Land Rover Discovery II 1999–2004 Workshop Manual (P/N VDR 100330 NAS (6))

Land Rover’s 2003 North American Specification (NAS) Discovery Series II workshop manual is titled “1999MY ON,” Publication Part No. VDR 100330 NAS (6). Coverage centers on the V8 engines. Td5 specifications and selected diesel procedures appear in shared sections, but dedicated Td5 engine, engine-management, fuel-delivery, and cooling repair chapters are not included.

PDF Search, Bookmarks and Page Count

Finding procedures and diagram details: The PDF has searchable text and embedded bookmarks for the technical sections. Small diagram labels and connector details are readable when enlarged.

The ZIP download contains one printable PDF with 1,529 pages, including 58 blank pages, the cover, the publication title/copyright page, and a repeated title/copyright page.

V8 Overhaul, Drivetrain Repair and Chassis Systems

The following highlights are selected contents, rather than a complete table of contents. Additional topics include park-distance-control diagnosis and diesel alternator and starter-motor replacement.

• V8 engine repair: Step-by-step engine removal and overhaul procedures cover cylinder heads, the timing chain, rocker shafts, pistons, and crankshaft bearings.

• Engine management and emissions: Bosch Motronic M5.2.1 sensor tests, ECM connector tables, P-codes, and secondary air injection fault-finding flowcharts.

• Manual transmission and transfer case: R380 and LT230SE disassembly, inspection, bearing setup, reassembly, and differential-lock adjustment procedures.

• Automatic transmission: ZF4HP22/24 stall testing, torque-converter replacement, fluid-pump repair, and valve-body and solenoid service.

• ACE and self-leveling suspension: Hydraulic bleeding, height-sensor calibration, and replacement of pumps, actuators, air springs, and control components.

• Brakes and steering: ABS, electronic traction control, hill descent control, modulator replacement, brake bleeding, steering pressure tests, and steering-box adjustment.

• Heating and A/C: Control-panel diagnostics, front and rear evaporator replacement, and refrigerant recovery, evacuation, and recharging.

Written for skilled technicians, the manual assumes workshop training and access to the specified diagnostic equipment; its introduction reserves safety-critical repairs for trained personnel.

Engine Service, Fuel Delivery and Cooling

The oil-pressure check connects measured pressure with oil-pump and main- and connecting-rod-bearing inspection, providing a practical starting point for investigating low oil pressure.

Fuel-system procedures cover the pump, tank, injectors, and associated components. Cooling-system instructions address draining and refilling, radiator removal, thermostat replacement, and coolant-pump gasket replacement. V8 clutch coverage includes assembly replacement, release components, and hydraulic bleeding.

Cylinder-head overhaul distinguishes early and modified valves and guides. The modified components can also be fitted to earlier engines in cylinder sets, so the documented identification details matter when selecting replacement parts.

Engine Variants and Emissions Diagnosis

V8 specifications distinguish low-compression 4.0L engines from high-compression 4.0L and 4.6L versions, with market-specific NAS and Rest of World (ROW) data.

For NAS vehicles, the manual identifies the 2003-model-year change to the larger V8 and ZF4HP24 automatic transmission. ECM replacement requires TestBook/T4 selection of the correct engine calibration.

Emission diagnostics distinguish NAS vacuum and positive-pressure EVAP leak-detection systems. Separate procedures before and from the 2003 model year address canisters, leak-detection pumps, and secondary-air vacuum reservoirs.

Drivetrain and Suspension Configuration

Transfer-case documentation separates differential-lock hardware and selector arrangements before and from the 2003 model year. Axle and driveshaft chapters cover differential overhaul, pinion-seal replacement, CV joints, and universal joints. Steering tests distinguish diesel, V8 LHD, and V8 RHD installations.

Both coil-spring and rear-air-spring configurations are documented. SLS calibration uses TestBook and blocks LRT-64-003/1 and LRT-64-003/2. ACE bleeding and calibration also require TestBook; brake-modulator replacement or work upstream of it requires the TestBook/T4 bleeding procedure.

Repair notes flag ACE pipe connections that can damage the hydraulic system if mixed up. They also explain how steering-wheel movement with the intermediate shaft or universal joint disconnected can damage the rotary coupler and steering-wheel switches.

Electrical, Body and Climate-System Repair

BCU replacement includes programming and calibration with TestBook. Security coverage explains immobilization, emergency key access, and configurable locking functions. Window, sunroof, and instrument sections describe electrical operation and component replacement.

Body repair extends to panel replacement, welding preparations, chassis/body measuring points, cavity-wax treatment, and water-leak testing. Panel-replacement time schedules support repair planning and include mechanical, electrical, trim, and painting allowances; the figures are guides rather than guaranteed job times.

Separate lighting and exterior-panel procedures address configurations before and from the 2003 model year. Heating documentation includes the diesel fuel-burning heater, while rear-A/C procedures cover its separate blower, expansion valve, and evaporator.

System Diagrams and Workshop References

Illustrations include the R380 gearbox cross section, ACE hydraulic circuit, SLS circuit, brake hydraulic schematic, and air-conditioning system schematic. System control diagrams, component layouts, and connector pin-out tables support electrical diagnosis.

Technical references include torque tables, fluid capacities, approved lubricants and sealants, wear limits, clearance specifications, and electrical test values.

Before beginning repair work, review the manual’s safety and environmental precautions for vehicle lifting, SRS, brake hydraulics, and refrigerant handling.

Selected Oil-Pressure and Gearbox Inspection Data

For the V8 lubrication system, the general-data section lists a minimum oil pressure of 0.7 bar at idle and 3.4 bar at 2,000 rpm with the engine hot.

R380 inspection data distinguishes new-component clearances from service limits. First-gear end float is specified as 0.050–0.200 mm when new, with a service limit of 0.327 mm.