1998-2004 Land Rover Discovery Series II Service & Repair Manual
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Workshop Manual
Discovery Series II
Discovery Series II
WORKSHOP MANUAL - 1999MY ON
Publication Part No. VDR 100330 NAS (6)
© Land Rover 2003
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form,
electronic, mechanical, recording or other means without prior written permission from Land Rover.
CONTENTS
CONTENTS 1
INTRODUCTION ...................................................................................... 01-1
How To Use This Manual ................................................................................................................ 01-1
Repairs and Replacements ............................................................................................................. 01-2
Specifications .................................................................................................................................. 01-2
Abbreviations and Symbols ............................................................................................................ 01-3
GENERAL INFORMATION ...................................................................... 03-1
General Precautions ....................................................................................................................... 03-1
Safety Instructions .......................................................................................................................... 03-2
Environmental Precautions ............................................................................................................. 03-3
General Fitting Instructions ............................................................................................................. 03-6
Ball and Roller Bearings ................................................................................................................. 03-7
Oil Seals.......................................................................................................................................... 03-8
Joints and Joint Faces .................................................................................................................... 03-9
Locking Devices .............................................................................................................................. 03-9
Screw Threads ................................................................................................................................ 03-10
Bolt and Nut Identification ............................................................................................................... 03-11
Flexible Pipes and Hoses ............................................................................................................... 03-13
Rolling Road Testing....................................................................................................................... 03-15
Fuel Handling Precautions .............................................................................................................. 03-16
Electrical Precautions ..................................................................................................................... 03-17
Supplementary Restraint System Precautions ............................................................................... 03-18
SRS Component Replacement Policy ............................................................................................ 03-23
Air Conditioning System Precautions .............................................................................................. 03-24
Air Conditioning Compressor Replacement .................................................................................... 03-26
Body Repairs .................................................................................................................................. 03-27
GENERAL DATA ..................................................................................... 04-1
Engine - Td5 ................................................................................................................................... 04-1
Engine - V8 ..................................................................................................................................... 04-4
Fuel system - Td5 ........................................................................................................................... 04-8
Fuel system - V8 ............................................................................................................................. 04-8
Cooling system - Td5 ...................................................................................................................... 04-9
Cooling system - V8 ........................................................................................................................ 04-10
Clutch - Td5 .................................................................................................................................... 04-11
Clutch - V8 ...................................................................................................................................... 04-12
Manual gearbox - R380 .................................................................................................................. 04-13
Transfer box - LT230SE.................................................................................................................. 04-14
Automatic gearbox - ZF4HP22/24 .................................................................................................. 04-15
Rear axle......................................................................................................................................... 04-16
Front axle ........................................................................................................................................ 04-16
Steering........................................................................................................................................... 04-17
Suspension ..................................................................................................................................... 04-18
Brakes ............................................................................................................................................. 04-19
Wheels and tyres ............................................................................................................................ 04-20
Air conditioning ............................................................................................................................... 04-21
Electrical - Td5 ................................................................................................................................ 04-22
Electrical - V8 .................................................................................................................................. 04-22
Dimensions ..................................................................................................................................... 04-23
Weights ........................................................................................................................................... 04-24
CONTENTS
2 CONTENTS
IDENTIFICATION NUMBERS .................................................................. 05-1
Vehicle Identification Number ......................................................................................................... 05-1
Identification Number Locations ..................................................................................................... 05-3
TORQUE WRENCH SETTINGS .............................................................. 06-1
Maintenance ................................................................................................................................... 06-1
Engine Td5 ..................................................................................................................................... 06-2
Engine V8 ....................................................................................................................................... 06-4
Emission control - Td5 .................................................................................................................... 06-5
Emission control - V8 ...................................................................................................................... 06-5
Engine management system - Td5 ................................................................................................. 06-6
Engine management system - V8................................................................................................... 06-6
Cooling system ............................................................................................................................... 06-7
Manifolds and exhaust systems - Td5 ............................................................................................ 06-8
Manifolds and exhaust systems - V8 .............................................................................................. 06-8
Clutch.............................................................................................................................................. 06-9
Manual gearbox - R380 .................................................................................................................. 06-10
Transfer box - LT230SE ................................................................................................................. 06-11
Automatic gearbox - ZF4HP22 ....................................................................................................... 06-12
Propeller shafts ............................................................................................................................... 06-13
Axles ............................................................................................................................................... 06-13
Steering .......................................................................................................................................... 06-14
Front suspension ............................................................................................................................ 06-15
Rear suspension ............................................................................................................................. 06-16
Brakes............................................................................................................................................. 06-17
Restraint systems ........................................................................................................................... 06-18
Body................................................................................................................................................ 06-19
Heating and air conditioning ........................................................................................................... 06-20
Wipers and washers ....................................................................................................................... 06-20
Electrical ......................................................................................................................................... 06-21
LIFTING AND TOWING ........................................................................... 08-1
LIFTING .......................................................................................................................................... 08-1
TOWING ......................................................................................................................................... 08-2
TRANSPORTING ........................................................................................................................... 08-4
CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS ...................... 09-1
Capacities ....................................................................................................................................... 09-1
Fluids .............................................................................................................................................. 09-2
Anti-Freeze Concentration .............................................................................................................. 09-2
Lubrication ...................................................................................................................................... 09-3
Sealants .......................................................................................................................................... 09-4
CONTENTS
CONTENTS 3
MAINTENANCE ........................................................................................ 10-1
PROCEDURES
V8 engine underbonnet view .......................................................................................................... 10-1
Diesel underbonnet view................................................................................................................. 10-2
Seats and seat belts ...................................................................................................................... 10-3
Lamps, horns and warning indicators ............................................................................................. 10-5
Wipers and washers ...................................................................................................................... 10-5
Handbrake .................................................................................................................................. 10-6
Alarm handset battery ..................................................................................................................... 10-6
Road wheels ................................................................................................................................... 10-6
Tyres .............................................................................................................................................. 10-6
Brake pads, discs and calipers ....................................................................................................... 10-6
Road wheel speed sensors ............................................................................................................. 10-7
Brake fluid ....................................................................................................................................... 10-7
Fuel filter - diesel engine ................................................................................................................. 10-7
Fuel filter sedimenter ...................................................................................................................... 10-7
Road wheels ................................................................................................................................... 10-8
Radiator/Intercooler ........................................................................................................................ 10-8
Ambient air Temperature and pressure sensor .............................................................................. 10-8
Doors, bonnet and fuel filler flap ..................................................................................................... 10-8
Air suspension intake filter .............................................................................................................. 10-9
Anti-freeze....................................................................................................................................... 10-9
Cooling system ............................................................................................................................... 10-9
Spark plugs - V8 engine.................................................................................................................. 10-10
Air cleaner - V8 engine ................................................................................................................... 10-10
Air cleaner and dump valve - diesel engine .................................................................................... 10-10
Auxiliary drive belt ........................................................................................................................... 10-11
Auxiliary drive belt - V8 engine ....................................................................................................... 10-11
Auxiliary drive belt - diesel engine .................................................................................................. 10-11
Fluid reservoirs ............................................................................................................................... 10-12
Steering box .................................................................................................................................... 10-13
Battery ............................................................................................................................................. 10-13
Intercooler - diesel engine............................................................................................................... 10-14
Engine oil - V8 engine ..................................................................................................................... 10-14
Engine oil - diesel engine ................................................................................................................ 10-15
Centrifuge rotor – diesel engine ...................................................................................................... 10-15
Engine oil filter - diesel engine ........................................................................................................ 10-16
Engine oil filter – V8 engine ............................................................................................................ 10-16
Manual gearbox .............................................................................................................................. 10-17
Automatic gearbox ......................................................................................................................... 10-18
Transfer box .................................................................................................................................... 10-19
Front and rear axle .......................................................................................................................... 10-20
Propeller shafts ............................................................................................................................... 10-20
Anti-roll bar links ............................................................................................................................. 10-22
ACE actuators ................................................................................................................................. 10-23
ACE filter ......................................................................................................................................... 10-23
CONTENTS
4 CONTENTS
Brake hose, brake, fuel, ACE, clutch pipes and unions/electrical harnesses ................................ 10-24
Engine, gearbox, transfer box and axles ........................................................................................ 10-25
Exhaust system .............................................................................................................................. 10-25
Steering box and front suspension ................................................................................................. 10-25
Steering rod ball joints ................................................................................................................... 10-27
Dampers and SLS height sensors .................................................................................................. 10-27
Front and rear axle suspension links .............................................................................................. 10-28
Towing bracket ............................................................................................................................... 10-29
Engine mountings - V8 engine........................................................................................................ 10-30
Road/roller test ............................................................................................................................... 10-31
CONTENTS
CONTENTS 5
ENGINE - V8 ............................................................................................. 12-2-1
DESCRIPTION AND OPERATION
V8 Engine ....................................................................................................................................... 12-2-1
Cylinder head components ............................................................................................................. 12-2-2
Cylinder block components ............................................................................................................. 12-2-4
Description ...................................................................................................................................... 12-2-6
ADJUSTMENTS
Engine oil pressure check .............................................................................................................. 12-2-11
REPAIRS
Seal - crankshaft - rear .................................................................................................................. 12-2-13
Gasket - cylinder head - LH ........................................................................................................... 12-2-14
Gasket - cylinder head - RH............................................................................................................ 12-2-16
Gasket - rocker cover - LH ............................................................................................................ 12-2-19
Gasket - rocker cover - RH ............................................................................................................ 12-2-20
Mounting - front - LH ...................................................................................................................... 12-2-22
Mounting - front - RH ..................................................................................................................... 12-2-23
Mounting - rear - LH ....................................................................................................................... 12-2-24
Mounting - rear - RH ...................................................................................................................... 12-2-25
Engine assembly............................................................................................................................. 12-2-26
Flywheel ........................................................................................................................................ 12-2-31
Plate - drive - automatic ................................................................................................................ 12-2-32
Ring gear - starter ......................................................................................................................... 12-2-34
Filter - oil ....................................................................................................................................... 12-2-35
Strainer - oil pick-up ...................................................................................................................... 12-2-35
Pump - oil ...................................................................................................................................... 12-2-36
Gasket - sump ................................................................................................................................ 12-2-37
Switch - oil pressure ....................................................................................................................... 12-2-39
Cooler - engine oil .......................................................................................................................... 12-2-39
Gasket - timing gear cover ............................................................................................................ 12-2-41
Seal - cover - timing gears ............................................................................................................ 12-2-43
OVERHAUL
Gasket - inlet manifold ................................................................................................................... 12-2-45
Gasket - exhaust manifold ............................................................................................................. 12-2-48
Seal - crankshaft - rear - automatic models .................................................................................... 12-2-49
Seal - crankshaft - rear - manual models ........................................................................................ 12-2-50
Bearing - spigot - crankshaft .......................................................................................................... 12-2-52
Gasket - engine sump .................................................................................................................... 12-2-53
Strainer - oil pick-up ....................................................................................................................... 12-2-54
Seal - timing gear cover ................................................................................................................. 12-2-55
Gasket - timing gear cover ............................................................................................................. 12-2-56
Timing chain and gears .................................................................................................................. 12-2-58
Rocker shaft - overhaul ................................................................................................................. 12-2-59
Gasket - cylinder head .................................................................................................................... 12-2-61
Cylinder head - overhaul ................................................................................................................ 12-2-63
Piston assemblies ........................................................................................................................... 12-2-67
Bearings - connecting rods ............................................................................................................ 12-2-72
Crankshaft and main bearings ........................................................................................................ 12-2-73
Camshaft ....................................................................................................................................... 12-2-77
CONTENTS
6 CONTENTS
EMISSION CONTROL - V8 ....................................................................... 17-2-1
DESCRIPTION AND OPERATION
Crankcase emission control system ............................................................................................... 17-2-1
Exhaust emission control ................................................................................................................ 17-2-2
Evaporative emission system component layout ............................................................................ 17-2-3
Evaporative emission system (with positive pressure leak detection) component layout (NAS only) 17-2-4
Evaporative emission system control diagram ............................................................................... 17-2-5
Secondary air injection system component layout.......................................................................... 17-2-6
Secondary air injection system control diagram ............................................................................. 17-2-8
Emission Control Systems .............................................................................................................. 17-2-9
Crankcase Emission Control System ............................................................................................. 17-2-10
Exhaust Emission Control System.................................................................................................. 17-2-11
Evaporative Emission Control System............................................................................................ 17-2-15
Secondary Air Injection System...................................................................................................... 17-2-26
Crankcase Emission Control Operation.......................................................................................... 17-2-34
Exhaust Emission Control Operation .............................................................................................. 17-2-35
Evaporative Emission Control Operation ........................................................................................ 17-2-39
Secondary Air Injection System Operation ..................................................................................... 17-2-43
SAI System Fault Finding and Check Malfunctions ........................................................................ 17-2-44
REPAIRS
Canister - EVAP ............................................................................................................................ 17-2-51
Canister - EVAP - Models with Fuel Leak Detection Pump - up to 03MY ...................................... 17-2-52
Canister - EVAP - Models with Fuel Leak Detection Pump - from 03MY ....................................... 17-2-53
Valve - purge control ..................................................................................................................... 17-2-54
Solenoid - evap canister vent solenoid (CVS) valve ..................................................................... 17-2-55
Sensor - heated oxygen (HO2S) - pre-catalytic converter .............................................................. 17-2-56
Sensor - heated oxygen (HO2S) - post-catalytic converter ............................................................ 17-2-57
Control Valve - Secondary Air Injection (SAI) ............................................................................... 17-2-58
Reservoir - Vacuum - Secondary Air Injection (SAI) - up to 03MY ................................................. 17-2-58
Reservoir - vacuum - Secondary Air Injection (SAI) - from 03MY .................................................. 17-2-59
Pump - Air - Secondary Air Injection (SAI) ..................................................................................... 17-2-59
Air Manifold - LH - Secondary Air Injection (SAI) ........................................................................... 17-2-60
Air Manifold - RH - Secondary Air Injection (SAI) .......................................................................... 17-2-61
Solenoid - Vacuum - Secondary Air Injection (SAI) ...................................................................... 17-2-62
Pipe - Secondary Air Injection (SAI) .............................................................................................. 17-2-62
Pump - Fuel Leak Detection - up to 03MY...................................................................................... 17-2-64
Pump - fuel leak detection - from 03MY ......................................................................................... 17-2-64
Filter - fuel leak detection pump - up to 03MY ................................................................................ 17-2-65
Filter - fuel leak detection pump - from 03MY ................................................................................. 17-2-65
CONTENTS
CONTENTS 7
ENGINE MANAGEMENT SYSTEM - V8 .................................................. 18-2-1
DESCRIPTION AND OPERATION
Engine management component location - Passenger compartment ............................................ 18-2-1
Engine management component location - Engine compartment .................................................. 18-2-2
Engine management block diagram ............................................................................................... 18-2-4
Description - engine management .................................................................................................. 18-2-6
Operation - engine management .................................................................................................... 18-2-49
DESCRIPTION AND OPERATION
Cruise control component layout .................................................................................................... 18-2-61
Cruise control block diagram .......................................................................................................... 18-2-62
Description - cruise control ............................................................................................................. 18-2-63
Operation - cruise control ................................................................................................................ 18-2-74
ADJUSTMENTS
Cable - throttle ............................................................................................................................. 18-2-77
Cable - cruise control .................................................................................................................... 18-2-77
REPAIRS
Spark plugs .................................................................................................................................. 18-2-79
Coil - ignition ................................................................................................................................. 18-2-80
Engine control module (ECM) ......................................................................................................... 18-2-81
Sensor - engine coolant temperature (ECT) ................................................................................ 18-2-82
Sensor - crankshaft position (CKP) ............................................................................................... 18-2-83
Sensor - radiator temperature ....................................................................................................... 18-2-84
Sensor - camshaft position (CMP) ................................................................................................. 18-2-84
Knock sensor (KS) .......................................................................................................................... 18-2-85
Air cleaner assembly ..................................................................................................................... 18-2-86
Element - air filter .......................................................................................................................... 18-2-87
Cable - throttle ................................................................................................................................ 18-2-88
Sensor - Mass Air Flow (MAF) ...................................................................................................... 18-2-89
Throttle Body................................................................................................................................... 18-2-90
Plenum chamber ............................................................................................................................. 18-2-91
Sensor - throttle position (TP) ....................................................................................................... 18-2-91
Valve - idle air control (IACV) ........................................................................................................ 18-2-92
Injectors ......................................................................................................................................... 18-2-92
Actuator - cruise control ................................................................................................................ 18-2-94
Vacuum control unit - up to 03MY................................................................................................... 18-2-94
Vacuum control unit - from 03MY ................................................................................................... 18-2-95
Cable - cruise control ..................................................................................................................... 18-2-96
Switch - cruise control (on/off) ........................................................................................................ 18-2-96
Switch - cruise control (set/resume) ............................................................................................... 18-2-97
Switch - clutch pedal - cruise control ............................................................................................ 18-2-97
ECU - Cruise control ..................................................................................................................... 18-2-98
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This is the complete official full factory service repair manual for the Land Rover Discovery Series II from 1998 to 2004. It provides detailed information for both professional mechanics and DIY enthusiasts. The manual includes step-by-step instructions, detailed illustrations, and photographs to guide the reader through each service and repair procedure. It covers a wide range of topics including general information, specifications, lubrication points, oil types, periodic maintenance, engine servicing, disassembly, reassembly, electrical system, troubleshooting, wiring diagrams, tools, tightening torques, and much more.
The manual is available in PDF format, which is compatible with all PC-based Windows operating systems and Mac. It can be saved to your hard drive and printed as needed. There are no restrictions on printing, and it does not require shipping. The language of the manual is English, and it can be viewed using Adobe Reader.
Get your Land Rover Discovery Series II 1998-2004 service manual now to access a comprehensive resource for maintaining and repairing your vehicle.
- Detailed substeps expand on repair procedure information
- Notes, cautions, and warnings throughout each chapter pinpoint critical information
- Numbered instructions guide you through every repair procedure step by step
- Bold figure numbers help you quickly match illustrations with instructions
- Enlarged inset helps you identify and examine parts in detail
- Numbered table of contents for easy navigation
Additionally, the manual covers topics such as chassis, wheels, brakes, steering, suspension, axles, servicing information, wire/cable/hose routing, service data, engine and fuel system service, gearbox, exhaust system, fault finding, clutch removal and installation, bodywork, cooling system, transmission, factory maintenance schedules, electrics, and more. It also includes abundant illustrations, pictures, diagrams, and more.
Whether you are looking for specific repair information or general maintenance guidelines, the Land Rover Discovery Series II 1998-2004 service manual is a valuable resource for keeping your vehicle in top condition.
