Land Rover Discovery 2 1995-2007 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Land Rover Model: Discovery 2 Years Covered: 1995-2007 Codes Chassis Codes: LT, LA (pre-facelift L318 variants), L322 (post-facelift variants, though manual primarily focuses on L318) 👋 Introduction Market Position Segment: Full-size SUV, premium off-roader Competitive Analysis Key Competitors During Era: Toyota Land Cruiser, Jeep Grand Cherokee, Mercedes-Benz M-Class, BMW X5, Mitsubishi Pajero/Montero Key Features Off Road Capability: Permanent four-wheel drive, center differential lock, optional rear differential lock, Electronic Traction Control (ETC), Hill Descent Control (HDC), Electronic Air Suspension (EAS) Drivetrain Technology: GKN viscous coupling unit for center differential Interior Amenities: Luxurious interiors (often leather, wood trim), spacious seating for up to seven occupants (with optional third row), advanced climate control 📋 Manual Details Coverage Areas Primary Regions Covered: Global (technical specifications often reflect UK/European market) Page Count Estimated Page Count: High, exceeding 2000 pages (typical for comprehensive factory service manuals) Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine mechanicals, fuel system, ignition system, exhaust system, cooling system, lubrication system Drivetrain: Transfer box, differentials (front, center, rear), driveshafts, CV joints, prop shafts Chassis And Suspension: Front suspension (double wishbone, coil springs/air springs), rear suspension (live axle, coil springs/air springs), steering system, braking system (ABS, EBD), Electronic Air Suspension (EAS) Electrical System: 12V electrical system, battery, charging system, starting system, lighting, instrumentation, infotainment, immobilizer, Body Control Module (BCM), SRS (Supplemental Restraint System) Body And Interior: Body structure, panels, doors, windows, seats, HVAC, interior trim, airbags Procedures Included Maintenance: Routine service checks, fluid changes (engine oil, coolant, brake fluid, transmission fluid, transfer box oil, differential oil), filter replacements (oil, air, fuel, cabin) Diagnostics: Troubleshooting guides for common issues, diagnostic trouble codes (DTCs), sensor testing, actuator testing Repair And Rebuild: Engine overhaul, transmission rebuild, suspension component replacement, brake caliper overhaul, electrical component repair, body panel repair Installation: Component installation, accessory fitting (where applicable) Technical Depth Depth: Comprehensive, from basic maintenance to advanced diagnostics and complete component overhauls, including detailed wiring schematics and troubleshooting trees. 📊 Manual Specifications File Format Digital Format: PDF Print Quality Printability: Yes, all pages are printable. Binding Type Binding Type: Digital (N/A for printed) Paper Type Paper Type: N/A (Digital) Compatibility Operating Systems: Windows/macOS Requirements Software Requirement: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Engine Code And Type: 2.5L TD5 I5 (diesel), 4.0L V8 (petrol - Rover V8), 4.6L V8 (petrol - Rover V8) Performance Td5 Horsepower: Approx. 136 hp @ 4200 rpm Td5 Torque: Approx. 221 lb-ft (300 Nm) @ 1900 rpm V8 4.0 Horsepower: Approx. 190 hp @ 4750 rpm V8 4.0 Torque: Approx. 236 lb-ft (320 Nm) @ 3750 rpm V8 4.6 Horsepower: Approx. 220 hp @ 4750 rpm V8 4.6 Torque: Approx. 282 lb-ft (383 Nm) @ 3250 rpm Fuel System Td5 Fuel System: Direct injection, electronically controlled unit injectors (EU3/EU4 emissions compliant variants) V8 Fuel System: Multi-point fuel injection (MPI), distributorless ignition system (DIS) Maintenance Td5 Timing Belt Or Chain: Timing chain (no replacement interval specified, but requires inspection) V8 Timing Belt Or Chain: Timing chain (no replacement interval specified, but requires inspection) 🔧 Transmission Standard Gearbox Options: 5-speed manual (LT77, R380), 4-speed automatic (ZF 4HP22) Optional Transmission Variations: 4-speed automatic for V8 and TD5, 5-speed manual primarily for TD5 and earlier V8 models. Features Transfer Case: Permanent 4WD with lockable center differential (2-speed transfer box with high/low range) Maintenance Manual Transmission Fluid: Refer to manual for specific specification (e.g., GL-4 or GL-5 gear oil, e.g., Castrol EPX 80W-90) Automatic Transmission Fluid: Dexron III (e.g., Castrol Transmax DEXIII MERCON V) Transfer Box Fluid: Refer to manual for specific specification (e.g., Castrol EPX 80W-90) 📐 Dimensions Exterior Length: Approx. 4706 mm (185.3 in) Width: Approx. 1888 mm (74.3 in) Height: Approx. 1941 mm (76.4 in) Weights Curb Weight: Approx. 2050-2200 kg (4519-4850 lbs) depending on engine and specification Gross Vehicle Weight: Approx. 3000-3150 kg (6614-6944 lbs) Towing Capacity: Up to 3500 kg (7716 lbs) (braked trailer), varies by market and specific model 🛡️ Safety Features Ratings Euro Ncap Rating: Not officially rated by Euro NCAP for the earlier models; later models saw some safety improvements but generally not benchmarked against modern standards. Active Features Hill Descent Control: Yes (HDC) Electronic Traction Control: Yes (ETC) Anti Lock Braking System: Yes (ABS), integrated with Electronic Brakeforce Distribution (EBD) Passive Features Airbags: Front airbags for driver and passenger, optional side airbags (market dependent) Seatbelts: Three-point seatbelts with pretensioners for front occupants, three-point seatbelts for rear occupants Structural Features Body Construction: Body-on-frame construction (separate chassis and body) - robust for off-roading but less sophisticated than monocoque in crash energy management. 💡 Technology Features Infotainment Head Unit: Factory fitted radios with CD players, often with integrated navigation systems on higher trims. Optional premium audio systems may be present. Driver Assistance Cruise Control: Yes,...
LT, LA (pre-facelift L318 variants), L322 (post-facelift variants, though manual primarily focuses on L318)
👋 Introduction
Market Position
Segment:
Full-size SUV, premium off-roader
Competitive Analysis
Key Competitors During Era:
Toyota Land Cruiser, Jeep Grand Cherokee, Mercedes-Benz M-Class, BMW X5, Mitsubishi Pajero/Montero
Key Features
Off Road Capability:
Permanent four-wheel drive, center differential lock, optional rear differential lock, Electronic Traction Control (ETC), Hill Descent Control (HDC), Electronic Air Suspension (EAS)
Drivetrain Technology:
GKN viscous coupling unit for center differential
Interior Amenities:
Luxurious interiors (often leather, wood trim), spacious seating for up to seven occupants (with optional third row), advanced climate control
📋 Manual Details
Coverage Areas
Primary Regions Covered:
Global (technical specifications often reflect UK/European market)
Page Count
Estimated Page Count:
High, exceeding 2000 pages (typical for comprehensive factory service manuals)
Comprehensive, from basic maintenance to advanced diagnostics and complete component overhauls, including detailed wiring schematics and troubleshooting trees.
4-speed automatic for V8 and TD5, 5-speed manual primarily for TD5 and earlier V8 models.
Features
Transfer Case:
Permanent 4WD with lockable center differential (2-speed transfer box with high/low range)
Maintenance
Manual Transmission Fluid:
Refer to manual for specific specification (e.g., GL-4 or GL-5 gear oil, e.g., Castrol EPX 80W-90)
Automatic Transmission Fluid:
Dexron III (e.g., Castrol Transmax DEXIII MERCON V)
Transfer Box Fluid:
Refer to manual for specific specification (e.g., Castrol EPX 80W-90)
📐 Dimensions
Exterior
Length:
Approx. 4706 mm (185.3 in)
Width:
Approx. 1888 mm (74.3 in)
Height:
Approx. 1941 mm (76.4 in)
Weights
Curb Weight:
Approx. 2050-2200 kg (4519-4850 lbs) depending on engine and specification
Gross Vehicle Weight:
Approx. 3000-3150 kg (6614-6944 lbs)
Towing Capacity:
Up to 3500 kg (7716 lbs) (braked trailer), varies by market and specific model
🛡️ Safety Features
Ratings
Euro Ncap Rating:
Not officially rated by Euro NCAP for the earlier models; later models saw some safety improvements but generally not benchmarked against modern standards.
Active Features
Hill Descent Control:
Yes (HDC)
Electronic Traction Control:
Yes (ETC)
Anti Lock Braking System:
Yes (ABS), integrated with Electronic Brakeforce Distribution (EBD)
Passive Features
Airbags:
Front airbags for driver and passenger, optional side airbags (market dependent)
Seatbelts:
Three-point seatbelts with pretensioners for front occupants, three-point seatbelts for rear occupants
Structural Features
Body Construction:
Body-on-frame construction (separate chassis and body) - robust for off-roading but less sophisticated than monocoque in crash energy management.
💡 Technology Features
Infotainment
Head Unit:
Factory fitted radios with CD players, often with integrated navigation systems on higher trims. Optional premium audio systems may be present.
Driver Assistance
Cruise Control:
Yes, electronically controlled cruise control available on most models.
Parking Assistance:
Rear parking sensors available on some later models, but not a universally standard feature.
Connectivity
Auxiliary Inputs:
Limited by era, primarily analog connections if available, often requiring aftermarket modifications for modern device connectivity.
Lighting
Headlights:
Halogen headlights, with some later models potentially offering Xenon HID headlights.
🔧 Maintenance
Service Intervals
Engine Oil And Filter Td5:
Typically 10,000 miles (16,000 km) or 12 months, whichever comes first.
Engine Oil And Filter V8:
Typically 6,000 miles (10,000 km) or 12 months, whichever comes first.
Fuel Filter Td5:
Every 24,000 miles (38,000 km) or 24 months.
Air Filter All Engines:
Every 12,000 miles (20,000 km) or 12 months.
Brake Fluid All Models:
Every 24 months, regardless of mileage.
Fluid Specifications
Engine Coolant:
OAT (Organic Acid Technology) type coolant, e.g., Rover Coolant (RTC9802) or equivalent, mixed 50/50 with distilled water.
Power Steering Fluid:
Automatic Transmission Fluid (ATF) Dexron II or III.
Known Issues
Td5 Engine Management:
Potential issues with the engine control unit (ECU), injector harnesses, and fuel pump. Head gasket failures are also a known, though not universal, issue, particularly with hard use or lack of proper maintenance.
V8 Engine Issues:
Head gasket failures are common, especially on the 4.6L variants. Inherent issues with the 'GEMS' (Gasoline Engine Management System) and later 'Bosch' engine management systems require careful diagnosis. Coolant leaks, particularly from the 'valley gasket', are also prevalent.
Electronic Air Suspension:
EAS compressor failures, valve block leaks, sensor failures, and air spring leaks are common wear items. Fault codes related to EAS can be complex to diagnose without the correct tools and knowledge.
Driveshafts And Cv Joints:
Wear and tear on universal joints and CV joints can lead to clunking noises and vibration, especially under acceleration or turning.
Body Rust:
Rust can affect the chassis, sills, wheel arches, and rear crossmember, particularly in damp climates. The manual will provide guidance on inspection and repair.
📚 Vehicle History
Brand Heritage
Land Rover Legacy:
Known for robust, go-anywhere 4x4 vehicles, with a strong heritage in off-road capability and exploration (e.g., Land Rover Series I, II, III, and Defender).
Model Evolution
Discovery Series 1 To 2 Transition:
The Discovery 2 replaced the original Discovery Series I. It featured updated styling, a revised interior, and significant mechanical upgrades including the TD5 diesel engine and the introduction of the Electronic Air Suspension (EAS) and Self-Levelling Suspension (SLS) options. It was built on a ladder chassis, sharing its platform with the Defender to some extent.
Production
Production Years For Discovery 2:
1998-2004 (though the manual covers up to 2007, reflecting market variations and potential for later registrations of earlier models, or simply an extended coverage for sale).
Manufacturing Location:
Solihull, West Midlands, United Kingdom
🏆 Awards & Recognition
Recognitions
Off Road Awards:
While not a direct award, the Land Rover Discovery series has consistently been recognized for its off-road prowess and utility, earning a strong reputation among adventurers and off-road enthusiasts globally.