1999 LAND ROVER DISCOVERY Workshop Manual

FRONT SUSPENSION
60-40 REPAIRS
Accelerometer - ACE - upper
$% 60.60.02
CAUTION: The accelerometer is an extremely
delicate component and can easily be rendered
unserviceable. Never use an accelerometer
which has been dropped or subjected to
mistreatment of any type.
Remove
1.Remove front stowage pocket.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Stowage pocket - front.
2.Disconnect multiplug from accelerometer.
3.Use LRT-60-014A to release clip and remove
accelerometer.
Refit
1.Using LRT-60-014A, fit accelerometer fully into
clip.
2.Connect accelerometer multiplug.
3.Fit front stowage pocket.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Stowage pocket - front.
4.If a replacement accelerometer has been fitted,
use TestBook to calibrate ACE system.
Accelerometer - ACE - lower
$% 60.60.03
CAUTION: The accelerometer is an extremely
delicate component and can easily be rendered
unserviceable. Never use an accelerometer
which has been dropped or subjected to
mistreatment of any type.
Remove
1.Raise vehicle on a ramp.
2.Disconnect multiplug from accelerometer.
3.Use LRT-60-014A to release clip and remove
accelerometer.
Refit
1.Use LRT-60-014A, fit accelerometer fully into
clip.
2.Connect accelerometer multiplug.
3.Lower vehicle.
4.If a replacement accelerometer has been fitted,
use TestBook to calibrate ACE system.

FRONT SUSPENSION
REPAIRS 60-41
Pump - ACE - V8
$% 60.60.10
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.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Loosen 3 clips securing air intake hose.
Release air intake hose and position aside.
Note: Pre 03 MY air intake hose illustrated.3.Position container to catch spillage.
4.Release clip on pump suction hose and
disconnect hose.
CAUTION: Always fit plugs to open
connections to prevent contamination.
5.Remove banjo bolt and disconnect pressure
pipe from ACE pump. Discard sealing washers.
CAUTION: Always fit plugs to open
connections to prevent contamination.
6.Remove 3 bolts securing ACE pump to
mounting and remove ACE pump.
7.Restrain pulley, remove 3 securing bolts and
remove pulley from ACE pump.

FRONT SUSPENSION
60-42 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.Position air intake hose and secure clips.
11.Fit auxiliary drive belt.

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

+ FRONT SUSPENSION, REPAIRS,
Filter - high pressure - ACE.
Pump - ACE - diesel
$% 60.60.10
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.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Disconnect multiplugs from mass air flow
sensor and ambient air pressure sensor.
3.Release clips and disconnect mass air flow
sensor from air cleaner.
4.Loosen hose clip, disconnect inlet air hose
from turbo charger and move hose aside.

FRONT SUSPENSION
REPAIRS 60-43
5.Release ACE/PAS reservoir from bracket and
move aside.
6.Loosen clip and disconnect inlet hose from
intercooler.
7.Position container to catch spillage. 8.Release clip and disconnect suction hose from
ACE pump.
9.Remove banjo bolt and disconnect pressure
pipe from ACE pump. Discard sealing washers.
CAUTION: Always fit plugs to open
connections to prevent contamination.
10.Remove 3 bolts securing ACE pump to
mounting and remove ACE pump.
11.Restrain pulley, remove 3 securing bolts and
remove pulley from ACE pump.

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
REPAIRS 60-45
4.Remove 2 bolts securing 2 rear pipe clips to
chassis. 5.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.
NOTE: Keep pipes assembled to clamping
plate to maintain correct pipe positions for
refitting.
6.Remove 2 nuts securing front pipe clamping
plate.

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.