2002 LAND ROVER DISCOVERY service

FRONT SUSPENSION
60-46 REPAIRS
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. 4.Remove 2 bolts securing 2 rear pipe clips to
chassis.

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
REPAIRS 60-51
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.
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.

FRONT SUSPENSION
60-54 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 60-57
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.

FRONT SUSPENSION
REPAIRS 60-61
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.
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.

FRONT SUSPENSION
REPAIRS 60-63
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.