Positioning:
A premium, capable off-road and on-road SUV, the Discovery Series II was positioned as a robust, versatile vehicle for adventure and family use. This manual addresses the technical intricacies of this generation.
Competitors:
Competed with vehicles like the Jeep Grand Cherokee, Toyota Land Cruiser, Ford Explorer, and Mercedes-Benz ML-Class.
Off Road Capability:
Renowned for its off-road prowess thanks to features like the permanent four-wheel drive, lockable center differential, and optional Electronic Air Suspension (EAS) providing adjustable ride height.
Interior Space:
Spacious interior offering comfortable seating for up to seven occupants, with versatile cargo configurations.
Durability:
Built on a ladder frame chassis, contributing to its ruggedness and towing capability.
Engine Mechanical:
V8 Petrol (4.0L/4.6L), TD5 Diesel (2.5L) - Engine assembly, disassembly, overhaul, cylinder head, crankshaft, pistons, connecting rods, camshafts, timing system, lubrication system, cooling system, intake and exhaust systems.
Engine Management:
Fuel injection (GEMS, P38A ECU variants), ignition system, sensors, actuators, emission control systems, ECU diagnostics.
Transmission:
Automatic (ZF 4HP22, 5HP24) and Manual (R380) transmissions - overhaul, diagnosis, fluid specifications, clutch, torque converter, gear selection.
Drivetrain:
Transfer box (LT230), differentials (front, center, rear), driveshafts, constant velocity (CV) joints, hub assemblies, wheel bearings.
Suspension:
Coil spring suspension, Electronic Air Suspension (EAS) system - components, operation, diagnosis, height sensors, compressor, air springs, control unit.
Brakes:
ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), EBD (Electronic Brakeforce Distribution), brake calipers, rotors, pads, brake lines, master cylinder, brake booster, parking brake.
Steering:
Power steering system, steering rack, power steering pump, steering column, steering wheel.
Electrical System:
Battery, alternator, starter motor, fuses, relays, wiring diagrams, lighting system, horn, ignition switch, power distribution.
Body And Chassis:
Body panels, doors, hinges, latches, windows, sunroof, roof rack, underbody protection, chassis frame inspection and repair.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system, climate control, refrigerant system, blower motor, heater core, evaporator core, A/C compressor.
Interior:
Seats, seat belts, airbags, dashboard, instrument cluster, interior trim, door panels, headliner, floor mats.
Chassis Electronics:
BCM (Body Control Module), SLABS (Slave ECU for ABS/TC/HDC), EAS ECU, SRS (Supplemental Restraint System) module.
Maintenance:
Routine maintenance, oil changes, filter replacements, fluid checks and changes, lubrication points, tire rotation, brake checks, scheduled servicing.
Troubleshooting:
Diagnostic procedures, symptom analysis, fault finding for all major systems, wiring harness testing, sensor testing, common issue diagnosis.
Repair:
Step-by-step repair instructions for all components and systems, component replacement, assembly and disassembly of mechanical and electrical parts.
Rebuilding:
Complete engine and transmission rebuilding procedures, including specifications and tolerances.
Restoration:
Guidance on restoring original specifications and functionality.
Diagnostics:
On-board diagnostics (OBD-II) procedures, fault code reading and clearing, live data interpretation for engine management and chassis electronics.
Calibration:
EAS system calibration, steering angle sensor calibration, ride height adjustments.
Depth:
Comprehensive, from basic maintenance to advanced component overhaul and diagnostics. Suitable for professional mechanics and experienced DIY enthusiasts.
Transmission Type Standard:
4-speed Automatic (ZF 4HP22 EH)
Transmission Type Optional:
5-speed Manual (R380)
Transmission Type Optional Petrol:
5-speed Automatic (ZF 5HP24)
Automatic Features:
Electronic control, selectable modes (e.g., Economy/Sport).
Manual Gear Ratios:
Refer to manual for specific R380 ratios (e.g., 1st: 3.15:1, 2nd: 1.90:1, 3rd: 1.34:1, 4th: 1.00:1, Reverse: 3.15:1).
Fluid Specification Automatic
Automatic Transmission Fluid:
ESSO LT 71141 or equivalent DEXRON III/Mercon.
Fluid Specification Manual
Manual Transmission Fluid:
API GL-1 or GL-4 75W-90 synthetic gear oil.
Service Intervals Petrol V8
Oil Change Interval:
Every 6,000 miles or 6 months. Refer to manual for exact interval based on driving conditions.
Air Filter Interval:
Every 12,000 miles or 12 months.
Spark Plug Interval:
Every 30,000 miles (for standard plugs, platinum plugs may extend this).
Oil Change Interval:
Every 6,000 miles or 6 months.
Air Filter Interval:
Every 12,000 miles or 12 months.
Fuel Filter Interval:
Every 12,000 miles or 12 months.
Engine Oil Capacity V8 Liters:
Approx. 6.7 Liters (with filter change) for 4.0L, 7.7 Liters for 4.6L. Refer to manual for exact fill level.
Engine Oil Specification V8:
API SJ or higher, SAE 10W-40 or 10W-30 (depending on climate).
Engine Oil Capacity Td5 Liters:
Approx. 7.3 Liters (with filter change).
Engine Oil Specification Td5:
API CG-4 or CH-4, SAE 15W-40 or 10W-30 (depending on climate).
Coolant Type:
OAT (Organic Acid Technology) coolant, typically pink or orange, mixed 50/50 with deionized water. Check manual for specific type.
Power Steering Fluid:
Pentosin CHF 11S or equivalent.
Common Issue Eas:
Leaking air springs, compressor failure, height sensor issues, control unit faults, leaking air lines.
Common Issue Td5:
Injector loom failure, oil in ECU loom (O-ring seal failure), crank sensor issues, ACE pipe leaks.
Common Issue V8:
Head gasket leaks, intake manifold gasket leaks, cooling system failures (radiator, hoses), viscous fan clutch failure.
Common Issue Drivetrain:
Propshaft center bearing wear, differential seal leaks, viscous coupling unit (VCU) failure in transfer box.
Common Issue Body:
Rust (especially on chassis, rear crossmember, door bottoms, wheel arches), headliner sagging, door seals deteriorating.
