetyproceduresandanyadditionalsafetysuggestions noted here.

General AdviceTheMGFhydragassuspensionissplitintotwoseparatesubsystems,interconnectedfronttorearoneachside,withasinglehighpressurevalveconnectionperside.Whendepressurisingeitherofthetwovalveswillseethesuspensionwillsettletothebumpstopsbothfrontandrearonthatside.ForthisreasonwesuggestthatthefittingoftheMGFHydragasSuspensionReplacementKitbedoneonesideatatime,andthatthesidetobeworkeduponisraisedandplacedonstandsBEFOREdepressurisation.Note! In addition to the safety advice seen at the start of these instructions, the car must not be driven with original suspension on one side and the new replacement suspension on the other, other than for simple manoeuvring to gain better access for fitting the replacement system to the remaining side.

Advisory note 1Beforedisconnectingthecarsbattery,checkthatthekeywilloperatethecentrallockingthroughthedriversdoorlock.Ifitdoesn’tthenitmeansthatthereisnocommunicationbetweenthedriversdoorlockswitchandthealarmECUandifyoudisconnectthebatteryyouwillNOTbeabletoresynchroniseandsothecarwillbeimmobilisedandneedtoberecoveredtoagarage/dealer/autoelectricianwithappropriatediagnosticequipmenttorectify.Assumingthatthecentrallockingsystemfunctionsusingthekeyinthedriver’sdoor,thefollowingwillallow

Page 1

1.Beforeyoustart

re-synchronisation of the fobs on the key ring to the cars alarm.MGFsusetheLucas5ASalarmsystemandwhenthebatteryisdisconnectedtherollingcodesynchronisationbetweenthetwoalarmfobsonthetwosetsofkeysallcarshave(had!)willbelostandtheprocessofre-synchronisation is listed in handbooks.ItisasimpleprocessofinsertingthekeyintothedriversdoorandturningittotheUNLOCKposition,followedbyrapidpressingofthelockbuttonofthealarmfobandafterseveralpressesthecarwillremotelylockandthenrespondnormallytounlockandlockcommands.Thisprocesshastoberepeatedforthesecond(andanyadditional)fobs.Note! MGF 1.6 models did not have remote central locking as standard, only key operated central locking; all other MGFs had remote locking.

Advisory note 2 ManyradiosinMGFshaveasecuritycode,whichwillbeneededtoreactivatetheradiooncethebatteryisreconnected.Ensurethatifyoursisonethathasasecuritycodethatyouhavethecode,andalsothemethodofenteringthecode.Therearedifferentmethodsfordifferentradiosandwecan’tprovidethisinformation.

Advisory note 3PriortofittingXPart’shydragassuspensionreplacementkit,theoriginalsuspensionmustbecheckedthoroughly,wornpartscanresultinunwantednoiseandhandlingcharacteristics.Wornordamagedcomponentsmustbereplaced(exceptthosepartsrelatingtothehydrolasticsystemthatwillbereplacedbythenewkit).

Check the Kit Contents - XPT006310Checkthecontentsofthekitagainstthelistbelow:

2xFrontXPartreplacementMGFdampers-XPT006330

2xRearXPartreplacementMGFdampers-XPT006320

2xFrontXPartreplacementMGFspringunits-XPT006350

2xRearXPartreplacementMGFspringunits-XPT006340

4xLockingrings(fittedtoreplacementMGFspringunits)

1xFittingNotes

1xBagcontaining:

4xSuspensionreboundstops-2A4267SLP (failure to fit these rebound stops may invalidate the kit warranty)

4xSuspensionReboundStopScrews-13H2776

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1.Beforeyoustart

Vehicle preparation1. Chockthewheels(Fig.1)onthesideofthecarnotbeing

workeduponfirst,thereisnoruledictatingwhichsidetostartwith.Theseinstructionsshowreplacementofthedrivers(right)sidefirst.

Thenextactionistoloosenthewheelnutsonthatsideandraisetherightsideofthecartoacomfortableworkingheightandplacingaxlestandsunderneath(Fig.2-3).

Note! The subframes offer very solid secure points to place axle stands, but try and position them so they are not directly under the displacers.

Thenremovethefrontandrearwheels.

Page 3

2. Fitting Instructions

Figure1,Chockthewheels.

Figures2-3,Placeaxlestands,frontandrear.

Figure4,Undothetwo10mmplasticnuts.

2 Openthebonnetandundothetwo10mmplasticnuts(Fig.4)holdingtherightedgeofthethinplasticmouldingthatcoverstherearoftheunderbonnetspace,thenliftthemoulding’s tabs off the studs.

Figure5,Priseouttherivetsection.

On the left side of the car is a scrivet holding the moulding totheheaterairintakevent(Figure5).(Ascrivetisatwopiececombinationofaplasticscrewandplasticrivet,wherethescrewcentrepushesout‘wings’oftheouterrivetwhenitisinserted).Unscrewthecentralscrewusingacrossheadscrewdriverandthenpriseouttherivetsection.

Removethesparewheelandtoolstogiveaccesstotheloweredgeoftheplasticmoulding,whichisretainedontwo‘barbed’studs.Pullthemouldingforwardstodisengagefrom the studs and then lift and ease the moulding out from aroundthebrakemastercylinder/servoandfromunderthescreen panel.

Vehicle preparation continued3. Thehydragaspipesandtwovalveconnectionpointsare

thenseenbehindthewasherbottle(Fig.6).Thevalvesarevisually identical to tyre valves but remember that there is around400psibehindthemsomefifteentimesthepressureseeninMGFtyres!!ThereforethecommonInternetdiscussedandusedmethodofawrappingaragaroundthevalve and pressing the valve centre to release pressure is not recommended.

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2. Fitting Instructions

Figure6,Twovalveconnectionpoints.

Figure7,Hydrolasticpumpandadaptor.

4. Therightsidesuspensionneedstobedepressurised(nottheleftsideatthistime)andtheimageshowstheuseofacorrecthydrolasticpumpwiththecorrectadaptorthatscrewsontothevalveandthepressureiscontainedwithinthepump.Movingthecontrolleverfrom‘pressurise’to‘depressurise’allowssimpleandsafedepressurisationofthesuspensionandthecollectionofthefluidinsidethepumpreservoir.

Figure8-9,Undoscrivetsandscrews

Figure10,Peeloutfrontinnerwheelarchliner.

Right front - removing the old hydrolastic suspension 5. Removethefrontinnerwheelarchliner(Fig.8-10).This

isretainedbythreecrossheadscrewsandthreeplasticscrivets,thescrewsbeingsteelmaybecorrodedanddifficultto remove.

Withallsixretainersremovedthelinerhastheedgenearestthewheelarch‘peeled’outfirsttoallowittoberemoved.

6. IfthecarhasABS,removethesensorcablefromtheretainingclips,whichareheldinplacebytwoofthedisplacersfrontretainingplatebolts,andeasethecabletoone side. Take care to avoid damage to the sensor.

7. Removethedamper(commonlyanderroneouslycalledashockabsorber,springsareshockabsorbers),byfirstremovingthelowerfixingbolt.Wirebrushingthenutandbolt(Fig.11)andapplyingsomelubricationtothethreadmakesforeasierremoval.Makeaspecificnoteofthepositionsofthebrakehoseclamp,spacerandtwowashers.Theimage(Fig.12)showsthecorrectorientationasitispossiblepreviousowner’sinterferencemayhaveseenincorrect reassembly.

Whentheboltisremovedcheckitisstraight,replacingorrectifying as needed.

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2. Fitting Instructions

Figure11,Wirebrushingthenutandbolt.

Figure12,Notethecorrectpositionsofthebrakehoseclamp,spacerandtwowashers.

8. Thedamperisnowhangingfromthetopfixingonly,andbestaccess to this is achieved by unclipping the electrical plug connections to the horns and then removing them and their bracketsfromthecarschassisleg(Fig.13).

Figure13,Removehornsandbrackets.

Figure14,Removethedamper.

Damperremovalwillrequirethetopshaftofthedamperbeingheldwhilstthenutisloosenedwithaspanner.Oncethenutisloosetakeholdofthedamperbodywithyournowsparehandtopreventthedamperdroppingoutwhenthenutisspunoff.Removetheupperwashersandrubberbush(Fig.14).

9. Placeafluidcatchtrayunderthedisplacerpositiontocollectspilthydrolasticfluid,andleaveitthereuntilyouhavefinishedthisside.Frominsidetheunderbonnetarealoosen the nut clamping the hydragas pipe to the displacer (Fig.15-16).Removethepipefromthedisplacerandpushitdownwardstoallowsomefluidtodrainintothetray. Leave it there until you have also removed the rear displacerconnectionasfurtherfluidwilldrainwhentherearis disconnected.

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2. Fitting Instructions

Figure15-16,Removepipefromdisplacer.

Figure17-18,Removethedisplacer.

10.Movebackunderthewheelarchtoremovethedisplacer.Itisheldbythefrontplate(Fig.17),thatissecuredtothesubframebyfourbolts;thelowertwousingcaptivenuts,buttheuppertwohave‘free’nuts,meaningyouhavetoplace a spanner on from behind. Once the plate is removed (Fig.18)thedisplacerisgentlypulledforward(Fig.19)todisengagethelocatingring,liftedandtiltedforwardtodisengagefromthe‘rollerfootjoint’,morecommonlyknownasthe‘knuckle’.Theremaybeaneedtogentlytapandprisetheknucklefromthedisplaceralloyshaft(piston).

Note! These knuckles do wear and should be checked as poor knuckles will impair the ride quality and generate noise.

11. Retainthespacerwasher(Fig.20)thatsitsovertheshaftofthe‘knuckle’andcleanoffanydirtorcorrosion.

Thespringfoundbetweenthe‘knuckle’anddisplacerisnotrefitted.Alightsmearofcoppergreasewillhelpreduceanyfuture sticking problems.

Check the rubber damper bump stop is in place and has not been damaged or lost. If lost or damaged then a replacementwillbeneeded.

Replacetheoldreboundbumpstopandscrew(insetFig.20),locatedunderthetoparm,betweenthearmandthesubframe,withnewonessuppliedwiththesuspensionreplacement kit.

Note! Failure to fit these rebound stops may invalidate the kit warranty.

Figure19,Gentlypulldisplacerforward.

Figure20,Retainthespacerwasher.

Right front - fitting the new suspension replacement kit12.Selectanewfrontsuspensionreplacementunit(check

thelabelontheunitFig.21),windouttheadjusteruntilitprotrudesby4mmfromthehexonthespringseat.Dropalockingringovertheknuckleshaft,thenfitthesuspensionunitovertheknuckle’sshaft(Fig.22).Ifthebodyofthesuspension unit is fouling the cars body and it can’t be slid overtheknucklepintemporarilywindbacktheadjuster,fittheunitandwindbackout.Onceslidontotheknuckletheunitcanbeplacedhomeinthesamewaytheoriginalhydragasunitsat.Thefrontcoverplateisthenfittedtolockthenewunitinplace(Fig.23),notingtoreplacetheABScable clips and cable if appropriate.

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2. Fitting Instructions

Figure21,Checklabel.

Figure23,Lockthenewunitinplace.

Figure22,Fitunit.

13.Oncefittedinplace,usingafelttippenorsimilarmarkthefrontflatofthehexagon(Fig.24),windoutthehexagonadjuster(Fig.25)fromthenewfronthydragassuspensionreplacementunitby18turns(Fig.26).Fitthelockingringtothethreadedadjusterbutdonottighten.

Fine tuning of the ride height can be done after the car has hadasettlementdriveandiscoveredinstep42,later.

Figure24,Markflat.

Figure26,Adjuster,woundoutby18turns.

Figure25,Windout.

Figure27-28,Feedthreadedshaftthrough-replace rubber.

14.Thenewdamperisfitted,notingthatthefrontonesdonothavetheoffwhitecolouredbumpstops.Thedampersupper dust cover needs to be slid on from the bottom and engagedontotheconcavetopfixedplate.Removethetoplocknut,concavewasherandupperrubber,leavingthelowerrubberandconcavewasherinplace.Feedthethreaded shaft of the damper up through the cars body dampermounting(Fig.27)andreplacetherubber(Fig.28)

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2. Fitting Instructions

Figure29-30,Replaceconcavewasher(con-caveface,facesrubber)-andnylocnut.

andconcavewasher(Fig.29)(concavefacealwaysfacestherubber),followedbyfingerscrewingthenylocknut(Fig.30)onasfarasyoucan.Finaltighteningofthisisdoneafterthenextstep.

15.Refitthelowerdamperbolt(Fig.31)throughthetoparm,feedingitthroughtheflexiblebrakehosebracket,slidingonthetubularspacerandsmallerwasherontoo.Nextslidethedamperslowerbushontotheboltandthenthelargeconcavewasher(dishfacingawayfromthedamperbush)beforerefittingthenylocknut.Boththisnutandboltandthentheuppermountingnutarefullytightened,37Nmtorqueloadingfortheuppernutand45Nmforthelowernutandbolt.Ensurethateachcomponentontheboltisinthesameorderasshownintheimage(Fig.32).

Note! The main shaft will need to be held with mole grips or similar (Fig. 33) whilst the upper nut is tightened as was needed for its removal. (Most torque wrenches will not allow the shaft to be held and tightened at the same time so here a guide is to wind down until there is obvious compression of the rubber of approximately 1/3rd from its uncompressed state).

16.Refitthehornsandelectricalconnectionsandthenrefittheplasticunderwingshields.

Figure31,Refitthelowerdamperbolt.

Figure32-33,Componentorderasshown-holdshaftwithMolegripswhiletheuppernutis tightened.

Figure34,Removethegrille.

Right rear - removing the old hydrolastic suspension 17. Open the boot and remove the grille covering the access to

therearoftheenginebay(Fig.34).

Figure35,Movethecoolantexpansiontank.

18. To access the rear right top damper mounting and the displacersfluidconnectionrequiresthecoolantexpansiontanktobemoved(Fig.35).Itisheldinplacebytwo8mmheadedboltsandanextension‘peg’onthetank’smouldingunderneath.Withtheboltremovedthetankcanbeliftedupandthelower‘peg’disconnects.Stretchwithinthehosesdoesallowittobemovedtothesideandabovethedipstickandoilfiller.

Page 9

2. Fitting Instructions19.Moveintothewheelarchandundoandremovetheantiroll

bartolinktopnutandbolt(Fig.36)toallowthesuspensionfree movement.

Figure36,Undoandremovetheantirollbarto link top nut and bolt.

Figure37,Removethereardisplacer.

20.Removethelowerandthenupperdampermountingnutsandboltsinthesamewayasdescribedinsteps7and8toremove the rear damper.

21.Removethereardisplacer(Fig.37)inthesamewayasdescribedforthefrontremovalinsteps9,10,notingthatthere is less free space and the displacer is best lifted out throughtheenginebay,ratherthanthewheelarch(Fig.38-39).(Itmaybenecessarytogentlyleverthedisplacersalloy piston into the displacer to fully disengage the piston fromthe‘knuckle’,thespringcanbethenpulledclear.)Thenfollowtoprocessasdescribedinstep11.

Figure38-39,Liftoutthedisplacerthroughtheenginebay,ratherthanthewheelarch.

Figure40-41,‘post’thenewunitupbetweenthe body and subframe - before negotiating it into position.

Right rear - fitting the new suspension replacement kit22.Selectanewrearhydragassuspensionreplacementunit

andfitthisinfromthewheelarchand‘post’itupbetweenthebodyandsubframe(Fig.40),beforenegotiatingitintoposition(Fig.41)inthesamewayasdescribedinstep12.

23.Followthesamesetupprocessasdescribedinstep13,noting that the rear springs are higher rated and so the pre-tensioning does make this much stiffer to turn.

Page 10

2. Fitting Instructions24.Thereardamperisfitted(Fig.42)asdescribedinsteps14

and15,withthefollowingdifferences.ThistimeyouuseadampermarkedRearandtheuppernut(Fig.43)tighteningtorqueisslightlyhigherat50Nm.Therearantirollbarisreconnected(Fig.44)(45Nm).

25.Theworkonthebackwillhaveseenmorehydrolasticfluidemptyintothetrayundertheexposedendofthefrontpipe and if you have access to compressed air you can clearresidualfluidfromthelinenow,althoughthisisnotabsolutely necessary.

26.Replacethewheelsandlowerthecar.27.Refittheexpansiontank. Figure42,Fitthereardamper.

Figure43-44,Theuppernuttorqueis50Nm-reconnecttherearantirollbar,torque45Nm.Left side of the car - preparation

28.Chockthewheelsontherightsideofthecar,andloosenthewheelnutsonthefrontandrearwheelsontheleftsideofthecar.Nowraisetheleftsideofthecartoacom-fortableworkingheightandplacingaxlestandsunderneath.

Note! The subframes offer very solid secure points to place axle stands, but try and position them so they are not directly under the displacers. Then remove the front and rear wheels.

Left front - removing the old hydrolastic suspension and fitting the new replacement suspension29.Followsteps5to7.30.Theunderbonnetfusebox(Fig.45)isnowinthewayofacc-

esstothedampertopfixingsohastobemovedtooneside. Note! See the appendix with regard to the cars security

system and radio security before proceeding. Firstremovethebatterynegative(earth)terminaland

place to one side so it can’t spring back to the terminal and remakeelectricalcontinuity.Thetwosecuringboltsfortheunderbonnetfuseboxcannowberemovedandthefuseboxmovedtooneside. Figure45,Movetheunderbonnetfusebox.

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2. Fitting Instructions

Figure46,TheECUneedstobemoved.

Figure47-48,DisconnecttheECUconnectors.

31.Followthedamperremovalinstructionsinthelatterpartofstep8,andthenfollowsteps9to15.

32. Refittheunderbonnetfuseboxbutleavethebatterydisconnecteduntiltherearunitisfitted.

Left rear - removing old the hydrolastic suspension and fitting the new replacement suspension33.TheengineECUandseveralmainelectricalconnections

(Fig.46)needtobemovedtoprovideaccesstothedispla-ceranddampertopnut,andthisiswhythebatteryshouldremaindisconnected.FirstdisconnecttheECUmainconnections(oneortwodependingonageandmodel).

34.TheECUsitsonabracket(Fig.46)whichalsocarriesa number of main electrical connections. The bracket is retainedbytwoboltsonthetopedgeandaslidingfootbelow.Theupperboltholesareinfactslotssoremovetheinnerboltandjustloosentheouter,whichallowsthebrackettobeslidtowardsthecarscentrelineandthenliftedtodisengagethelowerfoot.

35. Withthebracketdisengagedyouhaveaccesstothevariousconnectionsandrelaypackunderneath.ThewiringwillnothaveenoughfreeplaytoallowtheECUandbrackettobemovedoutofthewaysodisconnectthevariousconnectors(Fig.47).Therelaypackandhalfofeachmainconnector clip to tongues pressed out from the back of the bracket and these need to be disconnected. They usually havea‘barb’typeoflockintheplasticmouldingoftheplugs that has to be gently levered as you slide it off the tongue.OncedisconnectedthebracketwithECUcanbeplacedoutoftheway.

36.Dependingontheageandmodeltherearevariousstandardairfiltersthatcanbefittedandtheyinterferewithaccesstothedisplacertovaryingdegrees,somayhavetobemovedandthatrequirestherearofthehoodtobeopened and the engine cover removed. Non standard filterscanhaveawidervariationandsoaccesswiththesewillhavetobeassessedonanindividualbasis.

Thecommonstandardairfilterfitusesapairofboltsorplasticclipstothesideofthemainfilterboxthatisfacingtheleftsideofthecar,andoneortwomouldedpegsunderthebox.Thehosebetweenairfilterandthrottlebodyalsohas to be disconnected.

Mostfiltershavejustasinglehoseentryatthefrontofthefilterbox(Fig.49),connectingtoaresonatorthatthenhasacoldairpickuphosethatcanbeinthewayasitistrailed Figure49,Airfilter-singleentryhose.

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2. Fitting Instructions

Figure50,Airfilter-dualentryhose.

past the displacer and cable tied to the subframe. This can be easily removed if needed.

Trophymodelshaveadualentry(Fig.50)withthesecondentryattherearwithitshosealsotiedtothesubframe.Thisrearpipe/hosehasasinglescrewfixinginsidethefilterboxandremovalisnotpossiblewithoutalsoremovingthemainfilterbox.

Hoodremovalissimpleandachievedbyunclippingthetwo‘hoodtoscreenframe’catchestoremovehoodtension.Thenfrominsidethecarpullforwardthereardeckcarpet(underthehoodrearwindow)whereyouseethefivemoulded‘bumpouts’toaccessthefivespringclipsthatholdtherearlowersparofthehoodframeintotherearbody channel. These are unclipped and the ends moved outofcontactwiththehoodspar.Duetothefragilityoftheoriginalplasticrearwindows,andfrequencyofcrackingiffolded,itisadvisedtounziptherearwindowstopzipandseparatethetwosideVelcrofastenerstoallowtherearwindowtoremainflatwhilsttherearofthehoodisraised.

Thehood’slowersparcanthenbeeasedoutofthebodychannelandraised,feedingthenowpartiallylooserearwindowforwardtokeepitasflataspossible.Whenmovedthroughapproximately90degreesthesparcanbetiedtoholditinthisposition,aluggagestretchbungeestrapisideally suited to clip behind the spar and the front of the hoodframe(Fig.51).

Thecarpetandinsulationunderneathisremoved,notingthat often the carpet is glued to the insulation. On 2000 modelyearcarsandnewertherearerearspeakersinanacousticboxthatmakeatightfitfortheinsulationandithas often become stuck. Gently ease a scraper or similar betweenthebottomoftheboxandinsulationtoseparatethem before sliding this out.

Themainenginecoverisnowaccessibleandtheeleven10mmheadedboltsareremoved,threeundertheacousticboxarefiddly.Thecoveristhenmanoeuvredoutasyouhave to negotiate it around three of the hood spar catches (Fig.52).

37. Do not smoke or have naked flames anywhere near when looking to do the following operation. More access room is gained by disconnecting the charcoal canister electrical connectionandquickreleaseconnection(pressinthecentrecollarandpullthepipeoff)tothefueltankline.Itisthenliftedfromtherearbulkheadandcanbesliddownandtotheside.Thefuelfeedandreturnlinesalsohavequickrelease connections and removal of these adds more space.

Figure51,Holdsparinposition.

Figure52,Removeenginecover.

Page 13

2. Fitting Instructions Note! Have a rag wrapped around the joints as they are

released as some fuel spillage will be seen, especially from the feed line (the pipe coming from the fuel filter) as this should retain some residual fuel pressure.

38.Nowfollowsteps19to26. Note! 2000 on model year cars with the electronic

speedometer (identified by a digital odometer rather than mechanical) all have an ABS sensor on the left rear even if the car is not equipped with ABS.

39.Refittheairfilter,charcoalcanisterandassociatedconnections removed for access.

40.RefittheelectricalconnectionsandECUandbracket.41. Reconnect the battery

Fine tuning the new suspension42.Takethecarforatleastatwomileruntoallowittosettle,

initiallysomeextraneoussettlementnoisesmaybeheard.On returning park the car on a level surface and measure the ride height on all four corners of the car. Measure betweenthecentreofeachwheeltotheundersideofthewheelarchlipdirectlyaboveandnotetheresults.

ThenormalofficialMGrideheightofmainstreamMGFsis368mmforthefrontand363mmfortherear,bothplusorminus10mm.MGFTrophy160SEmodelshaveameasurementthatis20mmlowerforbothfrontandrear.Thenewsuspensionsystemhasalimitedadjustmentrangetoallowtheindividualcornerheightstobeadjustedtoreach the recommended heights.

The standard ride height for mainstream MGFs is aesthetic-allyseenastoohighbymostownersandsothesuggestedheightforthehydragassuspensionreplacementkitequipped mainstreamMGFis355mmfrontand353mmrear,whilsttheTrophy160SEmodelmaintainsitsnormal348mmfrontand343mmrearheights.Forthoselivinginareaswhereground clearance is limited then the ride height can be raised totheoriginal368/363mmbyretainingthespacerremovedinstep11.Allmodelsarethenfinetunedinthesameway.

Notehowfarinerrortherideheightsaretothemeasure-mentsappropriatetoyourmodel/choice.Thehexagonadjusterswillnowneedtobeturnedanappropriatenumberofturns/flatstoraiseorlowertherideheighttowithinthedesiredmeasurements.Afullturnofthehexagonadjusterwillaltertherideheightbyapproximately6mm(approx1mmperflatofthehexagon).Thecarwillneedtoberaised(individualwheelatatimeisfine)sothattheindividualsuspensionisinfull‘droop’.Adjustthehexagon

VEHICLE FRONT (+/-10mm)

REAR (+/-10mm)

Standard 368mm 363mm

Trophy160SE 348mm 343mm

Standard Kit 355mm 353mm

Raised Kit 368mm 363mm

My car

My car

My car

My car

My car

My car

Note your MGF’s ride height below:

Page 14

2. Fitting Instructions by the calculated amount and then make a different mark

onthefrontflatforfuturereferenceandthenrefitthewheel.Oncetherideheightissettotherequireddimensiontightenthelockring,thiscanbedoneusingaflatbladedscrewdriverandagentletapwiththepalmofahand.Repeatfor the other suspension units and then go for another test drive and return to the same measuring position and recheck the ride heights. If more than 10mm in error readjust,otherwiserunthecarfor100milesandrecheck.

Note! The above instructions assume that the suspension is using standard MG components to achieve standard MG ride heights. Where the standard knuckles (roller foot joints) have been replaced with non standard lowering versions you will not be able to adjust the new units to reach the new recommended ride heights. The use of non standard knuckles with the new suspension is NOT recommended as the resulting ride heights will be too low and too close to the damper compressed limit.

Removal of the hydragas system pipes ThenewMGFsuspensionsystemremovestheneedfor

thehydragassystem,andifthereisnolikelihoodthatthevehiclewilleverrequiretoberetrofittedbacktoitsoriginalsuspensionconfiguration,thentheoriginalfronttorearinterconnectionpipeswillnotbeneeded.

The hydragas pipes have been disconnected from the dis-placerandarefreetomakecontactwithothercomponentsonthevehicle(Fig.53),itissuggestedthatpipingisfurtherdisconnectedonthefront,thisisbeforethetwovalveconnection points.

Alsounderneaththecarattherear,nearthewheelarch(Fig.54).

Theremainderofthepipeswhichwereconnectedtothesepipes and displacers can be carefully removed.

Attherearofthecar,withtheuseofapairofwirecutterscutthehydragaspipes(Fig.55-56)asshown,onbothsidesof the vehicle.

Note! Do not cut the brake pipes. Oncecutlowerthepipeswhichwereconnectedatthefront

andgentlypulltheHydragaspipethrough(Fig.59-60). The pipes should remove freely from underneath the car. Fullremovalofthepipeswithoutcuttingcanbeachieved

butrequiresthesubstantialreinforcementplatethatisheldtotheundersideofthemainfloorpanby22,13mmheadedboltstoberemovedandthesetwosectionsofinterconnection pipe can then be removed intact.

Figure54,Chassishydragaspipes.

Figure53,Disconnectedhydragaspipes,front.

Figure55-56,Cuthydragaspipes.

Figure57-58,Lowerhydragaspipesandgently pull through.

Page 15

3. Vehicle InsuranceVehicle insurance declaration Please note that XPart cannot guarantee that your vehicle insurance company will provide insurance as a

result of the declaration below.

XPart MGF Hydragas Suspension Replacement Kit - Part Number XPT006310Historic NoteWhentheMGRoverCarCompanycollapsedthetoolingusedtoproducetheHydragasSphereswasdestroyed.OncetheunitsheldinstockbyMGandRoverpartsspecialistwereused,failureofasuspension sphere meant the car became irreparable.

Origin of DesignSuplexUKwasoriginallycommissionedbyCaterpillarLogistics,thenownersofXParttheofficialdistributorofgenuineMGROVERparts,todesignanalternativesuspensionsystem.TheintellectualpropertyrightstothealternativesuspensionsystemarenowownedbyM.A.D./Minisport.XPartarenowownedbyNeoviaLogistics(UK)Ltd..

Concept of DesignTheconceptwastoreplicatethecharacteristicsofthehydragaswithapurelymechanicalsystem.NOTE:ThesecondgenerationMGFtheMGTFutilizesamechanicallysprungsystem.TheengineersatSuplexUKLtd.werepreviouslyinvolvedinthedevelopmentoftheMGTFwiththeMG/Rovercompany.Detailedandinvolvedcalculationswereperformedalongwithphysicaltestingtodeterminetheeffectivespringrates,ridefrequencyanddampingforcesoftheoriginalhydropneumaticsystem.Theresultantdesignswereputthroughtwoyearsofevaluationandprovingbeforesignoffandrelease.

XPart and M.A.D./Minisport make the following statement:-The XPart MGF Hydragas Suspension Replacement Kit - Part Number XPT006310 is designed to replicate the performance and behavior of the original MGF suspension system. It is not designed as an enhancement, up-grade, or in any way a performance improvement. It imparts no adverse increase in loading or stress to any component of the car. It requires no cutting, welding or drilling when fitting.

It is recommended that it is fitted by competent motor engineers and that the fitting instructions are strictly adhered to.

XPart,adivisionofNeoviaLogisticsUnit4,HinckleyCommercialParkHinckleyLE103BQUK

Tel:08706092357Fax:01455825300

GeneralManager:StephenGeorge