1999 LAND ROVER DISCOVERY air filter

FRONT SUSPENSION
60-44 REPAIRS
Refit
1.Clean mating faces of pulley and ACE pump.
2.Position pulley to ACE pump and fit bolts.
Restrain pulley and tighten bolts to 25 Nm (18
lbf.ft).
3.Clean mating faces of ACE pump and
mounting.
4.Connect suction hose to ACE pump and secure
with clip.
5.Ensure there is sufficient fluid in ACE/PAS
reservoir to prime ACE pump.
6.Position ACE pump below level of ACE/PAS
reservoir, with suction hose uppermost, and
allow fluid from ACE/PAS reservoir to
completely fill ACE pump.
7.Position ACE pump to mounting, fit bolts and
tighten to 25 Nm (18 lbf.ft).
8.Rotate ACE pump clockwise (viewed from
pulley end) until a steady flow of fluid runs from
outlet port.
9.Connect pressure pipe to ACE pump with banjo
bolt and new sealing washers. Tighten banjo
bolt to 28 Nm (21 lbf.ft).
10.Connect hose to intercooler and secure with
clip.
11.Fit ACE/PAS reservoir into mounting bracket.
12.Connect air hose to turbo charger and secure
with clip.
13.Fit mass air flow sensor to air filter and secure
with clips.
14.Connect multiplugs to mass air flow sensor and
ambient air pressure sensor.
15.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
16.Renew ACE high pressure filter.

+ FRONT SUSPENSION, REPAIRS,
Filter - high pressure - ACE.
Valve block - ACE
$% 60.60.20
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 4 multiplugs from valve block.
3.Position container underneath valve block to
collect fluid spillage.

FRONT SUSPENSION
60-46 REPAIRS
7.Remove 3 bolts securing valve block to
chassis.
8.Release front pipes and clamping plate from
valve block and remove valve block.
CAUTION: Always fit plugs to open
connections to prevent contamination.
NOTE: Keep pipes assembled to clamping
plate to maintain correct pipe positions for
refitting.
9.Remove 6 bushes from valve block. Refit
1.Fit 6 bushes to valve block.
2.Ensure valve block and pipe connections are
clean.
3.It is important that the pipe ends are in good
condition to achieve a seal.
4.Position valve block and connect front pipes
and clamping plate. To avoid damage to
seals, keep pipes square to valve block. Fit
and tighten bolts securing valve block to
chassis to 18 Nm (13 lbf.ft).
CAUTION: Ensure pipes are installed in
their correct ports or serious system
damage will occur.
5.Fit and tighten nuts securing front clamping
plate to valve block to 21 Nm (15 lbf.ft).
6.Fit bolt securing front pipe clip to chassis and
tighten to 6 Nm (4.4 lbf.ft).
7.Connect rear 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.
8.Fit bolts securing rear pipe clips to chassis and
tighten to 6 Nm (4.4 lbf.ft) .
9.Connect 4 multiplugs to valve block.
10.If the same valve block has been refitted, renew
ACE high pressure filter.

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

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

FRONT SUSPENSION
REPAIRS 60-47
Filter - high pressure - ACE
$% 60.60.21
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 to collect fluid spillage.
3.Remove filter cap and discard 'O' ring.
4.Fit M6 bolt into base of filter and pull on bolt to
remove filter from valve block. Do not turn
filter in valve block.
CAUTION: Always fit plugs to open
connections to prevent contamination.Refit
1.Ensure new filter has 'O' ring fitted, then fit filter
to valve block.
2.Fit new 'O' ring to filter cap. Fit cap and tighten
to 35 Nm (26 lbf.ft).
3.Lower vehicle.
4.Check fluid level in ACE/PAS reservoir.

+ FRONT SUSPENSION,
ADJUSTMENTS, Fluid level check - ACE
system.
5.Start and run engine for 2 minutes, then re-
check fluid level in ACE/PAS reservoir.

+ FRONT SUSPENSION,
ADJUSTMENTS, Fluid level check - ACE
system.

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 60-51
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
60-54 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
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
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.