2002+ RANGE ROVER L322 Workshop/Service Repair Manual

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🏷️ Basic Information Identification Make: Land Rover Model: Range Rover Chassis Code: L322 Model Year Start: 2002 Generation Generation Code: Third Generation (L322) Generation Start Year: 2002 Generation End Year: 2012 Codes Engine Td6 Code: M57 (BMW) Engine V8 Petrol Code Early: M62 (BMW) Engine V8 Petrol Code Late: 4.4 AJ-V8 / 4.2 Supercharged AJ-V8 (Jaguar) 👋 Introduction Market Position Positioning: The Range Rover L322 represented the pinnacle of Land Rover's luxury SUV offerings for its era, competing with vehicles like the BMW X5, Mercedes-Benz ML-Class, and Lexus LX. It blended off-road capability with refined on-road manners and a luxurious interior. Competitive Analysis Competitors: BMW X5 (E53/E70), Mercedes-Benz ML-Class (W163/W164), Lexus LX (UZJ100/URJ202), Porsche Cayenne (955/957), Audi Q7 (4L). Key Features Luxury And Capability: The L322 is renowned for its robust construction, advanced (for its time) four-wheel-drive systems, optional air suspension, and upscale interior appointments. Its ability to handle challenging off-road conditions while providing a comfortable ride on pavement was a key selling point. Manual Value Proposition Cost Savings: Owning a luxury SUV like the Range Rover L322 can incur significant maintenance costs. This comprehensive workshop manual empowers owners and independent mechanics with the knowledge to perform diagnostics, routine maintenance, and repairs, leading to substantial savings compared to dealership servicing. 📋 Manual Details Coverage Areas Comprehensive Coverage: Full Workshop/Service Repair Manual Systems Listed: General Maintenance, Engine, Transmission, Gearbox, Engine Management System, Electrical, Fuel System, Cooling, Exhaust System, Intake, Front & Rear Axles, Drives & Propshaft, Suspension, Braking System (inc ABS), Parking Brake, Entertainment & Information Systems, Steering (inc Power Steering), Charging & Starting, Lighting, Security, Interior Trim, Seats, Sunroof, Washers & Wipers, Restraints (Seatbelts), Air Con/Heating/Ventilation, Windows, Body Control Unit, Driving Aids, Interior & Exterior, and more. Page Count Estimated Page Count: Likely 1000+ pages (typical for comprehensive workshop manuals of this era) Manual Type Type: Workshop / Service / Repair Manual Language Language: English Format Format: Digital (likely PDF) - implied by 'product information' 📖 Manual Coverage Systems Covered Engine Diesel: TD6 3.0 Litre Diesel Engine (BMW M57) Engine Petrol Early: 4.4 V8 Petrol Engine (BMW M62) Engine Petrol Late: 4.4 V8 Petrol Engine (Jaguar AJ-V8) and 4.2 Supercharged V8 Petrol Engine (Jaguar AJ-V8 S/C) Transmission Diesel: GM 5L40-E Automatic Transmission (for TD6) Transmission Petrol Early: ZF 5HP24 Automatic Transmission (for early 4.4 V8 Petrol) Transmission Petrol Late: ZF 6HP26 Automatic Transmission (for later 4.4 V8 Petrol and 4.2 S/C) Engine Management: Detailed diagnostics and calibration for both diesel and petrol engine control units (ECU). Electrical System: Complete wiring diagrams, component locations, diagnostic procedures for all electrical systems. Fuel System: Fuel delivery, injection systems (diesel common rail and petrol multi-point/direct injection), fuel pump, injectors, pressure regulation. Cooling System: Radiator, water pump, thermostat, cooling fans, coolant types and capacities, pressure testing. Exhaust System: Exhaust manifolds, catalytic converters, mufflers, oxygen sensors, emission control systems. Intake System: Air intake components, mass air flow (MAF) sensors, throttle bodies, intercoolers (for TD6). Drivetrain Axles: Front and rear differentials, axle ratios, hub assemblies, CV joints. Drivetrain Propshaft: Propshaft components, universal joints, center bearings, torque converter (for automatic). Suspension: Air suspension (ACE - Active Cornering Enhancement), springs, shock absorbers, control arms, bushings, leveling systems. Braking System: Disc brakes (front and rear), ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), brake fluid specifications, caliper servicing, rotor replacement. Parking Brake: Mechanical parking brake operation and adjustment. Entertainment Information: Audio systems, navigation, trip computer, parking sensors, display units. Steering: Power steering system, steering rack, steering column, alignment specifications. Charging Starting: Alternator, starter motor, battery specifications, charging system diagnostics. Lighting: Headlights, taillights, interior lighting, bulb types, wiring. Security System: Remote locking, alarm system, immobilizer, central locking. Interior Trim: Removal and installation of interior panels, dashboard components, center console. Seats Sunroof: Adjustment mechanisms, heating elements, power adjustments, sunroof operation and seals. Washers Wipers: Wiper motor, washer pump, fluid reservoir, blade replacement, nozzle adjustment. Restraints Seatbelts: Seatbelt operation, pretensioners, SRS (Supplemental Restraint System) airbag deployment and diagnostics. HVAC: Air conditioning system (refrigerant types, capacity), heating, ventilation, climate control unit, cabin filter replacement. Windows: Power window regulators, motors, switches, seals, privacy glass operation. Body Control Unit: Functions and diagnostics of the Body Control Module (BCM) responsible for various electronic features. Driving Aids: Hill Descent Control (HDC), Terrain Response (later models, though early L322 had basic traction control), cruise control. Bodywork Exterior: Body panel removal/installation, bumpers, grilles, trim pieces, door handles, mirrors. Procedures Included Maintenance Tasks: Oil changes, filter replacements, fluid checks and top-ups, spark plug replacement, belt inspection/replacement. Diagnostic Procedures: Troubleshooting guides, symptom-based diagnostics, fault code interpretation (OBD-II), component testing. Repair Procedures: Step-by-step instructions for component removal, repair, and reinstallation across all covered systems. Rebuild Procedures: Engine and transmission rebuild specifications, torque values, and assembly procedures. Calibration Procedures: Setting up sensors, modules, and systems after replacement or adjustment (e.g., steering angle sensor, ride...

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Description

🏷️ Basic Information

Identification

Make:

Land Rover

Model:

Range Rover

Chassis Code:

Model Year Start:

Generation

Generation Code:

Third Generation (L322)

Generation Start Year:

Generation End Year:

Codes

Engine Td6 Code:

M57 (BMW)

Engine V8 Petrol Code Early:

M62 (BMW)

Engine V8 Petrol Code Late:

4.4 AJ-V8 / 4.2 Supercharged AJ-V8 (Jaguar)

👋 Introduction

Market Position

Positioning:

The Range Rover L322 represented the pinnacle of Land Rover's luxury SUV offerings for its era, competing with vehicles like the BMW X5, Mercedes-Benz ML-Class, and Lexus LX. It blended off-road capability with refined on-road manners and a luxurious interior.

Competitive Analysis

Competitors:

BMW X5 (E53/E70), Mercedes-Benz ML-Class (W163/W164), Lexus LX (UZJ100/URJ202), Porsche Cayenne (955/957), Audi Q7 (4L).

Key Features

Luxury And Capability:

The L322 is renowned for its robust construction, advanced (for its time) four-wheel-drive systems, optional air suspension, and upscale interior appointments. Its ability to handle challenging off-road conditions while providing a comfortable ride on pavement was a key selling point.

Manual Value Proposition

Cost Savings:

Owning a luxury SUV like the Range Rover L322 can incur significant maintenance costs. This comprehensive workshop manual empowers owners and independent mechanics with the knowledge to perform diagnostics, routine maintenance, and repairs, leading to substantial savings compared to dealership servicing.

📋 Manual Details

Coverage Areas

Comprehensive Coverage:

Full Workshop/Service Repair Manual

Systems Listed:

General Maintenance, Engine, Transmission, Gearbox, Engine Management System, Electrical, Fuel System, Cooling, Exhaust System, Intake, Front & Rear Axles, Drives & Propshaft, Suspension, Braking System (inc ABS), Parking Brake, Entertainment & Information Systems, Steering (inc Power Steering), Charging & Starting, Lighting, Security, Interior Trim, Seats, Sunroof, Washers & Wipers, Restraints (Seatbelts), Air Con/Heating/Ventilation, Windows, Body Control Unit, Driving Aids, Interior & Exterior, and more.

Page Count

Estimated Page Count:

Likely 1000+ pages (typical for comprehensive workshop manuals of this era)

Manual Type

Type:

Workshop / Service / Repair Manual

Language

Language:

English

Format

Format:

Digital (likely PDF) - implied by 'product information'

📖 Manual Coverage

Systems Covered

Engine Diesel:

TD6 3.0 Litre Diesel Engine (BMW M57)

Engine Petrol Early:

4.4 V8 Petrol Engine (BMW M62)

Engine Petrol Late:

4.4 V8 Petrol Engine (Jaguar AJ-V8) and 4.2 Supercharged V8 Petrol Engine (Jaguar AJ-V8 S/C)

Transmission Diesel:

GM 5L40-E Automatic Transmission (for TD6)

Transmission Petrol Early:

ZF 5HP24 Automatic Transmission (for early 4.4 V8 Petrol)

Transmission Petrol Late:

ZF 6HP26 Automatic Transmission (for later 4.4 V8 Petrol and 4.2 S/C)

Engine Management:

Detailed diagnostics and calibration for both diesel and petrol engine control units (ECU).

Electrical System:

Complete wiring diagrams, component locations, diagnostic procedures for all electrical systems.

Fuel System:

Fuel delivery, injection systems (diesel common rail and petrol multi-point/direct injection), fuel pump, injectors, pressure regulation.

Cooling System:

Radiator, water pump, thermostat, cooling fans, coolant types and capacities, pressure testing.

Exhaust System:

Exhaust manifolds, catalytic converters, mufflers, oxygen sensors, emission control systems.

Intake System:

Air intake components, mass air flow (MAF) sensors, throttle bodies, intercoolers (for TD6).

Drivetrain Axles:

Front and rear differentials, axle ratios, hub assemblies, CV joints.

Drivetrain Propshaft:

Propshaft components, universal joints, center bearings, torque converter (for automatic).

Suspension:

Air suspension (ACE - Active Cornering Enhancement), springs, shock absorbers, control arms, bushings, leveling systems.

Braking System:

Disc brakes (front and rear), ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), brake fluid specifications, caliper servicing, rotor replacement.

Parking Brake:

Mechanical parking brake operation and adjustment.

Entertainment Information:

Audio systems, navigation, trip computer, parking sensors, display units.

Steering:

Power steering system, steering rack, steering column, alignment specifications.

Charging Starting:

Alternator, starter motor, battery specifications, charging system diagnostics.

Lighting:

Headlights, taillights, interior lighting, bulb types, wiring.

Security System:

Remote locking, alarm system, immobilizer, central locking.

Interior Trim:

Removal and installation of interior panels, dashboard components, center console.

Seats Sunroof:

Adjustment mechanisms, heating elements, power adjustments, sunroof operation and seals.

Washers Wipers:

Wiper motor, washer pump, fluid reservoir, blade replacement, nozzle adjustment.

Restraints Seatbelts:

Seatbelt operation, pretensioners, SRS (Supplemental Restraint System) airbag deployment and diagnostics.

HVAC:

Air conditioning system (refrigerant types, capacity), heating, ventilation, climate control unit, cabin filter replacement.

Windows:

Power window regulators, motors, switches, seals, privacy glass operation.

Body Control Unit:

Functions and diagnostics of the Body Control Module (BCM) responsible for various electronic features.

Driving Aids:

Hill Descent Control (HDC), Terrain Response (later models, though early L322 had basic traction control), cruise control.

Bodywork Exterior:

Body panel removal/installation, bumpers, grilles, trim pieces, door handles, mirrors.

Procedures Included

Maintenance Tasks:

Oil changes, filter replacements, fluid checks and top-ups, spark plug replacement, belt inspection/replacement.

Diagnostic Procedures:

Troubleshooting guides, symptom-based diagnostics, fault code interpretation (OBD-II), component testing.

Repair Procedures:

Step-by-step instructions for component removal, repair, and reinstallation across all covered systems.

Rebuild Procedures:

Engine and transmission rebuild specifications, torque values, and assembly procedures.

Calibration Procedures:

Setting up sensors, modules, and systems after replacement or adjustment (e.g., steering angle sensor, ride height sensors).

Technical Depth

Depth:

Comprehensive. Covers everything from basic scheduled maintenance to in-depth mechanical and electrical diagnostics and repairs. Likely includes torque specifications, clearances, diagnostic trouble codes (DTCs), and wiring schematics.

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format)

Print Quality

Digital Quality:

High Resolution (expected for professional workshop manuals, allowing clear viewing of diagrams and text).

Binding Type

Digital Binding:

N/A (Digital format)

Paper Type

Digital Paper Type:

N/A (Digital format)

Searchability

Text Search:

Searchable text content (standard for well-produced PDF workshop manuals).

⚙️ Engine Specifications

Primary Engine Td6

Engine Type:

Inline 6-Cylinder Turbocharged Diesel

Displacement:

2926 cc (3.0 Litres)

Bore X Stroke:

84.0 mm x 87.0 mm

Compression Ratio:

17.0:1

Horsepower Ps:

177 PS @ 4000 rpm

Torque Nm:

400 Nm @ 1900-3000 rpm

Fuel System:

Bosch High-Pressure Common Rail Direct Injection

Primary Engine V8 Petrol Early

Engine Type:

V8 Petrol

Displacement:

4398 cc (4.4 Litres)

Bore X Stroke:

93.0 mm x 78.0 mm

Compression Ratio:

10.0:1

Horsepower Ps:

286 PS @ 5400 rpm

Torque Nm:

440 Nm @ 3600 rpm

Fuel System:

Bosch Motronic Electronic Fuel Injection

Primary Engine V8 Petrol Late Naturally Aspirated

Engine Type:

V8 Petrol (Jaguar AJ-V8)

Displacement:

4398 cc (4.4 Litres)

Horsepower Ps:

292 PS @ 5500 rpm

Torque Nm:

425 Nm @ 4000 rpm

Primary Engine V8 Petrol Late Supercharged

Engine Type:

V8 Supercharged Petrol (Jaguar AJ-V8 S/C)

Displacement:

4196 cc (4.2 Litres)

Horsepower Ps:

396 PS @ 6000 rpm

Torque Nm:

550 Nm @ 3500 rpm

🔧 Transmission

Standard

Standard Transmission Td6:

5-speed Automatic (GM 5L40-E)

Standard Transmission Petrol Early:

5-speed Automatic (ZF 5HP24)

Standard Transmission Petrol Late:

6-speed Automatic (ZF 6HP26)

Features

Transfer Case:

Permanent four-wheel drive with a two-speed transfer box (high and low range).

Traction Control:

Advanced traction control systems, including Brake Traction Control (BTC) and Dynamic Stability Control (DSC).

Gear Ratios Zf 5Hp24:

1st: 3.19, 2nd: 2.09, 3rd: 1.41, 4th: 1.00, 5th: 0.74, Reverse: 2.73

Gear Ratios Gm 5L40-E:

1st: 3.06, 2nd: 1.63, 3rd: 1.00, 4th: 0.71, 5th: 0.71 (Overdrive), Reverse: 2.29

Fluid Type Td6 Gm5L40-E:

Dexron III or equivalent (check manual for specific superseded part numbers, e.g., Dexron VI).

Fluid Type Petrol Zf5Hp24:

ZF Lifeguardfluid 5 (or equivalent specification like LT 71141).

Fluid Type Petrol Zf6Hp26:

ZF Lifeguardfluid 6 (or equivalent specification like Shell M-1375.4).

📐 Dimensions

Exterior

Length:

4950 mm (approx.)

Width:

1956 mm (approx.)

Height:

1876 mm (approx.)

Wheelbase:

2880 mm (approx.)

Weights

Curb Weight Td6:

2370 kg (approx.)

Curb Weight V8:

2400-2500 kg (approx., depending on spec)

Gross Vehicle Weight:

3000-3200 kg (approx.)

Towing Capacity:

3500 kg (braked, typically)

Cargo

Boot Space:

Approximately 530-600 litres (depending on rear seat configuration and subwoofer placement).

Tire Size

Typical Tire Sizes:

255/55 R18, 255/50 R19, 275/40 R20 (varying by trim and option).

Wheel Bolt Pattern

Bolt Pattern:

5x120 mm

Center Bore:

72.5 mm

🛡️ Safety Features

Ratings

NHTSA Rating:

Not directly tested by NHTSA for this generation. Era-appropriate safety features installed.

Euro Ncap Rating:

4 Stars (for models tested around 2004).

Active Features

Anti-lock Braking System (ABS)

Electronic Stability Program (ESP) / Dynamic Stability Control (DSC)

Traction Control:

Traction Control System (TCS)

Hd C:

Hill Descent Control (HDC)

Active Cornering Enhancement (ACE) - hydraulic anti-roll system on some models.

Passive Features

Airbags:

Front airbags (driver and passenger), side airbags, curtain airbags (depending on model year and trim).

Seatbelts:

Three-point inertia reel seatbelts with pre-tensioners and load limiters.

Body Structure:

Reinforced body structure with crumple zones.

💡 Technology Features

Infotainment

Audio System:

Harman Kardon premium audio systems were common, often with CD changers and navigation. Early models had separate screen and controls; later models integrated systems.

Navigation:

Touchscreen or button-operated navigation systems, typically using DVD-based maps (upgradable).

Climate Control:

Dual-zone automatic climate control, often with independent rear climate controls.

Driver Assistance

Cruise Control:

Standard cruise control, adaptive cruise control (ACC) became available on later models.

Parking Aids:

Front and rear parking sensors, sometimes rearview cameras on later models.

Connectivity

Bluetooth:

Factory Bluetooth hands-free systems were introduced and improved over the years.

Auxiliary Input:

Auxiliary audio input jacks became more common in later model years.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 15,000 miles (24,000 km) or 12 months, whichever comes first. For diesel, shorter intervals might be recommended for heavy-duty use or short trips. Consult specific manual for exact recommendation.

Transmission Fluid Interval:

Recommended change every 60,000 miles (96,000 km) or 4 years for automatic transmissions. Some sources recommend earlier for heavier use. ZF transmissions in particular often benefit from regular fluid changes.

Coolant Interval:

Initial change at 100,000 miles (160,000 km), then every 50,000 miles (80,000 km) or 2-3 years. Always use the correct type of coolant (e.g., OAT - Organic Acid Technology).

Brake Fluid Interval:

Every 2 years (regardless of mileage) due to hygroscopic nature of brake fluid.

Engine Air Filter:

Replace every 30,000-45,000 miles (48,000-72,000 km) or as needed based on inspection. Critical for TD6.

Cabin Air Filter:

Replace annually or every 15,000 miles (24,000 km).

Fluid Specifications

Engine Oil Td6:

API CJ-4 or ACEA C3 (or a suitable synthetic 5W-30/5W-40 meeting BMW LL-04 or similar low SAPS specification).

Engine Oil V8 Petrol Early:

Mobil 1 5W-40 or 5W-30 (meeting BMW LL-98 or LL-01 specifications).

Engine Oil V8 Petrol Late:

Jaguar/Ford WSS-M2C925-A or equivalent (e.g., Castrol Professional OE 5W-20 for later models).

Coolant:

OAT (Organic Acid Technology) coolant, typically a pink/red colour. Example: Havoline XCL or Prestone Extended Life. Do NOT mix with older silicate-based coolants.

Power Steering Fluid:

Pentosin CHF 11S or equivalent.

Known Issues

Td6 Common Problems:

Turbocharger failure (oil starvation), injector seal leaks, EGR valve issues, glow plug failures, cracked cylinder heads (less common but serious), intercooler hose leaks, suspension compressor failures.

V8 Petrol Common Problems:

Head gasket failures (especially early BMW M62TU), coolant leaks (especially from the valley pan), timing chain tensioner issues (BMW M62TU), VANOS unit problems, ignition coil failures, intake manifold gaskets.

Air Suspension:

Air spring bag leaks, compressor failure, valve block issues, height sensor faults.

Electronics:

Various electronic control module (ECU) failures, CAN bus communication errors, parking sensor malfunctions, window regulator failures, LCM (Lighting Control Module) issues.

Ace System:

Hydraulic fluid leaks, pump failures, sensor faults.

📚 Vehicle History

Brand Heritage

Heritage:

Land Rover has a long history of producing capable off-road vehicles, starting with the Land Rover Series I in 1948. The Range Rover nameplate, introduced in 1970, established the concept of a luxury 4x4.

Model Evolution

L322 Development:

The L322 was largely developed under BMW ownership (following their acquisition of Rover Group) and initially shared many components with BMW's E38 7 Series. It represented a significant step up in luxury and refinement from its predecessor (P38A).

Ownership Change:

After BMW sold Rover Group to the Phoenix Consortium in 2000, Land Rover (including the L322) was acquired by Ford in 2000 as part of the Premier Automotive Group. This led to the introduction of Jaguar-derived V8 engines in later L322 models.

Production

Production Period:

2002-2012

Manufacturing Location:

Solihull, West Midlands, England

Model Updates

Facelifts:

The L322 received significant updates during its lifespan: the first major facelift (2006) brought the Jaguar V8 engines, updated interior, and new infotainment systems. A second facelift (2010) introduced revised styling (including the controversial 'split' grille on some markets) and updated technology.

🏆 Awards & Recognition

Recognitions

Off Road Capability Awards:

Consistently recognized for its off-road prowess and luxury blend. Often cited in 'best luxury SUV' or 'most capable SUV' lists during its production run.

Design Awards:

Received positive reviews for its robust and imposing design, which has largely stood the test of time.