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

• Covers V8 engine removal and overhaul, including cylinder heads, timing chains, rocker shafts, pistons, and crankshaft bearings.
• Bosch Motronic M5.2.1 documentation includes sensor tests, ECM connector tables, P-codes, and secondary air injection fault-finding flowcharts.
• R380 manual transmission and LT230SE transfer case sections detail disassembly, inspection, bearing setup, and reassembly.
• ZF4HP22/24 automatic transmission coverage includes stall testing, torque-converter replacement, fluid-pump repair, and valve-body and solenoid service.
• Active Cornering Enhancement (ACE) and self-leveling suspension (SLS) coverage includes ACE hydraulic bleeding, SLS height calibration, and component replacement.
• Brake documentation covers ABS, electronic traction control, hill descent control, hydraulic-modulator replacement, and system bleeding.
• Heating and A/C sections include control-panel diagnostics, front and rear evaporator repair, and refrigerant recovery, evacuation, and recharging.

This 1,529-page PDF contains Land Rover’s 2003 North American Specification (NAS) Discovery Series II workshop manual, Publication Part No. VDR 100330 NAS (6), titled “1999MY ON.” Written for skilled technicians, it assumes workshop training and access to the specified diagnostic equipment.

Coverage centers on the 4.0L and 4.6L V8. 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.

Model-Year and Engine Differences

The manual documents VIN plate locations as well as engine, transmission, transfer-case, and axle serial numbers. 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, it identifies the 2003-model-year change to the 4.6L V8 and ZF4HP24 automatic transmission. The 4HP22 remains associated with 4.0L V8 and Td5 applications. ECM replacement requires TestBook/T4 selection of the correct engine calibration.

Cylinder-head repair coverage identifies modified valves and guides from 4.0L engine numbers 55D 05678A, 56D 50788A, and 97D 05505A, with the modified parts fitted to all 4.6L engines.

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, Steering, and Suspension

Transfer-case documentation distinguishes 41D units without an interlock from 42D units with an interlock. It also 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 procedures include pressure testing for diesel and V8 systems, steering-box adjustment, and front-wheel alignment.

Both coil-spring and rear-air-spring configurations are documented. SLS procedures identify calibration blocks LRT-64-003/1 and LRT-64-003/2. ACE bleeding and suspension calibration depend on TestBook; the brake section specifies TestBook/T4 bleeding after replacement of the modulator or components upstream of it.

Repair notes flag ACE pipe connections that can damage the hydraulic system if mixed up. They also explain how steering-wheel movement with the linkage disconnected can damage the SRS rotary coupler.

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. Separate lighting and exterior-panel procedures address configurations before and from the 2003 model year.

Heating documentation includes the diesel fuel-burning heater. Rear-A/C procedures cover its separate blower, expansion valve, and evaporator.

Diagrams and Factory Reference Data

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

Technical data is organized by system, with 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.