2002-2010 Range Rover L322 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Land Rover Model: Range Rover Platform: L322 Codes Chassis Code: L322 👋 Introduction Market Position Segment: Luxury SUV Target Audience: Owners seeking to perform their own maintenance and repairs, independent repair shops, dealerships Competitive Analysis Competitors: BMW X5 (E53/E70), Mercedes-Benz ML-Class (W163/W164), Lexus RX (XU30), Porsche Cayenne (955/957) Key Features Vehicle Strengths: Off-road capability, luxury interior, advanced technology (for its time), strong V8 engines Manual Value Proposition: Empowers owners with factory-level repair and maintenance knowledge, reduces reliance on costly dealership services, provides accurate technical data for DIY enthusiasts and professionals. 📋 Manual Details Coverage Areas Years Covered: 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Regions Covered: Global (North America, Europe, Asia, etc.) Page Count Estimated Page Count: Thousands (comprehensive, often delivered in multiple volumes or sections) Manual Type Type: Workshop Service Repair Manual (WSRM) Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed overhaul procedures, component testing, timing, diagnostics for all L322 engine variants Engine Electrical: ECU operation, sensor testing, wiring diagrams, ignition system, fuel injection system Transmission Automatic: ZF 5HP24, ZF 6HP26 (and later variants if applicable) overhaul, service, diagnostics, fluid specifications, torque converter Powertrain Management: Engine Control Module (ECM), Transmission Control Module (TCM) diagnostics and programming Chassis Suspension: Air suspension system (ACE - Active Cornering Enhancement, EAS - Electronic Air Suspension), control module diagnostics, components, fluid replacement Brakes: ABS, DSC (Dynamic Stability Control), EBD (Electronic Brakeforce Distribution), brake caliper overhaul, rotor replacement, bleeding procedures, hydraulic systems Steering: Power steering system, steering rack, column, alignment specifications Body And Frame: Body panel removal and installation, door mechanisms, glass, weather stripping, chassis repair Electrical Systems: Comprehensive wiring diagrams for all systems, lighting, power windows, mirrors, seats, central locking, alarms HVAC: Climate control system, air conditioning, heating, ventilation, blower motor, refrigerant recharge Infotainment And Navigation: Navigation system, audio system, infotainment unit diagnostics and repair Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug replacement, fluid checks and top-ups Component Diagnosis: Diagnostic trouble codes (DTCs), fault finding, troubleshooting guides for all major systems Repair And Rebuild: Detailed step-by-step instructions for component overhaul, replacement, and reassembly Torque Specifications: Precise torque values for all fasteners and critical components Special Tools: Identification and usage instructions for specialized tools required for specific repairs Troubleshooting Guides: Systematic approaches to diagnosing and resolving common and uncommon faults Technical Depth Depth: Comprehensive - from basic owner maintenance to full engine and transmission rebuilds, advanced electrical diagnostics, and chassis component overhauls. 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable (OCR processed for scanned sections) Print Quality Quality: High-resolution scans/digital creation ensuring clarity of text and diagrams Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code V8: BMW M62 V8 (4.4L) Displacement V8: 4398 cc (4.4 Liters) Horsepower V8: 282 hp @ 5400 rpm (pre-2005 models) Torque V8: 325 lb-ft @ 3600 rpm (pre-2005 models) Engine Code V8 Facelift: Jaguar AJ-V8 Gen III (4.2L Supercharged & Naturally Aspirated) Displacement V8 Facelift: 4196 cc (4.2 Liters) Horsepower V8 Na: 292 hp @ 6000 rpm (2005-2009) Torque V8 Na: 305 lb-ft @ 4000 rpm (2005-2009) Horsepower V8 Sc: 390 hp @ 6100 rpm (Supercharged models, 2005-2009) Torque V8 Sc: 410 lb-ft @ 3500 rpm (Supercharged models, 2005-2009) Engine Code V8 Later: Jaguar AJ-V8 Gen IV (5.0L Naturally Aspirated & Supercharged) Displacement V8 Later: 5000 cc (5.0 Liters) Horsepower V8 5.0 Na: 375 hp @ 6500 rpm (2010) Torque V8 5.0 Na: 375 lb-ft @ 3500 rpm (2010) Horsepower V8 5.0 Sc: 510 hp @ 6000 rpm (Supercharged models, 2010) Torque V8 5.0 Sc: 461 lb-ft @ 2500 rpm (Supercharged models, 2010) Performance Acceleration 0-60 Mph: Varies by engine; approx. 7.4s (4.4L NA) to 5.0s (4.2L SC) Fuel System Injection Type: Multi-point fuel injection (MPFI) or Direct Injection (DI for later 5.0L) Fuel Type: Premium Unleaded Gasoline (91+ octane recommended) 🔧 Transmission Standard Transmission Type: 5-speed automatic (ZF 5HP24) for pre-2005 models Optional Transmission Type: 6-speed automatic (ZF 6HP26) for 2005-2009 models Transmission Type Later: 6-speed automatic (ZF 6HP26) for 2010 models (with slight updates) Features Drivetrain: Permanent Four-Wheel Drive (4WD) with differentials (center, rear) Transfer Case: Dual-range electronic transfer box Terrain Response: Standard across most L322 models, optimizing drivetrain, suspension, and throttle response for various terrains. 📐 Dimensions Exterior Length: Approx. 4950 mm (194.9 inches) Width: Approx. 1955 mm (77.0 inches) (excluding mirrors) Height: Approx. 1877 mm (73.9 inches) (variable with EAS) Wheelbase: Approx. 2885 mm (113.6 inches) Weights Curb Weight: Approx. 2300 - 2500 kg (5070 - 5512 lbs) Gross Vehicle Weight Rating Gvwr: Approx. 3000 - 3200 kg (6614 - 7055 lbs) Cargo Cargo Volume Behind Rear Seats: Approx. 985 Liters (34.8 cubic feet) Cargo Volume With Rear Seats Folded: Approx. 1950 Liters (68.9 cubic...

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Tags: 2002 2003 2004 2005 2006 2007 2008 2009 2010 Car L322 Range Rover

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Description

🏷️ Basic Information

Identification

Make:

Land Rover

Model:

Range Rover

Platform:

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Luxury SUV

Target Audience:

Owners seeking to perform their own maintenance and repairs, independent repair shops, dealerships

Competitive Analysis

Competitors:

BMW X5 (E53/E70), Mercedes-Benz ML-Class (W163/W164), Lexus RX (XU30), Porsche Cayenne (955/957)

Key Features

Vehicle Strengths:

Off-road capability, luxury interior, advanced technology (for its time), strong V8 engines

Manual Value Proposition:

Empowers owners with factory-level repair and maintenance knowledge, reduces reliance on costly dealership services, provides accurate technical data for DIY enthusiasts and professionals.

📋 Manual Details

Coverage Areas

Years Covered:

2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010

Regions Covered:

Global (North America, Europe, Asia, etc.)

Page Count

Estimated Page Count:

Thousands (comprehensive, often delivered in multiple volumes or sections)

Manual Type

Type:

Workshop Service Repair Manual (WSRM)

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed overhaul procedures, component testing, timing, diagnostics for all L322 engine variants

Engine Electrical:

ECU operation, sensor testing, wiring diagrams, ignition system, fuel injection system

Transmission Automatic:

ZF 5HP24, ZF 6HP26 (and later variants if applicable) overhaul, service, diagnostics, fluid specifications, torque converter

Powertrain Management:

Engine Control Module (ECM), Transmission Control Module (TCM) diagnostics and programming

Chassis Suspension:

Air suspension system (ACE - Active Cornering Enhancement, EAS - Electronic Air Suspension), control module diagnostics, components, fluid replacement

Brakes:

ABS, DSC (Dynamic Stability Control), EBD (Electronic Brakeforce Distribution), brake caliper overhaul, rotor replacement, bleeding procedures, hydraulic systems

Steering:

Power steering system, steering rack, column, alignment specifications

Body And Frame:

Body panel removal and installation, door mechanisms, glass, weather stripping, chassis repair

Electrical Systems:

Comprehensive wiring diagrams for all systems, lighting, power windows, mirrors, seats, central locking, alarms

HVAC:

Climate control system, air conditioning, heating, ventilation, blower motor, refrigerant recharge

Infotainment And Navigation:

Navigation system, audio system, infotainment unit diagnostics and repair

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, fluid checks and top-ups

Component Diagnosis:

Diagnostic trouble codes (DTCs), fault finding, troubleshooting guides for all major systems

Repair And Rebuild:

Detailed step-by-step instructions for component overhaul, replacement, and reassembly

Torque Specifications:

Precise torque values for all fasteners and critical components

Special Tools:

Identification and usage instructions for specialized tools required for specific repairs

Troubleshooting Guides:

Systematic approaches to diagnosing and resolving common and uncommon faults

Technical Depth

Depth:

Comprehensive - from basic owner maintenance to full engine and transmission rebuilds, advanced electrical diagnostics, and chassis component overhauls.

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable (OCR processed for scanned sections)

Print Quality

Quality:

High-resolution scans/digital creation ensuring clarity of text and diagrams

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code V8:

BMW M62 V8 (4.4L)

Displacement V8:

4398 cc (4.4 Liters)

Horsepower V8:

282 hp @ 5400 rpm (pre-2005 models)

Torque V8:

325 lb-ft @ 3600 rpm (pre-2005 models)

Engine Code V8 Facelift:

Jaguar AJ-V8 Gen III (4.2L Supercharged & Naturally Aspirated)

Displacement V8 Facelift:

4196 cc (4.2 Liters)

Horsepower V8 Na:

292 hp @ 6000 rpm (2005-2009)

Torque V8 Na:

305 lb-ft @ 4000 rpm (2005-2009)

Horsepower V8 Sc:

390 hp @ 6100 rpm (Supercharged models, 2005-2009)

Torque V8 Sc:

410 lb-ft @ 3500 rpm (Supercharged models, 2005-2009)

Engine Code V8 Later:

Jaguar AJ-V8 Gen IV (5.0L Naturally Aspirated & Supercharged)

Displacement V8 Later:

5000 cc (5.0 Liters)

Horsepower V8 5.0 Na:

375 hp @ 6500 rpm (2010)

Torque V8 5.0 Na:

375 lb-ft @ 3500 rpm (2010)

Horsepower V8 5.0 Sc:

510 hp @ 6000 rpm (Supercharged models, 2010)

Torque V8 5.0 Sc:

461 lb-ft @ 2500 rpm (Supercharged models, 2010)

Performance

Acceleration 0-60 Mph:

Varies by engine; approx. 7.4s (4.4L NA) to 5.0s (4.2L SC)

Fuel System

Injection Type:

Multi-point fuel injection (MPFI) or Direct Injection (DI for later 5.0L)

Fuel Type:

Premium Unleaded Gasoline (91+ octane recommended)

🔧 Transmission

Standard

Transmission Type:

5-speed automatic (ZF 5HP24) for pre-2005 models

Optional

Transmission Type:

6-speed automatic (ZF 6HP26) for 2005-2009 models

Transmission Type Later:

6-speed automatic (ZF 6HP26) for 2010 models (with slight updates)

Features

Drivetrain:

Permanent Four-Wheel Drive (4WD) with differentials (center, rear)

Transfer Case:

Dual-range electronic transfer box

Terrain Response:

Standard across most L322 models, optimizing drivetrain, suspension, and throttle response for various terrains.

📐 Dimensions

Exterior

Length:

Approx. 4950 mm (194.9 inches)

Width:

Approx. 1955 mm (77.0 inches) (excluding mirrors)

Height:

Approx. 1877 mm (73.9 inches) (variable with EAS)

Wheelbase:

Approx. 2885 mm (113.6 inches)

Weights

Curb Weight:

Approx. 2300 - 2500 kg (5070 - 5512 lbs)

Gross Vehicle Weight Rating Gvwr:

Approx. 3000 - 3200 kg (6614 - 7055 lbs)

Cargo

Cargo Volume Behind Rear Seats:

Approx. 985 Liters (34.8 cubic feet)

Cargo Volume With Rear Seats Folded:

Approx. 1950 Liters (68.9 cubic feet)

🛡️ Safety Features

Ratings

NHTSA Front Crash Test:

4/5 stars (for applicable model years)

IIHS Small Overlap Front:

Not rated by IIHS for early L322, later models would be evaluated as part of a broader category.

Active Features

Dynamic Stability Control Dsc:

Standard, integrates with ABS, traction control, and roll stability control.

Hill Descent Control Hdc:

Standard, aids in controlled descents on steep inclines.

Anti-Lock Braking System ABS:

Standard

Electronic Brakeforce Distribution Ebd:

Standard

Passive Features

Airbags:

Front airbags, side-curtain airbags, sometimes front side airbags (depending on year/trim).

Seatbelts:

Three-point seatbelts with pretensioners and load limiters for all seating positions.

Rollover Stability Control:

Integrated with DSC for enhanced stability.

💡 Technology Features

Infotainment

Infotainment System:

Touchscreen navigation and audio system (e.g., L322 'Highline' system), often with integrated climate controls and vehicle settings.

Audio Systems:

Available premium sound systems from Harman Kardon or Harman Kardon Logic 7 (on later models).

Driver Assistance

Adaptive Cruise Control Acc:

Available on higher trims, uses radar to maintain distance from the vehicle ahead.

Parking Sensors:

Front and rear parking sensors are standard on most models.

Bi-Xenon Headlights:

Adaptive Bi-Xenon headlights with automatic leveling and headlight washers available on higher trims.

Connectivity

Bluetooth:

Available for hands-free phone calls and audio streaming on later models.

Usb Aux Input:

Available on some later models for audio connectivity.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 15,000 km (9,300 miles) or 12 months, whichever comes first (check manual for specific engine/conditions).

Engine Oil Filter Replacement:

With every oil change.

Air Filter Replacement:

Check at 15,000 km (9,300 miles), replace as needed or every 30,000 km (18,600 miles).

Cabin Air Filter Replacement:

Check at 15,000 km (9,300 miles), replace as needed or every 24,000 km (15,000 miles).

Spark Plug Replacement V8:

BMW M62: Approx. 100,000 km (60,000 miles). Jaguar V8s: Approx. 160,000 km (100,000 miles).

Transmission Fluid And Filter Service:

Recommended every 60,000 - 100,000 km (37,000 - 60,000 miles) for automatic transmissions (ZF). Consult manual for specific recommendations.

Fluid Specifications

Engine Oil Type:

Varies by engine. BMW M62 typically requires Castrol EDGE Synthetic 5W-30. Jaguar V8s may require specific Jaguar-approved oils (e.g., Castrol SLX Professional). Check manual and oil cap.

Transmission Fluid Type:

ZF 5HP24/6HP26 require specific ZF Lifeguard fluid (e.g., Lifeguardfluid5 or Lifeguardfluid6). Do NOT use generic ATF.

Coolant Type:

Rover/BMW Pentofrost NF (Blue) or equivalent OAT coolant.

Brake Fluid Type:

DOT 4

Power Steering Fluid Type:

CHF 11S or equivalent Pentosin specification.

Known Issues

Eats Air Suspension Leaks:

Common issue: Air springs, compressor, and valve blocks can leak over time. Diagnosis and repair procedures are detailed in the manual.

Ace System Failures:

Active Cornering Enhancement system can develop leaks or actuator failures. Manual covers troubleshooting and repair.

Thermostat Housing Cracks:

Plastic thermostat housing on BMW engines is prone to cracking, leading to coolant leaks.

Pre 2005 V8 Timing Chain Guides:

BMW M62 engines have plastic timing chain guides that can degrade, leading to chain rattle or failure. Early intervention is crucial.

Door Lock Actuator Failure:

Central locking actuators can fail, affecting door locking and unlocking.

Harman Kardon Amplifiers:

Common failure of the audio amplifier, often leading to no sound or distorted sound.

Window Regulators:

Window regulators can fail, leading to windows not operating or falling into the door.

📚 Vehicle History

Brand Heritage

Brand Legacy:

Land Rover has a long history of producing capable off-road vehicles, beginning with the original Land Rover Series I in 1948. The Range Rover marque itself debuted in 1970, establishing the luxury SUV segment.

Model Evolution

L322 Introduction:

The L322 was introduced in 2001 for the 2002 model year, marking a significant shift towards a more integrated chassis and monocoque construction, though retaining its off-road prowess. It was developed under BMW ownership initially, then transitioned to Ford ownership and later Tata Motors.

L322 Facelift 2005:

Significant facelift in 2005 (2006 model year) included new BMW-derived engines (4.4L V8 and 4.2L Supercharged V8), updated interior styling, revised electronics, and the introduction of the Terrain Response system.

L322 Facelift 2010:

Further updates for the 2010 model year included the introduction of the Jaguar-sourced 5.0L V8 engines (naturally aspirated and supercharged) and more significant interior and exterior styling revisions.

Production

Manufacturing Location:

Solihull, West Midlands, United Kingdom

Production Period:

2001-2012 (L322 platform; this manual covers 2002-2010)

🏆 Awards & Recognition

Recognitions

Off Road Capability Awards:

While specific awards for the L322 variant aren't as prominent as dedicated off-road vehicles, the Range Rover lineage is consistently recognized for its off-road prowess and luxury SUV segment leadership.

Luxury Vehicle Accolades:

Range Rover models, including the L322, have frequently appeared on 'best luxury SUV' lists from various automotive publications, highlighting comfort, refinement, and features.

Ratings

Consumer Satisfaction:

Ratings vary by model year and specific issues, but often praised for comfort and capability, with some criticism regarding reliability in earlier BMW-era models.