Discovery 2. Manual — part 616
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: 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,
21. Fit RH splash shield and secure with screws.
22. Fit road wheel.
23. Fit valve block.
24. Renew ACE high pressure filter
25. Lower vehicle.
26. Fill cooling system.
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.
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 under valve block to collect
fluid spillage.
3. Remove 2 bolts securing 2 rear pipe clips to
chassis.
FRONT SUSPENSION
60-62
REPAIRS
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.
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.
8. Bleed ACE hydraulic system.
ADJUSTMENTS, ACE hydraulic system
bleeding.
9. Lower vehicle.
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.
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. 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
60-64
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.
8. Bleed ACE hydraulic system.
ADJUSTMENTS, ACE hydraulic system
bleeding.
9. Fit RH front road wheel and tighten nuts to 140
Nm (103 lbf.ft).
10. Lower vehicle.
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