service LAND ROVER DISCOVERY 1999 Repair Manual

FRONT SUSPENSION
REPAIRS 60-47
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.
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 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.Refit
1.Ensure new filter has 'O' ring fitted, then fit filter
to valve block.
2.Fit new 'O' ring to filter cap. Fit cap and tighten
to 35 Nm (26 lbf.ft).
3.Lower vehicle.
4.Check fluid level in ACE/PAS reservoir.

+ FRONT SUSPENSION,
ADJUSTMENTS, Fluid level check - ACE
system.
5.Start and run engine for 2 minutes, then re-
check fluid level in ACE/PAS reservoir.

+ FRONT SUSPENSION,
ADJUSTMENTS, Fluid level check - ACE
system.

FRONT SUSPENSION
60-48 REPAIRS
Pressure transducer - ACE
$% 60.60.22
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 vehicle on a ramp.
2.Disconnect multiplug from transducer.
3.Position container to collect fluid spillage.
4.Remove pressure transducer and discard 'O'
ring.
CAUTION: Always fit plugs to open
connections to prevent contamination.Refit
1.Ensure pressure transducer and port in valve
block is clean.
2.Fit new 'O' ring to pressure transducer. Fit and
tighten pressure transducer to 20 Nm (15
lbf.ft).
3.Connect multiplug to pressure transducer.
4.Renew ACE high pressure filter.

+ FRONT SUSPENSION, REPAIRS,
Filter - high pressure - ACE.
5.Lower vehicle.

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.

FRONT SUSPENSION
60-52 REPAIRS
Pipe assembly - pump or reservoir to
valve block - ACE - V8
$% 60.60.32
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.To avoid any possibility of swarf ingress,
remove the valve block.

+ FRONT SUSPENSION, REPAIRS,
Valve block - ACE.
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 RH front road wheel.
4.Remove 3 screws and remove splash shield.
5.Remove viscous fan.

+ COOLING SYSTEM - V8, REPAIRS,
Fan - viscous.6.Remove 2 screws securing lower fan cowl and
remove cowl.
7.Disconnect multiplug from MAF sensor.
Note: Pre 03 MY air intake hose illustrated.
8.Release clips and remove air flow meter from
air cleaner.
9.Collect 'O' ring.

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.
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.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
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.
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 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
REPAIRS 60-61
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.
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 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.

REAR SUSPENSION
64-14 DESCRIPTION AND OPERATION
The compressor is attached with Allen bolts to the motor housing and sealed with an O-ring. Attached to the
compressor is the air dryer which contains a silicate box for removing moisture from the compressed air. Air supplied
to inflate the air springs passes through the air dryer. When the air springs are deflated, the exhaust air also passes
through the air dryer, removing the moisture from the unit and expelling it to atmosphere.
Attached to end of the air dryer unit is the pressure limiting valve. The valve protects the air springs from over inflation.
The pressure limiting valve also operates when the exhaust valve is opened. The valve is pneumatically operated,
responding to air pressure applied to it.
The exhaust valve is also located with the pressure limiting valve. The exhaust valve is solenoid operated by the ECU
and directs air from the air springs and control valves to atmosphere when required.
The two air control valves for the LH and RH air springs are located at the forward end of the housing. Each valve is
connected to the compressor/air dryer unit through a shared single pipe which directs air to and from the air springs.
Each control valve is individually operated by the ECU.
All air connections to and from the air supply unit are made through the SLS air harness which is located along the
left hand chassis longitudinal.
If faults occur with the air supply unit, fault codes are stored in the SLABS ECU. These fault codes cover the
compressor power supply and the LH and RH air control valves and the exhaust valve. The current and past fault
codes can be retrieved with TestBook. TestBook can also be used to operate the compressor and the valves for
diagnostic purposes.
Air intake filter
The air intake filter is located in the left hand 'E' post, behind the tail lamp assembly. The filter comprises a plastic
moulded housing which contains two filters of differing density to remove particulate matter from the air drawn in by
the compressor. The air intake filter has a pipe which is connected to the SLS air harness by a quick release
connector. The air intake filter must be replaced as an assembly.
Air intake/Exhaust silencer
The air intake/exhaust silencer is located on the outside of the left hand chassis longitudinal, behind the air supply
unit. The silencer is an integral part of the SLS air harness and cannot be serviced individually.
The intake and exhaust air to and from the compressor passes through the silencer. The plastic moulded silencer has
two chambers. One chamber reduces system exhaust noise and the other dampens intake air pulses produced by
the compressor.

REAR SUSPENSION
REPAIRS 64-39
Actuator - rear - ACE
$% 64.60.40
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.
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.
Models with SLS:
WARNING: Ensure the air suspension system is
made safe before commencing work. Otherwise
the chassis may lower onto the bump stops
during repair.
Remove
1.Raise vehicle on ramp.
2.Remove nuts securing anti-roll bar links to
axle. Release links from axle.
3.Pull torsion bar down for access to actuator. 4.Remove nut securing anti-roll bar link to long
arm and remove link.
5.Position container to collect fluid spillage.
6.Remove cap nuts securing fluid pipes to
actuator. Disconnect pipes and remove and
discard sealing washers.
CAUTION: Always fit plugs to open
connections to prevent contamination.

REAR SUSPENSION
REPAIRS 64-41
Bushes - rear long arm - ACE
$% 64.60.46
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.
Models with SLS:
WARNING: Ensure the air suspension system is
made safe before commencing work. Otherwise
the chassis may lower onto the bump stops
during repair.
Remove
1.Raise vehicle on ramp.
2.Remove nuts securing anti-roll bar links to axle.
Release links from axle.
3.Pull torsion bar down for access to actuator.4.Remove securing nuts and remove anti-roll bar
links from torsion bar.
5.Position container to collect fluid spillage.
6.Remove cap nuts securing fluid pipes to
actuator. Disconnect pipes and remove and
discard sealing washers.
CAUTION: Always fit plugs to open
connections to prevent contamination.
7.With assistance, remove bolts securing torsion
bar clamps. Remove clamps and remove
torsion bar and actuator.