warning LAND ROVER DISCOVERY 1999 Workshop Manual

FRONT SUSPENSION
60-8 DESCRIPTION AND OPERATION
ACE system control diagram
1Upper accelerometer
2Lower accelerometer
3Pressure transducer
4Directional control valve
5Directional control valve
6Pressure control valve
7Instrument pack warning lamp
8Diagnostic socket9Reverse lamp switch
10SLABS ECU
11Engine Control Module (ECM)
12Ignition feed
13ACE relay
14Battery supply
15ACE ECU
M60 0589B
12
5
4
3
6
7
8
9
10
11
12
13
14
15

FRONT SUSPENSION
DESCRIPTION AND OPERATION 60-11
The ACE system uses a semi-synthetic hydraulic fluid which is the same as the fluid used for the PAS system. The
total capacity of the ACE system is 1.62 litres (0.42 US Gallons).
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.
In the event of an ECU or hydraulic failure the system will fail safe to a 'locked bars' condition. The 'locked bars'
condition will allow the torsion bars to operate in a similar manner as conventional 'passive' anti-roll bars. Prolonged
cornering forces will allow a progressive increase in roll angle due to hydraulic leakage through the actuators and
valve block. Failures will be relayed to the driver by the illumination of the ACE warning lamp in the instrument pack.
Faults are recorded by the ECU and can be retrieved using TestBook.
When the ignition switch is moved to position II, the warning lamp will illuminate for two seconds to check functionality.
The warning lamp functionality can also be checked using TestBook.
TestBook must also be used to perform a bleeding procedure after maintenance operations have been performed to
ensure that complete system bleeding is performed. Trapped air in the system can seriously reduce the system
performance.
Fluid reservoir
The moulded plastic fluid reservoir is mounted on the left hand side of the engine compartment on a bracket which is
attached to the inner wing. The reservoir is dual purpose, being divided into two separate chambers; one for the ACE
system and one for the PAS system. Each chamber has its own filler neck and cap and is identified by moulded
lettering on the reservoir adjacent to each filler.
A non-serviceable filter assembly is fitted in the base of each chamber. The filter is made from fine stainless steel
mesh which is moulded into the body of the reservoir. The filter removes particulate matter from the fluid before it is
drawn into the hydraulic pump.
Upper and lower fluid level marks are moulded onto the reservoir body. The capacity of the ACE reservoir chamber
to the upper level mark is 0.5 litre (0.13 US Gallon).

FRONT SUSPENSION
DESCRIPTION AND OPERATION 60-19
When system faults are detected by the ECU, the ACE warning lamp in the instrument pack is illuminated by the ECU
continuously in amber for minor faults or flashing red with an audible warning for faults which require the driver to stop
the vehicle immediately.
The ACE ECU supplies a control current to the pressure control valve in the valve block. The current supplied by the
ECU is determined by a number of input signals from the upper and lower accelerometers, road speed etc.. The
pressure control valve controls the hydraulic pressure supplied to the actuators proportional to the current supplied
by the ECU.
Power is supplied to the two solenoid operated directional control valves (DCV's) in the valve block by the ECU.
Together, the DCV's control the direction of flow of hydraulic fluid to the actuators. When the ECU supplies power to
the solenoids the valves open allowing hydraulic fluid to flow to the actuators. When power is removed the valves
close.
The pressure transducer in the valve block receives a 5 V supply from the ECU. The pressure transducer measures
hydraulic pressures in the range of 0 to 180 bar (0 to 2610 lbf.in
2) and returns a linear output voltage to the ECU
dependent on hydraulic pressure.
The ECU supplies a 5 V current to each of the accelerometers. Each accelerometer is capable of measuring lateral
acceleration in the range of ± 1.10 g. An analogue input to the ECU of between 0.5 and 4.5 V relative to the lateral
acceleration sensed is returned by each accelerometer. The ECU processes the two signals received to produce a
'pure' lateral acceleration signal which is then used as the main control signal for the ACE system.
ACE ECU connector pin details
Pin No. Description Input/Output
1 Not used -
2 Not used -
3 Spare Input
4 Not used -
5 Road speed Input
6ARC relay Output
7 to 9 Not used -
10 K line (diagnostics) -
11 Ignition switch Input
12 Accelerometer - lower (supply) Output
13 Pressure transducer (supply) Output
14 Reverse switch Input
15 Accelerometer - lower (signal) Input
16 Pressure transducer (signal) Input
17 Accelerometer - upper (signal) Input
18 Accelerometer - upper (supply) Output
19 Engine speed Input
20 Main earth 1 -

FRONT SUSPENSION
60-20 DESCRIPTION AND OPERATION
Failure modes
Failures where the vehicle can still be driven safely are indicated by the ACE warning lamp illuminating continuously
with an amber colour. The amber warning lamp will remain illuminated until the ignition is turned off. For all faults the
warning lamp will only illuminate again if the fault is still present. Failures which require the driver to stop the vehicle
immediately are indicated by the ACE warning lamp flashing with a red colour and an audible warning. All faults are
recorded by the ACE ECU and can be retrieved with diagnostic equipment.
The following tables show the type of system failures and their effects on the system operation. Torsion bar 'floppy'
means that fluid is allowed to circulate freely through the system. With no pressure in the actuators the torsion bar will
have no effect on vehicle roll. 'Locked bars' means that all pump flow is directed through the valve block and returns
to the reservoir. Both DCV's close and fluid is trapped in the actuators but can flow from one actuator to the other via
the valve block. In this condition the torsion bar will perform similar to a conventional anti-roll bar, resisting roll but still
allowing the axles to articulate.
Acceleration sensors
Pressure transducer
Road speed signal
21 Pressure transducer (earth) Input
22 DCV 2 (earth) Input
23 DCV 1 (earth) Input
24 DCV 1 & 2 (supply) Output
25 Pressure control valve (earth) Input
26 Not used -
27 Pressure control valve (supply) Output
28 Main supply (+ V Batt) Input
29 to 31 Not used -
32 Main earth 2 -
33 Accelerometer - lower (signal) Input
34 Accelerometer - upper (signal) Input
35 Not used -
36 Warning lamp Output
Failure Effect
Valve stuck closed No ACE control
Short circuit - Ground No ACE control
Short circuit - VBatt No ACE control
Loose sensor Erractic ACE activity when driving in straight line
Failure Effect
Short circuit - VBatt Large sensor dead band - possible random
movements
Failure Effect
Open circuit No ACE control - 'Locked bars' condition
Short circuit - Ground No ACE control - 'Locked bars' condition
Short circuit - VBatt No ACE control - 'Locked bars' conditionPin No. Description Input/Output

FRONT SUSPENSION
REPAIRS 60-27
REPAIRS
Bushes - Panhard rod
$% 60.10.07
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 2 nuts and bolts securing Panhard rod
to axle and chassis.
3.Remove Panhard rod from vehicle.
4.Use tool LRT-60-013 fitted with LRT-60-013/1
and LRT-60-013/3 to press out bushes from
Panhard rod. Refit
1.Clean bush locations in Panhard rod.
2.Use tool LRT-60-013 fitted with LRT-60-013/1
and LRT-60-013/2 to press new bushes into
Panhard rod. Ensure pressure is applied to
the outer edge of the bush, not the rubber
inner.
3.Position Panhard rod to axle and chassis.
4.Fit bolts securing Panhard rod but do not
tighten at this stage.
5.Remove stand(s) and lower vehicle.
6.Tighten bolts securing Panhard rod to 230 Nm
(170 lbf.ft).
CAUTION: Nuts and bolts must be tightened
with weight of vehicle on suspension.

FRONT SUSPENSION
60-32 REPAIRS
Road spring - front
$% 60.20.11
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.Support vehicle under chassis.
3.Remove front road wheels.
4.Support weight of front axle.
5.Remove 2 nuts securing anti-roll bar links to
front axle and disconnect links from axle.
6.Remove 2 bolts securing each damper to front
axle.
WARNING: Make sure the axle cannot move
when the damper is disconnected. The
damper limits the downward movement of
the axle. If the axle is not restrained,
disconnecting the damper will allow
unrestricted movement which may cause
personal injury or damage to equipment.
7.Lower front axle.
CAUTION: Ensure brake hoses and ABS
sensor harnesses are not damaged when
lowering front axle.
8.Release and remove front spring from damper.Refit
1.Clean front spring seats.
2.Position front spring, with close coil uppermost,
over damper and locate in cut out in lower
spring seat.
3.Ensure both front springs are correctly located
in spring seats and raise front axle. Fit bolts
securing both dampers to front axle and tighten
to 45 Nm (33 lbf.ft).
4.Ensure washer is in place on lower ball joint of
each anti-roll bar link, then connect lower ball
joints to axle. Tighten nuts to 100 Nm (74 lbf.ft).
5.Fit front road wheels and tighten nuts to 140
Nm (103 lbf.ft).
6.Remove stands and lower vehicle.

FRONT SUSPENSION
REPAIRS 60-33
Wheel hub
$% 60.25.01
Remove
1.Release ABS sensor harness grommet from
inner wing valance and disconnect multiplug.
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 road wheel.
4.Pull ABS sensor harness through aperture into
wheel arch.5.Release harness from brackets on inner wing
valance, suspension turret and front hub.
6.Release stake from drive shaft nut.
7.With assistance, remove drive shaft nut.
Discard the nut.
8.Remove front brake disc.

+ BRAKES, REPAIRS, Brake disc -
front.
9.Remove 4 bolts securing wheel hub to steering
knuckle.
10.Release wheel hub from steering knuckle, then
remove wheel hub and drive shaft assembly
from axle.
CAUTION: Do NOT remove the ABS sensor
from the hub. The hub and the sensor are
supplied as an assembly.

FRONT SUSPENSION
REPAIRS 60-35
6.Apply a 3 mm (0.125 in) wide bead of sealant,
Part No. STC 50554 around drive shaft
circumference, as illustrated.
7.Ensure ABS harness is located in cut out in
steering knuckle.
8.Fit wheel hub to drive shaft and align steering
knuckle. The sealant will smear along the
length of the splines as the wheel hub is fitted
to the drive shaft.
9.Fit wheel hub bolts and tighten to 100 Nm (74
lbf.ft).
10.Fit new drive shaft nut and lightly tighten.
11.Fit front brake disc.

+ BRAKES, REPAIRS, Brake disc -
front.
12.With assistance, final tighten drive shaft nut to
490 Nm (360 lbf.ft). Stake drive shaft nut. The
drive shaft nut must be tightened before
sealant has cured.
13.Secure ABS sensor harness to brackets and
secure grommet to inner wing.
14.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
15.Remove stand(s) and lower vehicle.
16.Connect ABS sensor multiplug.
Damper - front
$% 60.30.02
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 road wheel.
3. RH damper: Release coolant reservoir and
position aside.
4.Loosen through bolt securing damper to turret.
WARNING: Make sure the axle cannot move
when the damper is disconnected. The
damper limits the downward movement of
the axle. If the axle is not restrained,
disconnecting the damper will allow
unrestricted movement which may cause
personal injury or damage to equipment.
M51 0058

FRONT SUSPENSION
REPAIRS 60-37
Bushes - radius arm
$% 60.35.18
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 road wheel.
3.Remove and discard nut securing track rod to
steering knuckle.
4.Using LRT-57-036 break taper, release track
rod and position aside5.Remove and discard cable tie securing front
axle breather
6.Remove nut and bolt securing radius arm to
chassis.
7.Remove 2 nuts securing radius arm to axle.
8.Remove rear bolt from radius arm.
9.Remove front bolt from radius arm and remove
radius arm from axle.

FRONT SUSPENSION
60-50 REPAIRS
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.
4.Remove 3 screws securing splash shield and
remove shield. 5.Position containers under valve block and
actuator to collect fluid spillage.
6.Remove bolt securing pipe clamp to chassis
and remove clamp.
7.Release harness strap from suspension turret
and position harness aside.
8.Remove nut securing pipe clamp to bracket on
suspension turret and remove clamp.