Hi all, I recently joined this forum in the hope that you kind people may be able to assist me as I attempt to restore a Daihatsu Copen back to full working order. It is a 2005 660cc Jap import which is almost road worthy now. I am now focusing my attention on getting the roof mechanism to operate correctly. Basically everything seems to work correctly until the roof section should retract, but this never happens. I have identified numerous leaks and have sorted all these now. But I am now thinking that there may be air in the system which is preventing the roof from operating. Does anybody know how to bleed the system correctly? I disconnected the rams from the roof and then operated it and noticed that the rams wouldn't move at all. I then slightly loosened the bolts connecting the hydraulic lines to the pump to allow a release of pressure, and this allowed me to manually move the rams. Although it did result in hydraulic fluid squirming everywhere. After tightening the bolts up and operating it all again I saw that the rams would move so I attached them back to the roof and assumed that everything was fixed. But after trying it again the rams would not move. So annoying. So I am thinking that there may be some air in the system? I just dont know the best way of bleeding the system. If anybody has any advice I will be incredibly grateful and will recommend you for a Nobel Peace Prize or something. I just have run out of ideas. Also, I have noticed that the banjo bolts that secure the hydraulic lines to the pump consist of 2 different types. 2 of them are completely open. The other 2 (darker coloured ones) have some sort of valve inside. Does anybody know which ones go where? in case I have connected them up incorrectly. Many thanks for any help
Hi Richard I have posted some pics of ‘Dennis the Menace’. On the pictures you will see side view were the pipes go into the block they should be numbered as follows. Left to right, bottom row, inner 11 outer 13, inner 21 outer 23 & inner 12 outer 14. Above those three, the single one, inner 22 outer 24. Please note banjo bolt colours. Picture shows the reservoir level at the end of the pencil point. At the end of the reservoir is a little Allen screw 4mm which is access for refill up to this level. THE SYSTEM IS SELF BLEEDING and should be run a few times with the screw replaced and topped up as necessary until all air is removed. Once this has been achieved and there are no leaks you will need to gain access to the ECU for the roof to check if there are any errors that need to be cleared. All the information can be downloaded from the resources section on this site and you will need to refer to section 15-42 to 15-101 regarding roof operations.
Hi GuzziMan, Many thanks for the reply and the help. I greatly appreciate it. I have been away from the Copen for a while as have been busy with other projects but did have a tinker with it the other week and may have made the situation worse. Doh!!! Basically I got hold af a whole replacement roof mechanism with hinges and hydraulics, pump etc. All was completely sealed so no need to bleed it or anything. Anyway, I swapped it all around but now I am getting absolutely no response from the roof or boot at all. Just a lot of error codes. These are: 11, 12, 13, 21, 22, 31 Do you think I should just swap the bits back or do you have any idea if these error codes can be sorted. It seems like a decent set of equipment so I can't imagine it is faulty
