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Land Rover 1999-2003 DISCOVERY Series 2 Full Workshop Manual

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🏷️ Basic Information Identification Make: Land Rover Model: Discovery Series II Generation: Series II Production Years Covered: 1999-2003 Codes Platform Code: L322 (Series II Platform) 👋 Introduction Market Position Vehicle Segment: Premium Mid-size to Full-size SUV, known for off-road capability and luxury. Competitive Analysis Competitors: Jeep Grand Cherokee, Toyota Land Cruiser, Lexus LX, Mercedes-Benz M-Class, BMW X5 (depending on specific market and trim). Key Features Off Road Prowess: Center differential, optional locking rear differential, high ground clearance, robust chassis, and sophisticated suspension systems (especially ACE and SLS). Luxury And Comfort: Spacious interior, premium materials, comfortable ride for a large SUV of its era. 📋 Manual Details Coverage Areas Manual Type: Full Workshop Manual Language: English Format: Digital (likely PDF, but specified as 'Full Workshop Manual' implying comprehensive content) Page Count Estimated Page Count: Over 1500 pages (typical for full workshop manuals of this era) 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel Delivery, Cooling, Exhaust, Clutch, Manual Gearbox, Automatic Gearbox, Transfer Box Chassis: Propeller Shafts, Front Axle, Rear Axle, Steering, Front Suspension, Rear Suspension, Brakes Electrical: Engine Management, Emission Control, Body Control Unit, Harnesses, Driving Aids, Navigation System, Instruments Bodywork: General Information, Identification Number, Lifting and Towing, Interior Fittings, Screens, Seats, Panel Repair, Air Conditioning Procedures Included Maintenance: Scheduled Maintenance, Lubrication, Filter Changes, Inspections Repair And Overhaul: Engine Rebuilds, Transmission Overhauls, Suspension Component Replacement, Brake System Repairs, Electrical System Diagnostics Diagnostics And Troubleshooting: Fault Code Interpretation, Symptom-Based Diagnosis, Component Testing Technical Specifications: Torque Values, Clearances, Fluid Capacities, Electrical Schematics, Component Data Technical Depth Diagnostic Tools: Includes procedures for using diagnostic tools relevant to the era (e.g., Land Rover TestBook or early OBD-II scanners). Component Rebuilds: Detailed instructions for complete disassembly, inspection, repair, and reassembly of major components like engines, gearboxes, and differentials. Electrical Schematics: Comprehensive wiring diagrams and schematics for all vehicle systems. 📊 Manual Specifications File Format Digital Format Details: Likely a searchable PDF for easy navigation and printing. High resolution for clarity of diagrams and text. Print Quality Diagram Clarity: High-quality reproduction of technical drawings, schematics, and exploded views. Binding Type Physical Manual Binding: N/A (assumed digital, but if printed: likely spiral-bound or perfect-bound for durability in a workshop environment) Paper Type Physical Manual Paper: N/A (assumed digital, but if printed: heavy-duty paper stock to withstand workshop conditions) ⚙️ Engine Specifications Primary Engine Td5 Engine Code: Td5 Displacement: 2.5 Liters (2498 cc) Configuration: Inline 5-cylinder Turbocharged Diesel Power Output: Approx. 136 hp (101 kW) @ 4200 rpm Torque Output: Approx. 207 lb-ft (280 Nm) @ 1900 rpm Fuel System: Electronic Direct Injection (EDC) with rotary injection pump and electronically controlled injectors. Emissions Control: Catalytic converter, EGR (Exhaust Gas Recirculation) system. Rover V8 4.0 Engine Code: 4.0L Rover V8 (often designated GEMS or Thor depending on specific VIN range within the production years) Displacement: 4.0 Liters (3950 cc) Configuration: 90-degree V8 (Rover SD1 heritage) Power Output: Approx. 182 hp (136 kW) @ 4750 rpm Torque Output: Approx. 236 lb-ft (320 Nm) @ 2600 rpm Fuel System: Multi-point Fuel Injection (MPI), managed by Lucas GEMS or Bosch engine management systems. Rover V8 4.6 Engine Code: 4.6L Rover V8 (often designated GEMS or Thor) Displacement: 4.6 Liters (4624 cc) Configuration: 90-degree V8 Power Output: Approx. 217 hp (162 kW) @ 4750 rpm Torque Output: Approx. 280 lb-ft (380 Nm) @ 3000 rpm Fuel System: Multi-point Fuel Injection (MPI), managed by Lucas GEMS or Bosch engine management systems. 🔧 Transmission Automatic Transmission Type: 4 Speed Automatic (ZF 4HP22 HSE or similar) Transmission Features: Electronic control, CommandShift manual override (select models/years). Fluid Type: TF82SC (or equivalent specification for ZF 4HP22 HSE). Manual Transmission Type: 5 Speed Manual (R380 gearbox) Clutch Type: Hydraulically actuated single dry plate clutch. Gearbox Oil Type: API GL-4 SAE 75W/90 synthetic gear oil. Transfer Case Transfer Case Type: Permanent Four-Wheel Drive with a center differential (open type), optional locking rear differential. Transfer Case Oil Type: API GL-4 SAE 75W/90 gear oil. 📐 Dimensions Exterior Length: Approx. 186.3 inches (4732 mm) Width: Approx. 70.1 inches (1781 mm) (excluding mirrors) Height: Approx. 73.5 inches (1867 mm) (with roof rails, varies with suspension height) Weights Curb Weight: Approx. 4,800 - 5,100 lbs (2177 - 2313 kg), varies by engine and configuration. Gross Vehicle Weight Rating: Approx. 6,500 - 6,800 lbs (2948 - 3084 kg) Towing Capacity: Up to 7,700 lbs (3500 kg) depending on market and configuration. 🛡️ Safety Features Ratings NHTSA Crash Test Rating: NCAP ratings from the era are available, but direct NHTSA equivalence can vary. Known for robust construction. Active Features Electronic Traction Control: Traction Control System (TCS) on rear-wheel slip, and often linked to ABS. Anti Lock Brakes: Standard on all models, providing enhanced braking control. Electronic Brake Force Distribution: Integrated with ABS to optimize braking performance based on load. Hill Descent Control: Standard on most models, assists...
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Sku: 473055
Collecties: ALL Land Rover

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Land Rover 1999-2003 DISCOVERY Series 2 Full Workshop Manual
🏷️ Basic Information
Identification
Make:
Land Rover
Model:
Discovery Series II
Generation:
Series II
Production Years Covered:
1999-2003
Codes
Platform Code:
L322 (Series II Platform)
👋 Introduction
Market Position
Vehicle Segment:
Premium Mid-size to Full-size SUV, known for off-road capability and luxury.
Competitive Analysis
Competitors:
Jeep Grand Cherokee, Toyota Land Cruiser, Lexus LX, Mercedes-Benz M-Class, BMW X5 (depending on specific market and trim).
Key Features
Off Road Prowess:
Center differential, optional locking rear differential, high ground clearance, robust chassis, and sophisticated suspension systems (especially ACE and SLS).
Luxury And Comfort:
Spacious interior, premium materials, comfortable ride for a large SUV of its era.
📋 Manual Details
Coverage Areas
Manual Type:
Full Workshop Manual
Language:
English
Format:
Digital (likely PDF, but specified as 'Full Workshop Manual' implying comprehensive content)
Page Count
Estimated Page Count:
Over 1500 pages (typical for full workshop manuals of this era)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Fuel Delivery, Cooling, Exhaust, Clutch, Manual Gearbox, Automatic Gearbox, Transfer Box
Chassis:
Propeller Shafts, Front Axle, Rear Axle, Steering, Front Suspension, Rear Suspension, Brakes
Electrical:
Engine Management, Emission Control, Body Control Unit, Harnesses, Driving Aids, Navigation System, Instruments
Bodywork:
General Information, Identification Number, Lifting and Towing, Interior Fittings, Screens, Seats, Panel Repair, Air Conditioning
Procedures Included
Maintenance:
Scheduled Maintenance, Lubrication, Filter Changes, Inspections
Repair And Overhaul:
Engine Rebuilds, Transmission Overhauls, Suspension Component Replacement, Brake System Repairs, Electrical System Diagnostics
Diagnostics And Troubleshooting:
Fault Code Interpretation, Symptom-Based Diagnosis, Component Testing
Technical Specifications:
Torque Values, Clearances, Fluid Capacities, Electrical Schematics, Component Data
Technical Depth
Diagnostic Tools:
Includes procedures for using diagnostic tools relevant to the era (e.g., Land Rover TestBook or early OBD-II scanners).
Component Rebuilds:
Detailed instructions for complete disassembly, inspection, repair, and reassembly of major components like engines, gearboxes, and differentials.
Electrical Schematics:
Comprehensive wiring diagrams and schematics for all vehicle systems.
📊 Manual Specifications
File Format
Digital Format Details:
Likely a searchable PDF for easy navigation and printing. High resolution for clarity of diagrams and text.
Print Quality
Diagram Clarity:
High-quality reproduction of technical drawings, schematics, and exploded views.
Binding Type
Physical Manual Binding:
N/A (assumed digital, but if printed: likely spiral-bound or perfect-bound for durability in a workshop environment)
Paper Type
Physical Manual Paper:
N/A (assumed digital, but if printed: heavy-duty paper stock to withstand workshop conditions)
⚙️ Engine Specifications
Primary Engine Td5
Engine Code:
Td5
Displacement:
2.5 Liters (2498 cc)
Configuration:
Inline 5-cylinder Turbocharged Diesel
Power Output:
Approx. 136 hp (101 kW) @ 4200 rpm
Torque Output:
Approx. 207 lb-ft (280 Nm) @ 1900 rpm
Fuel System:
Electronic Direct Injection (EDC) with rotary injection pump and electronically controlled injectors.
Emissions Control:
Catalytic converter, EGR (Exhaust Gas Recirculation) system.
Rover V8 4.0
Engine Code:
4.0L Rover V8 (often designated GEMS or Thor depending on specific VIN range within the production years)
Displacement:
4.0 Liters (3950 cc)
Configuration:
90-degree V8 (Rover SD1 heritage)
Power Output:
Approx. 182 hp (136 kW) @ 4750 rpm
Torque Output:
Approx. 236 lb-ft (320 Nm) @ 2600 rpm
Fuel System:
Multi-point Fuel Injection (MPI), managed by Lucas GEMS or Bosch engine management systems.
Rover V8 4.6
Engine Code:
4.6L Rover V8 (often designated GEMS or Thor)
Displacement:
4.6 Liters (4624 cc)
Configuration:
90-degree V8
Power Output:
Approx. 217 hp (162 kW) @ 4750 rpm
Torque Output:
Approx. 280 lb-ft (380 Nm) @ 3000 rpm
Fuel System:
Multi-point Fuel Injection (MPI), managed by Lucas GEMS or Bosch engine management systems.
🔧 Transmission
Automatic
Transmission Type:
4 Speed Automatic (ZF 4HP22 HSE or similar)
Transmission Features:
Electronic control, CommandShift manual override (select models/years).
Fluid Type:
TF82SC (or equivalent specification for ZF 4HP22 HSE).
Manual
Transmission Type:
5 Speed Manual (R380 gearbox)
Clutch Type:
Hydraulically actuated single dry plate clutch.
Gearbox Oil Type:
API GL-4 SAE 75W/90 synthetic gear oil.
Transfer Case
Transfer Case Type:
Permanent Four-Wheel Drive with a center differential (open type), optional locking rear differential.
Transfer Case Oil Type:
API GL-4 SAE 75W/90 gear oil.
📐 Dimensions
Exterior
Length:
Approx. 186.3 inches (4732 mm)
Width:
Approx. 70.1 inches (1781 mm) (excluding mirrors)
Height:
Approx. 73.5 inches (1867 mm) (with roof rails, varies with suspension height)
Weights
Curb Weight:
Approx. 4,800 - 5,100 lbs (2177 - 2313 kg), varies by engine and configuration.
Gross Vehicle Weight Rating:
Approx. 6,500 - 6,800 lbs (2948 - 3084 kg)
Towing Capacity:
Up to 7,700 lbs (3500 kg) depending on market and configuration.
🛡️ Safety Features
Ratings
NHTSA Crash Test Rating:
NCAP ratings from the era are available, but direct NHTSA equivalence can vary. Known for robust construction.
Active Features
Electronic Traction Control:
Traction Control System (TCS) on rear-wheel slip, and often linked to ABS.
Anti Lock Brakes:
Standard on all models, providing enhanced braking control.
Electronic Brake Force Distribution:
Integrated with ABS to optimize braking performance based on load.
Hill Descent Control:
Standard on most models, assists in controlled descents on steep gradients.
Passive Features
Airbags:
Frontal airbags for driver and passenger; side airbags optional or standard on higher trims.
Seatbelts:
Three-point inertia reel seatbelts for all seating positions, pre-tensioners for front seats.
Body Structure:
Body-on-frame construction with a strong ladder chassis providing excellent rigidity and crash protection.
💡 Technology Features
Infotainment
Audio System:
Premium audio systems, often with CD players and multiple speakers. Some models may have optional Harman Kardon systems.
Navigation System:
Optional factory-fitted navigation systems were available, typically using CD-ROM based maps.
Driver Assistance
Parking Aids:
Rear parking sensors were an option on later models.
Connectivity
Phone Integration:
Some models featured provisions for early mobile phone integration (e.g., Bluetooth or cradle).
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Td5: Every 6,000 miles (9,600 km) or 12 months. V8s: Every 6,000 miles (9,600 km) or 12 months.
Air Filter Replacement:
Td5: Every 12,000 miles (19,200 km) or 24 months. V8s: Every 12,000 miles (19,200 km) or 24 months.
Fuel Filter Replacement:
Td5: Every 12,000 miles (19,200 km) or 24 months. V8s: Not a regular replacement interval, but checked for blockage.
Transmission Fluid Change:
Automatic: Every 48,000 miles (77,000 km) or 48 months. Manual: Checked regularly, fluid typically replaced at 100,000 miles (160,000 km) or if contaminated.
Fluid Specifications
Engine Oil Td5:
ACEA B3/B4, API CG-4/CF-4, SAE 5W-40 or 10W-40 synthetic diesel engine oil.
Engine Oil V8:
API SJ or higher, SAE 10W-40 or 20W-50 depending on climate and specific V8 variant (refer to manual for precise recommendation), often a high-zinc content oil for flat tappet protection if applicable.
Coolant:
OAT (Organic Acid Technology) coolant, typically blue or pink (e.g., Rover Coolant or equivalent meeting BS 6580:1992 standard).
Known Issues
Td5 Engine:
Head gasket failures (due to block deck cooling design), injector harness leaks (under the rocker cover), oil in the ECU connector, fuel pump issues, turbocharger problems.
V8 Engine:
Head gasket failures, coolant leaks from front timing cover and rear crank seal, distributorless ignition system issues (if applicable to later models), oil cooler leaks.
Suspension And Electronics:
ACE system hydraulic pump failures and leaks, SLS compressor issues, air suspension spring failures, EATCL (Electronic Automatic Traction Control) faults, ABS sensor failures.
Body And Chassis:
Rusting in sills, rear crossmember, door bottoms, and wheel arches. Door seals and window seals can degrade, leading to leaks.
📚 Vehicle History
Brand Heritage
Land Rover Legacy:
Roots in robust, go-anywhere British off-road vehicles dating back to the original Land Rover Series I.
Model Evolution
Discovery Series Ii Development:
An evolution of the original Discovery platform, featuring significant upgrades in chassis, suspension, and technology compared to the original Discovery (Series I).
Key Series Ii Innovations:
Revised chassis, improved seating capacity, introduction of Active Cornering Enhancement (ACE) and Self-Levelling Suspension (SLS) as optional features for enhanced on-road handling and off-road articulation.
Production
Manufacturing Plant:
Solihull, United Kingdom.
🏆 Awards & Recognition
Recognitions
Off Road Awards:
Consistently recognized for its off-road capability and versatility in various automotive publications and adventurer reviews.
Ratings
Towing Ratings:
Highly rated for its towing capacity, making it a popular choice for large trailers and caravans.
Certifications
Automotive Standards:
Manufactured to meet all relevant European and global automotive safety and emissions standards for its production period.
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