Land Rover D2 Workshop Manual

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🏷️ Basic Information Identification Make: Land Rover Model: Discovery Series II Model Code: P38A (chassis sharing) / L322 (subsequent generation) Generation: Second Generation (L318) Production Years: 1998-2004 Codes Engine Codes Primary: 10P (4.0L V8), 16P (4.6L V8) Engine Codes Diesel: Td5 (2.5L 5-cylinder turbodiesel - Note: Manual title indicates 'D2', potentially referring to diesel variant coverage) 👋 Introduction Market Position Vehicle Positioning: Premium, rugged, go-anywhere SUV with significant off-road capability and luxury appointments. Competitive Analysis Competitors: Jeep Grand Cherokee, Toyota Land Cruiser, Mercedes-Benz M-Class, BMW X5. Key Features Vehicle Key Features: Integrated body-frame construction, permanent four-wheel drive with center differential lock, optional rear locking differential, Electronic Traction Control (ETC), Hill Descent Control (HDC), optional Active Cornering Enhancement (ACE), air suspension. Manual Value Proposition Value: Provides comprehensive technical repair information typically found in expensive factory shop manuals, accessible via common PC platforms. 📋 Manual Details Coverage Areas Primary Coverage: Land Rover Discovery Series II (all variants) Secondary Coverage Potential: General Land Rover V8 and Td5 engine technologies applicable to other models of the era. Page Count Estimated Page Count: Extensive (as indicated by 'COMPLETE Workshop Service / Repair Manual', typically over 1000 pages for factory equivalents). Manual Type Type: Workshop Service and Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine overhaul (V8, Td5), fuel injection systems, ignition systems, lubrication, cooling, exhaust, emissions control. Drivetrain: Manual and automatic transmissions (ZF 4HP22, R380), transfer case (GFT 222/223), propeller shafts, differentials, axles. Suspension Steering: Coil spring and Air Suspension (SLS) systems, shock absorbers, springs, control arms, steering rack, power steering. Brakes: Front and rear disc brakes, ABS (Anti-lock Braking System), electronic brake force distribution (EBD), brake calipers, master cylinder, fluid systems. Electrical: Complete electrical system, battery, charging system, lighting, starter motor, fuses, relays, ECUs (Engine Control Unit, ABS Control Module, etc.). Bodywork: Chassis, body panels, doors, windows, interior trim, seals, body maintenance, corrosion protection. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant, blower motor, climate control panel, ducting. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, lubrication points, tune-ups. Diagnostics: Troubleshooting guides for common and uncommon issues, fault code interpretation (OBD-II where applicable), symptom-based diagnosis. Repair: Component removal and installation, rebuild procedures for major sub-assemblies (engine, transmission, differentials), replacement of worn parts. Wiring Diagrams: Detailed wiring diagrams for all electrical systems, component location charts, circuit tracing. Technical Depth Depth: Comprehensive, from basic fluid changes to complete engine and transmission rebuilds. Covers factory-level repair procedures and specifications. 📊 Manual Specifications File Format Format: PDF Searchability: Likely searchable text content, facilitating quick information retrieval. Print Quality Print Capability: Printable by the user, allowing for sectional or full manual printing. Image Quality: High quality, with 'lots of pictures and diagrams'. Binding Type Digital Binding: N/A (Digital PDF) Paper Type Digital Paper Equivalent: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type Petrol: Rover V8 (all-alloy OHV, pushrod V8) Displacement Petrol 40: 3947 cc (4.0 Litre) Displacement Petrol 46: 4554 cc (4.6 Litre) Bore Stroke 40: 94.0 mm x 71.0 mm Bore Stroke 46: 94.0 mm x 82.0 mm Horsepower 40: Approx. 182 hp @ 4750 rpm Torque 40: Approx. 236 lb-ft @ 3000 rpm Horsepower 46: Approx. 217 hp @ 4750 rpm Torque 46: Approx. 280 lb-ft @ 3000 rpm Compression Ratio 40: 8.13:1 Compression Ratio 46: 8.8:1 Fuel System: Multi-point fuel injection (MPI) Ignition System: Distributorless ignition system (DIS) Diesel Engine Engine Type Diesel: 2.5L 5-cylinder turbodiesel (Td5) Displacement Diesel: 2495 cc Horsepower Diesel: Approx. 134 hp @ 4200 rpm Torque Diesel: Approx. 221 lb-ft @ 1900 rpm Fuel System Diesel: Direct injection, electronically controlled (ACE - Active Cylinder Control via ECU) Turbocharger Diesel: Variable geometry turbocharger (VGT) 🔧 Transmission Standard Transmission Type Petrol: ZF 4HP22 EH 4-speed automatic with electronic control Optional Transmission Type Diesel: R380 5-speed manual transmission Transmission Type Diesel Auto: ZF 4HP22 EH 4-speed automatic transmission (also available on Td5 models) Features Transfer Case: GFT 222/223 permanent four-wheel drive with locking center differential. Transfer Case Ratios: High range: 1.213:1, Low range: 3.276:1 📐 Dimensions Exterior Length: Approx. 4709 mm (185.4 in) Width: Approx. 1793 mm (70.6 in) Height: Approx. 1941 mm (76.4 in) with standard suspension, higher with air suspension at full extension. Wheelbase: Approx. 2545 mm (100.2 in) Weights Curb Weight Petrol: Approx. 2050 kg (4519 lbs) Curb Weight Diesel: Approx. 2100 kg (4630 lbs) Gross Vehicle Weight: Approx. 2740 kg (6041 lbs) Towing Capacity: Approx. 3500 kg (7716 lbs) braked trailer. Ground Clearance: Variable, approx. 200 mm (7.9 in) to over 220 mm (8.7 in) depending on suspension setting. 🛡️ Safety Features Ratings Eceu Crash Test Rating: Information is scarce and not consistently reported for this era of vehicle; Euro NCAP did not test the Discovery Series II extensively. Active Features Driver Assistance Hd: Hill Descent...

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Description

🏷️ Basic Information

Identification

Make:

Land Rover

Model:

Discovery Series II

Model Code:

P38A (chassis sharing) / L322 (subsequent generation)

Generation:

Second Generation (L318)

Production Years:

1998-2004

Codes

Engine Codes Primary:

10P (4.0L V8), 16P (4.6L V8)

Engine Codes Diesel:

Td5 (2.5L 5-cylinder turbodiesel - Note: Manual title indicates 'D2', potentially referring to diesel variant coverage)

👋 Introduction

Market Position

Vehicle Positioning:

Premium, rugged, go-anywhere SUV with significant off-road capability and luxury appointments.

Competitive Analysis

Competitors:

Jeep Grand Cherokee, Toyota Land Cruiser, Mercedes-Benz M-Class, BMW X5.

Key Features

Vehicle Key Features:

Integrated body-frame construction, permanent four-wheel drive with center differential lock, optional rear locking differential, Electronic Traction Control (ETC), Hill Descent Control (HDC), optional Active Cornering Enhancement (ACE), air suspension.

Manual Value Proposition

Value:

Provides comprehensive technical repair information typically found in expensive factory shop manuals, accessible via common PC platforms.

📋 Manual Details

Coverage Areas

Primary Coverage:

Land Rover Discovery Series II (all variants)

Secondary Coverage Potential:

General Land Rover V8 and Td5 engine technologies applicable to other models of the era.

Page Count

Estimated Page Count:

Extensive (as indicated by 'COMPLETE Workshop Service / Repair Manual', typically over 1000 pages for factory equivalents).

Manual Type

Type:

Workshop Service and Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Powertrain:

Engine overhaul (V8, Td5), fuel injection systems, ignition systems, lubrication, cooling, exhaust, emissions control.

Drivetrain:

Manual and automatic transmissions (ZF 4HP22, R380), transfer case (GFT 222/223), propeller shafts, differentials, axles.

Suspension Steering:

Coil spring and Air Suspension (SLS) systems, shock absorbers, springs, control arms, steering rack, power steering.

Brakes:

Front and rear disc brakes, ABS (Anti-lock Braking System), electronic brake force distribution (EBD), brake calipers, master cylinder, fluid systems.

Electrical:

Complete electrical system, battery, charging system, lighting, starter motor, fuses, relays, ECUs (Engine Control Unit, ABS Control Module, etc.).

Bodywork:

Chassis, body panels, doors, windows, interior trim, seals, body maintenance, corrosion protection.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant, blower motor, climate control panel, ducting.

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, lubrication points, tune-ups.

Diagnostics:

Troubleshooting guides for common and uncommon issues, fault code interpretation (OBD-II where applicable), symptom-based diagnosis.

Repair:

Component removal and installation, rebuild procedures for major sub-assemblies (engine, transmission, differentials), replacement of worn parts.

Wiring Diagrams:

Detailed wiring diagrams for all electrical systems, component location charts, circuit tracing.

Technical Depth

Depth:

Comprehensive, from basic fluid changes to complete engine and transmission rebuilds. Covers factory-level repair procedures and specifications.

📊 Manual Specifications

File Format

Format:

Searchability:

Likely searchable text content, facilitating quick information retrieval.

Print Quality

Print Capability:

Printable by the user, allowing for sectional or full manual printing.

Image Quality:

High quality, with 'lots of pictures and diagrams'.

Binding Type

Digital Binding:

N/A (Digital PDF)

Paper Type

Digital Paper Equivalent:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type Petrol:

Rover V8 (all-alloy OHV, pushrod V8)

Displacement Petrol 40:

3947 cc (4.0 Litre)

Displacement Petrol 46:

4554 cc (4.6 Litre)

Bore Stroke 40:

94.0 mm x 71.0 mm

Bore Stroke 46:

94.0 mm x 82.0 mm

Horsepower 40:

Approx. 182 hp @ 4750 rpm

Torque 40:

Approx. 236 lb-ft @ 3000 rpm

Horsepower 46:

Approx. 217 hp @ 4750 rpm

Torque 46:

Approx. 280 lb-ft @ 3000 rpm

Compression Ratio 40:

8.13:1

Compression Ratio 46:

8.8:1

Fuel System:

Multi-point fuel injection (MPI)

Ignition System:

Distributorless ignition system (DIS)

Diesel Engine

Engine Type Diesel:

2.5L 5-cylinder turbodiesel (Td5)

Displacement Diesel:

2495 cc

Horsepower Diesel:

Approx. 134 hp @ 4200 rpm

Torque Diesel:

Approx. 221 lb-ft @ 1900 rpm

Fuel System Diesel:

Direct injection, electronically controlled (ACE - Active Cylinder Control via ECU)

Turbocharger Diesel:

Variable geometry turbocharger (VGT)

🔧 Transmission

Standard

Transmission Type Petrol:

ZF 4HP22 EH 4-speed automatic with electronic control

Optional

Transmission Type Diesel:

R380 5-speed manual transmission

Transmission Type Diesel Auto:

ZF 4HP22 EH 4-speed automatic transmission (also available on Td5 models)

Features

Transfer Case:

GFT 222/223 permanent four-wheel drive with locking center differential.

Transfer Case Ratios:

High range: 1.213:1, Low range: 3.276:1

📐 Dimensions

Exterior

Length:

Approx. 4709 mm (185.4 in)

Width:

Approx. 1793 mm (70.6 in)

Height:

Approx. 1941 mm (76.4 in) with standard suspension, higher with air suspension at full extension.

Wheelbase:

Approx. 2545 mm (100.2 in)

Weights

Curb Weight Petrol:

Approx. 2050 kg (4519 lbs)

Curb Weight Diesel:

Approx. 2100 kg (4630 lbs)

Gross Vehicle Weight:

Approx. 2740 kg (6041 lbs)

Towing Capacity:

Approx. 3500 kg (7716 lbs) braked trailer.

Ground Clearance:

Variable, approx. 200 mm (7.9 in) to over 220 mm (8.7 in) depending on suspension setting.

🛡️ Safety Features

Ratings

Eceu Crash Test Rating:

Information is scarce and not consistently reported for this era of vehicle; Euro NCAP did not test the Discovery Series II extensively.

Active Features

Driver Assistance Hd:

Hill Descent Control (HDC)

Driver Assistance ABS:

Anti-lock Braking System (ABS)

Driver Assistance Etc:

Electronic Traction Control (ETC)

Driver Assistance Ace:

Optional Active Cornering Enhancement (ACE) system for reduced body roll.

Passive Features

Airbags:

Driver and front passenger airbags. Side airbags were optional on later models.

Seatbelts:

Three-point seatbelts with pre-tensioners for front occupants, three-point belts for rear occupants.

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio/cassette or CD player with optional premium sound system and amplifier. Often featured steering wheel mounted controls.

Navigation:

Optional factory-fitted GPS navigation system (often CRT screen-based).

Driver Assistance

Cruise Control:

Standard or optional cruise control system.

Parking Aids:

Optional rear parking sensors on later models.

Connectivity

Connectivity Features:

Limited by era, primarily focused on diagnostic ports (OBD-II for later models) and basic electronic control units for engine, transmission, and ABS.

🔧 Maintenance

Service Intervals

Oil Change Petrol Recommendation:

Every 6,000 miles or 6 months, whichever comes first. Some sources suggest 7,500 miles or 12 months with high-quality synthetic oil.

Oil Change Diesel Recommendation:

Every 6,000 miles or 6 months, whichever comes first. Td5 engines are sensitive to oil quality.

Transmission Fluid Change Auto:

Recommended every 60,000 miles or 48 months. Filter change is crucial.

Transfer Case Fluid Change:

Recommended every 60,000 miles or 48 months.

Differential Fluid Change:

Recommended every 60,000 miles or 48 months.

Coolant Flush Replacement:

Every 30,000 miles or 24 months. Use of specific OAT coolant is critical for later models and mixed systems.

Spark Plugs Petrol Replacement:

Typically every 30,000 - 60,000 miles depending on type (copper vs. platinum/iridium).

Fluid Specifications

Engine Oil Petrol Spec:

API SJ/SL or ACEA A3/B3, SAE 10W-40 or 5W-40. Check manual for exact grade.

Engine Oil Diesel Spec:

API CG-4 or ACEA B3/B4, SAE 15W-40 or 5W-40. Critical for Td5 lubrication and injector sealing.

Transmission Fluid Auto Spec:

ZF TE-ML 14A or equivalent (e.g., ATF Dexron III/Mercon). Critical for proper operation.

Transfer Case Fluid Spec:

API GL-4 SAE 75W-90 or 80W-90.

Differential Fluid Spec:

API GL-5 SAE 75W-90 or 80W-90. Limited Slip Differential fluid additive may be required for some rear axles.

Coolant Spec:

OAT (Organic Acid Technology) type coolant, typically orange or red. Avoid mixing with older HOAT or IAT coolants.

Known Issues

Engine Petrol Common Problems:

Head gasket failure (especially on earlier 4.6L), timing chain guides wear, oil cooler leaks, thermostat housing leaks, potential piston ring wear.

Engine Diesel Common Problems:

Cylinder head cracking, injector seals failing (oil in loom), turbocharger oil feed pipe leaks, oil pump drive wear, glow plug issues, harmonic balancer failure.

Suspension Common Problems:

Air suspension compressor failure, SLS reservoir leaks, SLS height sensors/lines, ACE hydraulic leaks, proneness to axle bush wear.

Electrical Common Problems:

BCU (Body Control Unit) issues, window regulator failures, central locking problems, Lucas electrics in early models, ABS sensor failures.

Drivetrain Common Problems:

Propshaft U-joint wear, center diff lock actuator issues, gearbox oil leaks, DMF (Dual Mass Flywheel) wear on manual diesels.

📚 Vehicle History

Brand Heritage

Brand Legacy:

Land Rover has a long-standing reputation for producing robust, capable off-road vehicles since the Series I in 1948.

Model Evolution

Predecessor:

Land Rover Discovery Series I (1989-1998).

Development Focus:

The Discovery Series II was an evolution of the Series I, featuring a longer wheelbase, improved chassis rigidity, updated styling, and significantly enhanced electronic systems, particularly the suspension.

Successor:

Land Rover Discovery 3 (LR3) / Discovery 4 (LR4) (2004-2016).

Production

Production Locations:

Solihull, England.

🏆 Awards & Recognition

Recognitions

Off Road Acclaim:

Consistently recognized for its exceptional off-road capability and versatility, a hallmark of the Land Rover brand.

Tow Rating Recognition:

High towing capacity was a significant selling point, making it popular for caravanning and hauling.

Ratings

Consumer Satisfaction:

Mixed consumer satisfaction due to reliability concerns in some areas, but highly praised for its utility and comfort by owners who maintain them well.