1999 LAND ROVER DISCOVERY Workshop Manual

FRONT SUSPENSION
60-56 REPAIRS
11.Loosen clip, disconnect air hose from
turbocharger and move hose aside.
12.Release clip and disconnect pressure sensing
hose from turbocharger outlet pipe.
13.Loosen clips securing turbocharger outlet pipe
hoses.
14.Remove turbocharger outlet pipe and hoses as
an assembly. 15.Release clips and disconnect 2 thermostat
housing hoses from coolant pipe.
16.Release clip and disconnect bottom hose from
radiator.
17.Remove thermostat housing with hoses.
18.Position container to collect ACE fluid loss.
19. 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.

FRONT SUSPENSION
REPAIRS 60-57
20. 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.
21.Remove bolts securing 2 pipe clamps to
chassis front cross member and remove
clamps.
22. Valve block to reservoir pipe: Release fluid
return pipe from clip on LH chassis member. 23.Remove bolt securing pipe clamp to RH
chassis member and remove clamp.
24.Release harness clip from RH suspension
turret.
25.Remove nut securing pipe clamp to bracket on
RH suspension turret and remove clamp.
26.Release pipe from isolator above chassis RH
front outrigger.
27.Cut pipe at suitable point near suspension
turret.
28.Remove and discard front and rear sections of
pipe.

FRONT SUSPENSION
60-58 REPAIRS
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 of pipe 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 pipes, align clamps to
chassis front cross member and fit bolts.
8. Valve block to reservoir pipe: F it pi pe to c li p
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 thermostat housing and hoses and secure
hoses with clips.
13.Fit turbocharger outlet pipe and secure hoses
with clips.
14.Connect turbocharger pressure sensing hose
and secure with clip.
15.Fit 'O' ring to air cleaner.
16.Fit air hose to turbocharger and tighten clip.
17.Fit air flow meter to air cleaner and secure with
clips.
18.Connect multiplug to air flow meter.
19.Fit lower half of fan cowl and secure with
screws.
20.Fit viscous fan.

+ COOLING SYSTEM - Td5, REPAIRS,
Fan - viscous.
21.Fit RH splash shield and secure with screws.
22.Fit road wheel.23.Fit valve block.

+ FRONT SUSPENSION, REPAIRS,
Valve block - ACE.
24.Renew ACE high pressure filter

+ FRONT SUSPENSION, REPAIRS,
Filter - high pressure - ACE.
25.Lower vehicle.
26.Fill cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.

FRONT SUSPENSION
REPAIRS 60-59
Pipe assembly - valve block to rear
actuator - ACE
$% 60.60.33
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.Position container under valve block to collect
fluid spillage.
3.Remove 2 bolts securing 2 rear pipe clips to
chassis.
4.Remove 2 nuts securing rear anti-roll bar links
to axle.
5.Release links from axle and pull long arm down
for access to actuator pipe unions.
6.Position container under actuator to collect
fluid spillage.

FRONT SUSPENSION
60-60 REPAIRS
7.Remove 2 cap nuts securing pipes to ACE rear
actuator. Disconnect pipes, remove and
discard sealing washers.
CAUTION: Always fit plugs to open
connections to prevent contamination.
8.Remove 2 nuts securing rear pipe clamping
plate. Release clamping plate and pipes from
valve block.
CAUTION: Always fit plugs to open
connections to prevent contamination.
9.Remove pipe assembly.
10.Remove collets and clamping plate from rear
pipes. Refit
1.Ensure valve block and pipe connections are
clean.
2.Install clamping plate and collets on rear pipes.
3.Position pipe assembly to vehicle and connect
pipes and clamping plate to valve block. To
avoid damage to seals, 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.
4.Fit bolts securing rear pipe clips to chassis and
tighten to 6 Nm (4.4 lbf.ft).
5.Connect pipes to 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.
6.Ensure washer is in place on lower ball joint of
each anti-roll bar link, then connect lower ball
joints to axle and tighten nuts to 100 Nm (74
lbf.ft).
7.Renew ACE high pressure filter.

+ FRONT SUSPENSION, REPAIRS,
Filter - high pressure - ACE.
8.Bleed ACE hydraulic system.

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

FRONT SUSPENSION
REPAIRS 60-61
Actuator - front - ACE
$% 60.60.40
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.Remove RH front road wheel.
3.Position container to collect fluid spillage.
4.Remove cap nuts securing fluid pipes to
actuator. Disconnect pipes and discard sealing
washers.
CAUTION: Always fit plugs to open
connections to prevent contamination.5.Remove 2 nuts securing anti-roll bar links to
axle. Release links from axle.
6.With assistance, remove 2 bolts and remove
both clamp plates from torsion bar.
7.Remove mounting rubbers from torsion bar.
8.Remove torsion bar and actuator assembly.
CAUTION: While removed from the vehicle,
ensure torsion bar is stored without any
load on the anti-roll bar links, or the ball
joints and/or link rods could be damaged.

FRONT SUSPENSION
60-62 REPAIRS
9.Use LRT-60-009 to remove nut securing
actuator to long arm.
10.Remove nut and bolt securing actuator to short
arm and remove actuator.
CAUTION: The short arm and torsion bar
are supplied as an assembly and must not
be separated.Refit
1.Fit actuator to torsion bar. Use LRT-60-009to
tighten actuator to long arm nut to 48 Nm (35
lbf.ft). Tighten actuator to short arm nut and bolt
to 180 Nm (133 lbf.ft).
2.Ensure torsion bar mounting rubber mating
faces are clean and free from damage.
3.Fit mounting rubbers to torsion bar.
4.With assistance, position torsion bar and
actuator assembly to vehicle. Fit clamp plates
and tighten bolts to 45 Nm (33 lbf.ft).
5.Ensure washer is in place on lower ball joint of
each anti-roll bar link, then connect lower ball
joint to axle and tighten nuts to 100 Nm (74
lbf.ft).
6.Connect pipes to 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.
7.Renew ACE high pressure filter.

+ FRONT SUSPENSION, REPAIRS,
Filter - high pressure - ACE.
8.Bleed ACE hydraulic system.

+ FRONT SUSPENSION,
ADJUSTMENTS, ACE hydraulic system
bleeding.
9.Fit RH front road wheel and tighten nuts to 140
Nm (103 lbf.ft).
10.Lower vehicle.

FRONT SUSPENSION
REPAIRS 60-63
Bushes - front long arm - ACE
$% 60.60.46
Remove
1.Remove ACE front actuator.

+ FRONT SUSPENSION, REPAIRS,
Actuator - front - ACE.
2.Remove securing nut and remove anti-roll bar
link from torsion bar.
3.Restrain torsion bar and remove long arm
securing bolt and washer. Remove long arm
from torsion bar.
CAUTION: The short arm and torsion bar
are supplied as an assembly and must not
be separated.
4.Use a suitable drift to remove both halves of
slipper bush from long arm.
5.Use suitable adaptors to press actuator rod end
bush from long arm.Refit
1.Clean bush locations in long arm.
2.Use suitable adaptors to press new actuator
rod end bush into long arm. Ensure hole in bush
is correctly aligned with hole in long arm.
3.Align slots in new slipper bush halves with
those in long arm. Carefully press both halves
of slipper bush into long arm. Ensure the
sealing rings on the slipper bush faces are not
damaged.
4.Clean long arm and mating face on torsion bar.
5.Fit long arm to torsion bar. Restrain torsion bar
and tighten bolt to 180 Nm (133 lbf.ft).
6.Fit anti-roll bar link to long arm and tighten nut
to 50 Nm (37 lbf.ft).
7.Fit ACE front actuator.

+ FRONT SUSPENSION, REPAIRS,
Actuator - front - ACE.