FRONT SUSPENSION
DESCRIPTION AND OPERATION 60-13
Lateral acceleration of the body is sensed by two accelerometers and signals are transmitted to the ECU. The engine
driven hydraulic pump supplies a constant hydraulic flow to the valve block. Two directional control valves are
solenoid operated by the ECU and these supply fluid to the applicable side of each actuator to apply an equal and
opposite force to the torsion bar. In operation the ACE system maintains the attitude of the vehicle body when
cornering.
The ACE system uses a semi-synthetic hydraulic fluid which is the same as the fluid used for the PAS system. The
total capacity of the ACE system is 1.62 litres (0.42 US Gallons).
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.
In the event of an ECU or hydraulic failure the system will fail safe to a 'locked bars' condition. The 'locked bars'
condition will allow the torsion bars to operate in a similar manner as conventional 'passive' anti-roll bars. Prolonged
cornering forces will allow a progressive increase in roll angle due to hydraulic leakage through the actuators and
valve block. Failures will be relayed to the driver by the illumination of the ACE warning lamp in the instrument pack.
Faults are recorded by the ECU and can be retrieved using TestBook.
When the ignition switch is moved to position II, the warning lamp will illuminate for two seconds to check functionality.
The warning lamp functionality can also be checked using TestBook.
TestBook must also be used to perform a bleeding procedure after maintenance operations have been performed to
ensure that complete system bleeding is performed. Trapped air in the system can seriously reduce the system
performance.
Fluid reservoir
The moulded plastic fluid reservoir is mounted on the left hand side of the engine compartment on a bracket which is
attached to the inner wing. The reservoir is dual purpose, being divided into two separate chambers; one for the ACE
system and one for the PAS system. Each chamber has its own filler neck and cap and is identified by moulded
lettering on the reservoir adjacent to each filler.
A non-serviceable filter assembly is fitted in the base of each chamber. The filter is made from fine stainless steel
mesh which is moulded into the body of the reservoir. The filter removes particulate matter from the fluid before it is
drawn into the hydraulic pump.
Upper and lower fluid level marks are moulded onto the reservoir body. The capacity of the ACE reservoir chamber
to the upper level mark is 0.5 litre (0.13 US Gallon).
FRONT SUSPENSION
REPAIRS 60-43
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. 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.
FRONT SUSPENSION
REPAIRS 60-45
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.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.
FRONT SUSPENSION
60-48 REPAIRS
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.
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.
FRONT SUSPENSION
REPAIRS 60-49
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.
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.
FRONT SUSPENSION
60-50 REPAIRS
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.
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.
FRONT SUSPENSION
REPAIRS 60-53
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
REPAIRS 60-57
7.Fit pipe clamps to pipe, align clamps to 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 '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.
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.