Discovery 2. Manual — part 193

FRONT SUSPENSION

REPAIRS

60-55

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.

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. 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.

7. Remove 2 screws securing lower half of fan

cowl and remove cowl.

8. Disconnect multiplug from air flow meter.

9. Release clips and remove air flow meter from

air cleaner.

10. Collect 'O' ring.

FRONT SUSPENSION

60-56

REPAIRS

11. Loosen clip, disconnect air hose from

turbocharger and move hose aside.

12. Release clip and disconnect pressure sensing

hose from turbocharger outlet pipe.

13. Loosen clips securing turbocharger outlet pipe

hoses.

14. Remove turbocharger outlet pipe and hoses as

an assembly.

15. Release clips and disconnect 2 thermostat

housing hoses from coolant pipe.

16. Release clip and disconnect bottom hose from

radiator.

17. Remove thermostat housing with hoses.
18. Position container to collect ACE fluid loss.

19. Pump to valve block pipe: Remove banjo

bolt securing fluid hose to ACE pump and
discard sealing washers.

CAUTION: Always fit plugs to open
connections to prevent contamination.

FRONT SUSPENSION

REPAIRS

60-57

20. Valve block to reservoir pipe: Release clip,

disconnect hose from ACE fluid reservoir and
remove clip from hose.

CAUTION: Always fit plugs to open
connections to prevent contamination.

21. Remove bolts securing 2 pipe clamps to

chassis front cross member and remove
clamps.

22. Valve block to reservoir pipe: Release fluid

return pipe from clip on LH chassis member.

23. Remove bolt securing pipe clamp to RH

chassis member and remove clamp.

24. Release harness clip from RH suspension

turret.

25. Remove nut securing pipe clamp to bracket on

RH suspension turret and remove clamp.

26. Release pipe from isolator above chassis RH

front outrigger.

27. Cut pipe at suitable point near suspension

turret.

28. Remove and discard front and rear sections of

pipe.

FRONT SUSPENSION

60-58

REPAIRS

Refit

1. Fit both sections of new pipe to vehicle.
2. Ensure 'O' ring is fitted to union on front section

of pipe.

3. Push both sections of pipe together squarely

and tighten union nut to 16 Nm (12 lbf.ft).

4. Locate pipe in isolator above chassis RH front

outrigger. Fit cable tie around isolator to secure
pipe.

5. Valve block to reservoir pipe: Fit clip to

reservoir hose, connect hose to reservoir and
secure with clip.

6. Pump to valve block pipe: Ensure pipe banjo

and ACE pump connections are clean, fit new
sealing washers, align banjo to pump and
tighten bolt to 29 Nm (21 lbf.ft).

7. Fit pipe clamps to pipes, align clamps to

chassis front cross member and fit bolts.

8. Valve block to reservoir pipe: Fit pipe to clip

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.