Remove Factory Installed Pipe

CAUTION:
The ACE system is extremely sensitive to dirt and debris.

^ All surfaces and components must be thoroughly cleaned before opening the system. Use a pressure washer to clean the entire length of the lines. Wait for the vehicle to dry before starting the repair.

^ To avoid system contamination when installing the new pipes the protective end caps must remain in place at all times until the connection is made.

1. Drive the vehicle onto a lift. Place the transmission in Park, set the handbrake and ensure that the ignition is off.

2. Raise the vehicle on the lift.

3. Remove the right front wheel.

4. Lower the chassis onto a support, allowing the right front hub to travel down to the full rebound position.

5. Remove the radiator underbelly tray by removing the 5 screws.

6. Remove the front mud flap for ease of access.

NOTE:
The forward splash shield screw cannot be accessed unless the suspension is fully extended.





7. Remove the splash shield in the right front wheel housing by removing the three screws, and removing it from the engine bay. (Figure 2)

CAUTION:
Pipe mounting brackets must be marked for orientation to permit installation in the same position at the completion of the repair.

8. Remove the two-way isolator and bracket from the chassis cross member below the radiator.

9. Remove the two 13 mm keeper plate securing nuts from the front of the valve block located on the right chassis side member.

CAUTION:
It is very important that the four pipes remain in the valve block while the keeper plate is loosened and moved back along the pipes.

NOTE:
If the pipe identification sleeve is positioned behind the tangs, you will not be able to squeeze the collet tangs together.

10. If any of the identification sleeves are found behind the tangs, slide them along the pipes away from the valve block.





11. Using needle-nosed pliers squeeze the collet tangs on all four pipes (Figure 3) and gently pry the keeper plate 5 mm (3/16 in.) away from the valve block.

NOTE:
The bottom pipe in the keeper plate is identified with the letter "P" on the identification sleeve. The letter "P" is also stamped on the face of the keeper plate in the bottom location.

12. Slide the keeper plate away from the valve block.





NOTE:
With the collet removed from the "P" pipe, that pipe can later be removed from the valve block without further disassembly.

13. Remove and discard the collet on the pipe labeled P (Figure 4).

CAUTION:
It is important to temporarily secure the keeper plate during pipe removal to avoid leakage and to remove the possibility that a pipe might disengage from the valve block.

14. Reposition the keeper plate onto the valve block and secure finger-tight with the two 13 mm nuts previously removed.

15. Cut away the glued two-way isolator supporting the rigid pipes in front of the shock tower and discard.

NOTE:
All removed brackets must be marked for orientation to ensure that they are installed in the same position during assembly.





16. From inside the engine compartment remove the four-way isolator and bracket from the shock absorber tower. (Figure 5)





17. Locate and remove the four-way isolator inside the right front wheel housing. (Figure 6)





18. Locate the four-way isolator above the chassis outrigger. (Figure 7)

NOTE:
The outrigger isolator is glued to the pipes.

^ Only the "P" pipe is to be cut free from the four-way isolator.

^ The "P" pipe is the second pipe in from the outside of the vehicle.

^ Cutting the isolator as described will permit removal of the "P" pipe in a following step.

19. Using a razor blade knife, make two cuts completely through the outrigger isolator, one on each side of the "P" pipe. (Figure 7)

20. Ensure that the correct pipe, labeled "P" at the valve block and second from the bottom at the shock tower is selected for the next step.

CAUTION:
An appropriate cutting tool must be used to cut the high-pressure pipe. Care must be taken to ensure that no contamination enters the system and that no damage is done to any surrounding components.





21. Cut the high-pressure "P" pipe behind the shock tower. (Figure 8)

22. Promptly bend the cut pipes downward to prevent debris from flowing into the system.





23. Cut the "P" pipe a second time in front of the shock tower (Figure 9).

24. Remove and discard the section of pipe between the two cuts

CAUTION:
Care must be exercised to ensure that the "A," "B" and "T" pipes remain engaged in the valve block. The keeper plate on the valve block must remain in position. It should not be loosened to aid in the removal of the "P" pipe.

NOTE:
The "P" pipe will need to be pulled and twisted in order to free it from the cut four-way isolator above the chassis outrigger.

25. Remove and discard the section of "P" pipe that is still connected to the valve block.





26. Remove the 19 mm banjo bolt and disconnect the pipe from the pump. (Figure 10)

27. Discard the two seals from the banjo bolt.

28. Remove the flexible section of pipe from the vehicle and discard.