New Two-Part Pipe Installation Procedure
CAUTION:The ACE system is extremely sensitive to dirt and debris. To avoid system contamination when fitting the new pipes, the protective end caps must remain in place at all times until the connection is made.
1. Feed the new flexible pipe (RQB100250K) through the inner fender until the banjo fitting is in place next to the pump.
2. Install the banjo bolt as follows: (Figure 11)
^ Remove the protective cap on the fitting.
^ Install a new washer under the banjo bolt head.
^ Insert banjo bolt through the fitting and install the second new washer.
^ Thread the bolt into the pump and torque bolt to 27 - 30 Nm (20 to 22 lbf.ft.).
3. Continue to feed the pipe through the inner fender until the capped end of the rigid pipe is located in front of the shock tower.
4. Gently bend the inner fender away from the chassis in the area behind the shock tower where the flexible brake pipes are attached.
CAUTION:
When fitting the new rigid pipe section (RQB100260K), care must be exercised to avoid dislodging the accelerometer wiring harness.
5. Move aside the electrical harness from the shock tower to ease fitting of the rigid pipe (RQB100260K).
6. Refer to Figure 12 and position the new rigid rear pipe section as follows:
^ Orient the pipe with the fitting end toward the front of the vehicle.
^ Insert the rear pipe end into position, starting from the front wheel arch and locating it above the outrigger and inboard of the body mount.
^ Slide the pipe under the four-way isolator that was previously cut. (Figure 13)
^ Continue to slide the pipe end beyond the valve block.
7. Route the front end of the pipe inside the inner fender and inboard of the shock tower.
CAUTION:
The three pipes not under repair must remain engaged in the valve block. Care must be exercised to ensure that no dirt or debris enters the valve block or pipes.
8. Remove the two nuts securing the valve block keeper and slide the keeper back along the pipes.
9. Insert new pipe "P" through the keeper plate and into the valve block. (Figure 14)
10. Slide the new collet (ANR6700K) over the ridge on the "P" pipe with the "ears" of the collet facing the front of the vehicle.
11. Close the collet over the pipe.
12. Slide the keeper plate down the pipes and over all four collets ensuring that all the "ears" on the four collets are latched in the keeper plate.
13. Install the keeper plate nuts and tighten to 19 - 25 Nm (14 to 18.5 lbf.ft.).
14. Remove the two protective caps from each side of the rigid pipe union.
15. Tighten the high-pressure pipe union finger-tight. (Figure 15)
CAUTION:
To ensure that noise levels from the ACE system are kept to the lowest possible levels, careful installation of the isolator rubbers and brackets is required.
NOTE:
A wire-tie can be used to hold the two halves of the isolators together during the super glue cure time.
16. Refer to Figure 16 and install a four-way isolator above the chassis outrigger as follows:
^ Install the new four-way isolator directly behind the previously cut four-way isolator.
^ Glue the isolator into position using super glue.
^ Hold the isolator together for approximately 15 seconds to permit the glue to cure.
17. Refer to Figure 17 and install a new 2-way isolator to the two pipes above the chassis rail forward of the shock tower as follows:
^ Position the two-way isolator.
^ Glue the two halves together using super glue.
^ Hold the isolator together for approximately 15 seconds to permit the glue to cure.
CAUTION:
Pipe mounting brackets must be installed in the same orientation as the original assembly position.
18. Install the two-way isolator and bracket on the front cross member under the radiator.
19. Torque the cross member bracket fastener to 7 - 10 Nm (62 to 88.5 lbf.in.).
20. Install the four-way isolator and bracket on the shock tower ensuring that all four pipes are properly placed in the isolator recesses. (Figure 18)
21. Torque the shock tower bracket fastener to 7 - 10 Nm (62 to 88.5 lbf.in.).
22. Install the four-way isolator on the chassis side member ensuring that all four pipes are properly placed in the isolator recesses. (Figure 19)
23. Torque the chassis side member bracket fastener to 7 - 10 Nm (62 to 88.5 lbf.in.).
24. Push the inner fender section back into position and reposition the electrical harness to ensure there is no contact with the ACE piping.
25. Torque the high-pressure pipe union to 23 - 27 Nm (17 to 20 lbf.ft.).
26. Remove any tie-wraps used to hold super-glued isolators.
27. Top up the ACE reservoir with approved cold climate PAS fluid (LRN2261).
28. Perform a final ACE system visual check to ensure that no piping is in contact with chassis or body components.
29. Start the engine and allow the vehicle to idle for one minute.
30. Check the ACE system piping for leaks with particular attention paid to the new connections made at the pump, the pipe union and at the valve block.
31. Install the mud flap and under-radiator cover
32. Install the plastic splash shield in the right front wheel housing and secure using the three screws removed previously.
33. Install the right front wheel and lower the vehicle back down onto its front suspension.
34. Check and top up the ACE system reservoir with cold climate PAS fluid (LRN2261).