1999 LAND ROVER DISCOVERY Workshop Manual

FRONT SUSPENSION
60-48 REPAIRS
Pressure transducer - ACE
$% 60.60.22
CAUTION: The ACE hydraulic system is
extremely sensitive to the ingress of dirt or
debris. The smallest amount could render the
system unserviceable. It is imperative that the
following precautions are taken.
lACE components are thoroughly cleaned
externally before work commences;
lall opened pipe and module ports are
capped immediately;
lall fluid is stored in and administered
through clean containers.
Remove
1.Raise vehicle on a ramp.
2.Disconnect multiplug from transducer.
3.Position container to collect fluid spillage.
4.Remove pressure transducer and discard 'O'
ring.
CAUTION: Always fit plugs to open
connections to prevent contamination.Refit
1.Ensure pressure transducer and port in valve
block is clean.
2.Fit new 'O' ring to pressure transducer. Fit and
tighten pressure transducer to 20 Nm (15
lbf.ft).
3.Connect multiplug to pressure transducer.
4.Renew ACE high pressure filter.

+ FRONT SUSPENSION, REPAIRS,
Filter - high pressure - ACE.
5.Lower vehicle.

FRONT SUSPENSION
REPAIRS 60-49
Solenoid - pressure control valve - ACE
$% 60.60.23
Remove
1.Raise vehicle on a ramp.
2.Disconnect multiplug from solenoid.
3.Remove cap securing solenoid to pressure
control valve and discard 'O' ring.
4.Remove solenoid from pressure control valve
and discard 'O' ring from base of valve.
Refit
1.Ensure solenoid and pressure control valve are
clean.
2.Fit new 'O' ring to base of pressure control
valve.
3.Fit solenoid to pressure control valve, with
arrow on solenoid pointing away from valve
block and connector in correct position.
4.Fit new 'O' ring to solenoid securing cap. Fit cap
and tighten to 11 Nm (8 lbf.ft).
5.Connect multiplug to solenoid.
6.Lower vehicle.
Solenoid - directional control valve - ACE
$% 60.60.24
Remove
1.Raise vehicle on a ramp.
2.Disconnect multiplug from solenoid.
3.Loosen cap securing solenoid to directional
control valve.
4.Remove 3 bolts securing valve block to
chassis, lower block sufficiently only to remove
solenoid.
5.Remove cap securing solenoid to directional
control valve and discard 'O' ring.
6.Remove solenoid from directional control valve
and discard 'O' ring from base of valve.
Refit
1.Ensure solenoid and directional control valve
are clean.
2.Fit new 'O' ring to base of directional control
valve.
3.Fit solenoid to directional control valve, with
arrow on solenoid pointing up and connector in
correct position.
4.Fit new 'O' ring to solenoid securing cap. Fit cap
to solenoid but do not tighten at this stage.
5.Fit 3 bolts securing valve block to chassis and
tighten to 18 Nm (13 lbf.ft) .
6.Tighten solenoid securing cap to 11 Nm (8
lbf.ft) .
7.Connect multiplug to solenoid.
8.Lower vehicle.

FRONT SUSPENSION
60-50 REPAIRS
Pipe assembly - valve block to front
actuator - ACE
$% 60.60.31
Introduction
CAUTION: The ACE hydraulic system is
extremely sensitive to the ingress of dirt or
debris. The smallest amount could render the
system unserviceable. It is imperative that the
following precautions are taken.
lACE components are thoroughly cleaned
externally before work commences;
lall opened pipe and module ports are
capped immediately;
lall fluid is stored in and administered
through clean containers.
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove RH front road wheel.
3.Remove 7 screws securing RH front wheel arch
liner extension and remove extension.
4.Remove 3 screws securing splash shield and
remove shield. 5.Position containers under valve block and
actuator to collect fluid spillage.
6.Remove bolt securing pipe clamp to chassis
and remove clamp.
7.Release harness strap from suspension turret
and position harness aside.
8.Remove nut securing pipe clamp to bracket on
suspension turret and remove clamp.

FRONT SUSPENSION
REPAIRS 60-51
9.Remove 2 nuts securing pipe clamping plate to
valve block.
10.Release clamping plate and pipes from valve
block. Remove collets and release pipes from
clamping plate.
CAUTION: Always fit plugs to open
connections to prevent contamination.
11.Remove 2 cap nuts securing pipes to ACE
actuator. Disconnect pipes and discard sealing
washers.
CAUTION: Always fit plugs to open
connections to prevent contamination.
12.Release pipes from isolator above chassis RH
front outrigger.
13.Remove pipe assembly.Refit
1.Position pipe assembly.
2.Locate pipes in isolator above chassis RH front
outrigger. Fit cable tie around isolator to secure
pipes.
3.Ensure valve block and pipe connections are
clean.
4.Fit collets and pipes to clamping plate.
5.Connect pipes to valve block. To avoid seal
damage, keep pipes square to valve block.
Fit and tighten nuts securing clamping plate to
valve block to 21 Nm (15 lbf.ft).
CAUTION: Ensure pipes are installed in
their correct ports or serious system
damage will occur.
6.Fit pipe clamps. Secure to chassis with bolt and
to bracket on suspension turret with nut.
7.Connect pipes to ACE actuator with cap nuts
and new sealing washers Tighten cap nuts to
29 Nm (21 lbf.ft). Ensure pipes are not under
tension or kinked.
8.Secure harness to suspension turret.
9.Fit splash shield and secure with screws.
10.Fit RH wheel arch liner extension and secure
with screws.
11.Renew ACE high pressure filter.

+ FRONT SUSPENSION, REPAIRS,
Filter - high pressure - ACE.
12.Fit road wheel(s) and tighten nuts to 140 Nm
(103 lbf.ft).
13.Refill and bleed ARC system.

+ FRONT SUSPENSION,
ADJUSTMENTS, ACE hydraulic system
bleeding.
14.Lower vehicle.

FRONT SUSPENSION
60-52 REPAIRS
Pipe assembly - pump or reservoir to
valve block - ACE - V8
$% 60.60.32
Introduction
CAUTION: The ACE hydraulic system is
extremely sensitive to the ingress of dirt or
debris. The smallest amount could render the
system unserviceable. It is imperative that the
following precautions are taken.
lACE components are thoroughly cleaned
externally before work commences;
lall opened pipe and module ports are
capped immediately;
lall fluid is stored in and administered
through clean containers.
Remove
1.To avoid any possibility of swarf ingress,
remove the valve block.

+ FRONT SUSPENSION, REPAIRS,
Valve block - ACE.
2.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
3.Remove RH front road wheel.
4.Remove 3 screws and remove splash shield.
5.Remove viscous fan.

+ COOLING SYSTEM - V8, REPAIRS,
Fan - viscous.6.Remove 2 screws securing lower fan cowl and
remove cowl.
7.Disconnect multiplug from MAF sensor.
Note: Pre 03 MY air intake hose illustrated.
8.Release clips and remove air flow meter from
air cleaner.
9.Collect 'O' ring.

FRONT SUSPENSION
REPAIRS 60-53
10.Loosen clip and disconnect air hose from
throttle body.
Note: Pre 03 MY air intake hose illustrated.
11.Position container to collect fluid loss.
12. Pump to valve block pipe:Remove banjo bolt
securing fluid hose to ACE pump and discard
sealing washers.
CAUTION: Always fit plugs to open
connections to prevent contamination.13. Valve block to reservoir pipe: Release clip,
disconnect hose from ACE fluid reservoir and
remove clip from hose.
CAUTION: Always fit plugs to open
connections to prevent contamination.
14.Remove bolts securing 2 pipe clamps to front
cross member and remove clamps.
15. Valve block to reservoir pipe: Release pipe
from clip on LH chassis member.

FRONT SUSPENSION
60-54 REPAIRS
16.Remove bolt securing pipe clamp to RH
chassis member and remove clamp.
17.Release harness clip from RH suspension
turret.
18.Remove nut securing pipe clamp to bracket on
RH suspension turret and remove clamp.
19.Release pipe from isolator above chassis RH
front outrigger.
20.Cut pipe at suitable point near suspension
turret.
21.Remove and discard front and rear sections of
pipe. Refit
1.Fit both sections of new pipe to vehicle.
2.Ensure 'O' ring is fitted to union on front section
of pipe.
3.Push both sections ofpipe together squarely
and tighten union nut to 16 Nm (12 lbf.ft).
4.Locate pipe in isolator above chassis RH front
outrigger. Fit cable tie around isolator to secure
pipe.
5. Valve block to reservoir pipe:Fit clip to
reservoir hose, connect hose to reservoir and
secure with clip.
6. Pump to valve block pipe: Ensure pipe banjo
and ACE pump connections are clean, fit new
sealing washers, align banjo to pump and
tighten bolt to 29 Nm (21 lbf.ft).
7.Fit pipe clamps to pipe, align clamps to front
cross member and fit bolts.
8. Valve block to reservoir pipe: Fit pipe to clip
on LH chassis member.
9.Fit pipe clamp to pipes, align clamp to
suspension turret and secure with nut.
10.Fit pipe clamp to pipes, align clamp to RH
chassis member and secure with bolt.
11.Align and secure harness to suspension turret.
12.Fit 'O' ring to air cleaner.
13.Fit air hose to throttle body and secure with clip.
14.Fit air flow meter and secure with clips.
15.Connect multiplug to MAF sensor.
16.Fit lower fan cowl and secure with screws.
17.Fit viscous fan.

+ COOLING SYSTEM - V8, REPAIRS,
Fan - viscous.
18.Fit RH splash shield and secure with screws.
19.Fit road wheel(s).
20.Fit valve block.

+ FRONT SUSPENSION, REPAIRS,
Valve block - ACE.
21.Renew ACE high pressure filter.
22.Lower vehicle.

FRONT SUSPENSION
REPAIRS 60-55
Pipe assembly - pump or reservoir to
valve block - ACE - diesel
$% 60.60.32
CAUTION: The ACE hydraulic system is
extremely sensitive to the ingress of dirt or
debris. The smallest amount could render the
system unserviceable. It is imperative that the
following precautions are taken.
lACE components are thoroughly cleaned
externally before work commences;
lall opened pipe and module ports are
capped immediately;
lall fluid is stored in and administered
through clean containers.
Remove
1.To avoid any possibility of swarf ingress,
remove valve block.

+ FRONT SUSPENSION, REPAIRS,
Valve block - ACE.
2.Drain cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
3.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
4.Remove RH front road wheel.
5.Remove 3 screws and remove splash shield.
6.Remove viscous fan.

+ COOLING SYSTEM - Td5, REPAIRS,
Fan - viscous.7.Remove 2 screws securing lower half of fan
cowl and remove cowl.
8.Disconnect multiplug from air flow meter.
9.Release clips and remove air flow meter from
air cleaner.
10.Collect 'O' ring.