Discovery 2. Manual - part 194

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.

ACE components are thoroughly cleaned
externally before work commences;

all opened pipe and module ports are
capped immediately;

all 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

ACE components are thoroughly cleaned
externally before work commences;

all opened pipe and module ports are
capped immediately;

all 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.

Content .. 192 193 194 195 ..