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Land Rover Discovery 2 2004 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Land Rover Model: Discovery 2 Year: 2004 Codes Chassis Code: L322 (though often referred to as Discovery Series II, it shares platform elements with the later L322 generation) 👋 Introduction Market Position Market Segment: Mid-size luxury SUV, known for its off-road capability and versatility. Competitive Analysis Key Competitors: Jeep Grand Cherokee, Toyota Land Cruiser, Mercedes-Benz ML-Class, BMW X5. Key Features Distinguishing Features: Go anywhere capability, sophisticated V8 engines, comfortable interior, advanced electronic aids (e.g., Hill Descent Control, ABS, Traction Control). 📋 Manual Details Coverage Areas Systems Covered Overview: Comprehensive coverage of all mechanical, electrical, and body systems for the 2004 Land Rover Discovery 2. Page Count Estimated Page Count: Extensive (actual PDF page count varies by specific version but typically exceeds 1000 pages for a complete factory service manual). Manual Type Manual Type: Factory Service Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: V8 engine (4.0L, 4.6L variants), engine management, cooling, exhaust, emissions control. Powertrain Systems: Manual gearbox (R380), Transfer box (LT230SE), Automatic gearbox (ZF4HP22-24), clutch, propeller shafts, front and rear axles. Chassis And Suspension: Steering, front and rear suspension, brakes, chassis and body dimensions. Body And Interior: Doors, exterior fittings, interior trim, screens, seats, sunroof, panel repairs, body sealing, corrosion prevention, painting. Electrical Systems: Charging and starting, lighting, body control unit, alarm, horn, windows, infotainment, navigation, instruments, harnesses, driving aids. HVAC Systems: Heating and ventilation, air conditioning, wipers and washers. Procedures Included Maintenance Procedures: Scheduled maintenance, fluid changes, lubrication, filter replacements, tune-ups. Repair Procedures: Detailed step-by-step repair instructions for all major components and systems, including engine, transmission, suspension, brakes, and electrical systems. Diagnostic Procedures: Troubleshooting guides, diagnostic charts, and procedures for identifying and resolving common and complex issues. Specification Data: Torque wrench settings, fluid capacities, lubricant specifications, sealants, identification numbers, general data. Body And Paint Repairs: Detailed guidance on panel repairs, body sealing, corrosion prevention, and painting procedures. HVAC Repair Procedures: Instructions for servicing the heating, ventilation, and air conditioning systems, including refrigerant handling and component replacement. Electrical Diagnostics: Comprehensive wiring diagrams, component location charts, and diagnostic procedures for electrical issues. Technical Depth Diagnostic Depth: Advanced diagnostic procedures, including information on electronic control units (ECUs) and sensor testing. Rebuild Depth: Comprehensive rebuild procedures for engine, transmissions, axles, and other major mechanical components. 📊 Manual Specifications File Format File Quality: High-resolution PDF, printable. Text is likely searchable. Print Quality Printability: Yes Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: V8 (Rover). Displacement: 4.0L (3948cc) and 4.6L (4554cc). Performance Horsepower 4.0L: Approximately 188 hp @ 4750 rpm. Torque 4.0L: Approximately 267 lb-ft @ 2600 rpm. Horsepower 4.6L: Approximately 217 hp @ 4750 rpm. Torque 4.6L: Approximately 300 lb-ft @ 2600 rpm. Fuel System Fuel Injection: Electronic Fuel Injection (EFI) with multi-point injection (MPI). Engine Management System ECU Type: Bosch Motronic or Lucas GEMS engine management systems, depending on specific engine and market. 🔧 Transmission Standard Transmission Type: Optional manual or automatic transmissions. Optional Manual Transmission Model: R380 (5-speed manual). Automatic Transmission Model: ZF 4HP22-24 (4-speed automatic). Features Transfer Case: LT230SE 2-speed transfer case with locking center differential. Differential Lock: Center differential lock (manual operation via transfer case lever) for enhanced off-road traction. 📐 Dimensions Exterior Length: Approximately 190.2 inches (4831 mm). Width: Approximately 72.2 inches (1834 mm). Height: Approximately 76.1 inches (1933 mm). Weights Curb Weight: Approximately 4,600 - 4,800 lbs (2087 - 2177 kg). Towing Capacity: Typically rated around 7,700 lbs (3500 kg). 🛡️ Safety Features Ratings NHTSA Crash Test Ratings: Not consistently rated by NHTSA for this era, but equipped with robust safety structures. Active Features Traction Control: Advanced Traction Control (ETC) system. Stability Control: Optional Electronic Stability Control (ESC) on some models. Braking Systems: Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Hill Descent Control (HDC). Passive Features Airbags: Front airbags for driver and passenger, optional side airbags. Seatbelts: Three-point seat belts with pretensioners. 💡 Technology Features Infotainment Audio System: Factory fitted radio/cassette or CD player, with optional premium sound systems. Navigation: Optional factory navigation system, often a period-appropriate CRT or LCD screen-based unit. Driver Assistance Cruise Control: Standard cruise control system. Connectivity Bluetooth: Not typically factory-equipped; aftermarket solutions available. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 6,000 miles or 12 months, whichever comes first, using the correct specification oil. Major Service Intervals: Refer to manual for specific mileage/time intervals for spark plug replacement, coolant flush, transmission fluid service, etc. (e.g., spark plugs at 100,000 miles). Fluid Specifications Engine Oil: API SG/SH/SJ or higher, SAE 40 or 5W-30/5W-40 depending on climate. Consult manual for exact specification (e.g., Castrol GTX Magnatec 10W-40 often recommended). Coolant: Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Specific Land Rover recommended coolant is...
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Land Rover Discovery 2 2004 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Land Rover
Model:
Discovery 2
Year:
2004
Codes
Chassis Code:
L322 (though often referred to as Discovery Series II, it shares platform elements with the later L322 generation)
👋 Introduction
Market Position
Market Segment:
Mid-size luxury SUV, known for its off-road capability and versatility.
Competitive Analysis
Key Competitors:
Jeep Grand Cherokee, Toyota Land Cruiser, Mercedes-Benz ML-Class, BMW X5.
Key Features
Distinguishing Features:
Go anywhere capability, sophisticated V8 engines, comfortable interior, advanced electronic aids (e.g., Hill Descent Control, ABS, Traction Control).
📋 Manual Details
Coverage Areas
Systems Covered Overview:
Comprehensive coverage of all mechanical, electrical, and body systems for the 2004 Land Rover Discovery 2.
Page Count
Estimated Page Count:
Extensive (actual PDF page count varies by specific version but typically exceeds 1000 pages for a complete factory service manual).
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Systems:
V8 engine (4.0L, 4.6L variants), engine management, cooling, exhaust, emissions control.
Powertrain Systems:
Manual gearbox (R380), Transfer box (LT230SE), Automatic gearbox (ZF4HP22-24), clutch, propeller shafts, front and rear axles.
Chassis And Suspension:
Steering, front and rear suspension, brakes, chassis and body dimensions.
Body And Interior:
Doors, exterior fittings, interior trim, screens, seats, sunroof, panel repairs, body sealing, corrosion prevention, painting.
Electrical Systems:
Charging and starting, lighting, body control unit, alarm, horn, windows, infotainment, navigation, instruments, harnesses, driving aids.
HVAC Systems:
Heating and ventilation, air conditioning, wipers and washers.
Procedures Included
Maintenance Procedures:
Scheduled maintenance, fluid changes, lubrication, filter replacements, tune-ups.
Repair Procedures:
Detailed step-by-step repair instructions for all major components and systems, including engine, transmission, suspension, brakes, and electrical systems.
Diagnostic Procedures:
Troubleshooting guides, diagnostic charts, and procedures for identifying and resolving common and complex issues.
Specification Data:
Torque wrench settings, fluid capacities, lubricant specifications, sealants, identification numbers, general data.
Body And Paint Repairs:
Detailed guidance on panel repairs, body sealing, corrosion prevention, and painting procedures.
HVAC Repair Procedures:
Instructions for servicing the heating, ventilation, and air conditioning systems, including refrigerant handling and component replacement.
Electrical Diagnostics:
Comprehensive wiring diagrams, component location charts, and diagnostic procedures for electrical issues.
Technical Depth
Diagnostic Depth:
Advanced diagnostic procedures, including information on electronic control units (ECUs) and sensor testing.
Rebuild Depth:
Comprehensive rebuild procedures for engine, transmissions, axles, and other major mechanical components.
📊 Manual Specifications
File Format
File Quality:
High-resolution PDF, printable. Text is likely searchable.
Print Quality
Printability:
Yes
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
V8 (Rover).
Displacement:
4.0L (3948cc) and 4.6L (4554cc).
Performance
Horsepower 4.0L:
Approximately 188 hp @ 4750 rpm.
Torque 4.0L:
Approximately 267 lb-ft @ 2600 rpm.
Horsepower 4.6L:
Approximately 217 hp @ 4750 rpm.
Torque 4.6L:
Approximately 300 lb-ft @ 2600 rpm.
Fuel System
Fuel Injection:
Electronic Fuel Injection (EFI) with multi-point injection (MPI).
Engine Management System
ECU Type:
Bosch Motronic or Lucas GEMS engine management systems, depending on specific engine and market.
🔧 Transmission
Standard
Transmission Type:
Optional manual or automatic transmissions.
Optional
Manual Transmission Model:
R380 (5-speed manual).
Automatic Transmission Model:
ZF 4HP22-24 (4-speed automatic).
Features
Transfer Case:
LT230SE 2-speed transfer case with locking center differential.
Differential Lock:
Center differential lock (manual operation via transfer case lever) for enhanced off-road traction.
📐 Dimensions
Exterior
Length:
Approximately 190.2 inches (4831 mm).
Width:
Approximately 72.2 inches (1834 mm).
Height:
Approximately 76.1 inches (1933 mm).
Weights
Curb Weight:
Approximately 4,600 - 4,800 lbs (2087 - 2177 kg).
Towing Capacity:
Typically rated around 7,700 lbs (3500 kg).
🛡️ Safety Features
Ratings
NHTSA Crash Test Ratings:
Not consistently rated by NHTSA for this era, but equipped with robust safety structures.
Active Features
Traction Control:
Advanced Traction Control (ETC) system.
Stability Control:
Optional Electronic Stability Control (ESC) on some models.
Braking Systems:
Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Hill Descent Control (HDC).
Passive Features
Airbags:
Front airbags for driver and passenger, optional side airbags.
Seatbelts:
Three-point seat belts with pretensioners.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette or CD player, with optional premium sound systems.
Navigation:
Optional factory navigation system, often a period-appropriate CRT or LCD screen-based unit.
Driver Assistance
Cruise Control:
Standard cruise control system.
Connectivity
Bluetooth:
Not typically factory-equipped; aftermarket solutions available.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 6,000 miles or 12 months, whichever comes first, using the correct specification oil.
Major Service Intervals:
Refer to manual for specific mileage/time intervals for spark plug replacement, coolant flush, transmission fluid service, etc. (e.g., spark plugs at 100,000 miles).
Fluid Specifications
Engine Oil:
API SG/SH/SJ or higher, SAE 40 or 5W-30/5W-40 depending on climate. Consult manual for exact specification (e.g., Castrol GTX Magnatec 10W-40 often recommended).
Coolant:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Specific Land Rover recommended coolant is preferred.
Automatic Transmission Fluid:
ZF LifeguardFluid 5 or equivalent Dexron III/Mercon. Consult manual for specific part number.
Manual Transmission Fluid:
API GL-4 or GL-5, SAE 75W-90 or 80W-90. Consult manual for R380 specification.
Transfer Case Fluid:
API GL-5, SAE 80W-90.
Brake Fluid:
DOT 3 or DOT 4.
Power Steering Fluid:
Dexron III or equivalent. Consult manual for specific Land Rover part number.
Known Issues
Common Problems:
Slightly oil leaks (e.g., rocker cover gaskets, rear main seal), ABS/ETC warning lights (often due to wheel speed sensors or SLABS unit), head gasket issues (especially on earlier V8s), power steering pump leaks, door seal degradation, sagging headliner.
Suspension Wear:
Air suspension components (air springs, compressor) can wear out, leading to sag or uneven ride height. Bushings and ball joints in the solid axle suspension are also common wear items.
📚 Vehicle History
Brand Heritage
Manufacturer Legacy:
Land Rover is renowned for its off-road vehicles, established with the original Land Rover Series in 1948.
Model Evolution
Discovery Series Evolution:
The Discovery 2 (Series II) built upon the success of the original Discovery, introducing significant updates, including a longer wheelbase, improved engines, and enhanced comfort features.
Production
Production Years:
Discovery Series II produced from 1998 to 2004.
Manufacturing Location:
Solihull, West Midlands, United Kingdom.
🏆 Awards & Recognition
Recognitions
Off Road Accolades:
Consistently recognized for its off-road prowess and capability in various adventure and automotive publications.
Ratings
Consumer Satisfaction:
Varied consumer satisfaction depending on specific model year and maintenance history, with a strong following among off-road enthusiasts.
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