Land Rover Discovery II V8 1999–2003 Workshop Manual (P/N VDR 100330 NAS (6))

This Land Rover Discovery Series II workshop manual is the 2003 NAS sixth edition, titled “1999MY ON,” P/N VDR 100330 NAS (6). It covers V8 repair alongside Td5 specifications and selected shared-system procedures. Td5 coverage is partial: dedicated Td5 engine, engine-management, fuel-delivery, and cooling repair chapters are not included.

Searchable Text, Bookmarks, and PDF Contents

Search and diagram detail: The main text is searchable, although labels embedded in some illustrations are not. Embedded chapter and procedure bookmarks support navigation. Small callouts in the brake and transmission control diagrams are readable; zooming makes finer assembly details easier to inspect.

One printable PDF contains 1,529 pages, including three cover/title pages, one of which is repeated, 28 contents pages, and 63 blank or intentionally blank pages. These pages are already included in the total.

V8 Overhaul, Drivetrain, and Chassis Systems

These selected workshop topics represent part of the manual rather than a complete contents list. Other sections include park-distance control and navigation-system diagnostics.

• V8 engine repair: Step-by-step engine removal and overhaul procedures, including cylinder heads, timing chains, pistons, and crankshaft bearings.

• Fuel and emissions: Bosch Motronic M5.2.1 diagnostics, sensor data, EVAP testing, and secondary-air injection fault-finding charts.

• Drivetrain: R380 internal service, LT230SE transfer-box overhaul, and ZF4HP22/24 stall testing and torque-converter replacement.

• ACE and SLS: Hydraulic-component replacement, TestBook-directed ACE bleeding, air-spring service, and height-sensor calibration.

• Brakes and steering: SLABS fault diagnosis, ABS modulator replacement, hydraulic bleeding, steering-box adjustment, and power-steering pressure checks.

• Body and restraints: Panel replacement, body measurements, SRS component replacement, electrical-system descriptions, and harness removal and refitting.

• Heating and A/C: Heater repair, control-panel diagnostics, front and rear evaporator replacement, and refrigerant recovery and recharging.

Written for skilled technicians, this manual assumes repair training and access to the specified workshop equipment; safety-critical repairs are not intended for untrained owners.

V8 Inspection, Fuel Management, and Cooling

Cylinder-head work includes valve-guide replacement and dimensional checks. The overhaul section distinguishes early and modified valve components, while lubrication coverage includes a separate engine oil-pressure test.

EVAP documentation distinguishes vacuum and positive-pressure NAS leak detection. Sensor failure modes, ECM connector tables, and fault codes support fault isolation. Replacement ECM setup requires TestBook/T4 to select the correct engine calibration.

Cooling coverage includes coolant-flow illustrations, drain-and-refill procedures, thermostat replacement, and coolant-pump gasket replacement. Routine maintenance procedures also address filters, drive belts, fluid changes, and chassis inspections.

Gearbox, Transfer-Box, and Axle Repair

R380 coverage extends to shafts, synchronizers, selector forks, and bearing replacement. Automatic-transmission sections include fluid-pump, valve-body, and solenoid repairs.

Transfer-box documentation distinguishes differential-lock hardware and selector arrangements before and from the 2003 model year. Clutch hydraulic service, differential overhaul, axle seals, CV joints, and propeller-shaft repair are also covered.

Suspension Calibration and Brake Diagnosis

ACE bleeding and SLS calibration depend on TestBook. The SLS section identifies calibration blocks LRT-64-003/1 and LRT-64-003/2; these procedures require the diagnostic equipment rather than relying on the PDF alone.

SLABS documentation relates warning-lamp combinations to faults and default operating strategies. This helps distinguish sensor, shuttle-valve switch, relay, and ECU faults during diagnosis. Brake bleeding after replacement of the modulator or components upstream of it specifically requires TestBook/T4.

The ACE repair notes warn that incorrect pipe-port connections can cause serious system damage. Steering procedures also explain how steering-wheel movement with the intermediate shaft disconnected can damage the SRS rotary coupler.

Body Electronics, Restraints, and Climate Systems

BCU replacement includes TestBook programming and calibration. Electrical coverage explains immobilization, locking, windows, sunroofs, and instrument operation, with component replacement procedures and connector pin assignments.

Body sections extend to welding preparations, panel replacement, corrosion protection, sealing, and water-leak checks. SRS coverage includes airbags, seat-belt pretensioners, the diagnostic control unit, and rotary-coupler replacement.

Heating coverage includes the Td5 fuel-burning heater. Rear-A/C documentation covers its separate blower, expansion valve, and evaporator.

System Diagrams and Workshop Reference Data

Illustrations include the R380 gearbox cross section, brake system control diagram, SRS block diagram, evaporative emission system component layout, and ACE hydraulic circuit. System-specific torque tables, fluid capacities, approved lubricants, wear limits, and electrical test data accompany the procedures.

Review the manual’s safety precautions and consult a qualified technician before heavy mechanical service or electrical testing, particularly work involving pyrotechnic SRS components and high-pressure hydraulics.

Examples of SLABS Resistance Specifications

The brake section lists a nominal ABS sensor resistance of 950–1100 ohms. Shuttle-valve switch data distinguishes 2977–3067 ohms with both switches open (brakes off) from 1007–1037 ohms with both closed (brakes on), alongside tables explaining the corresponding fault responses.