Discovery 2. Manual — part 612

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

60-46

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.

l

ACE components are thoroughly cleaned
externally before work commences;

l

all opened pipe and module ports are
capped immediately;

l

all 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

REPAIRS

60-47

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.

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).

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.

l

ACE components are thoroughly cleaned
externally before work commences;

l

all opened pipe and module ports are
capped immediately;

l

all 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.