ENGINE
| Application | Description | ||
|---|---|---|---|
| Lubrication | |||
| Type | Wet sump, pressure fed | ||
| Pump Type | Eccentric rotor, crankshaft driven integral with stiffener plate | ||
| Filter Type | |||
| Primary | Centrifuge filter | ||
| Secondary | Disposable canister with full flow by-pass | ||
| Pressure At Idle (Cold) | 3.0 Bar (43.5 psi) | ||
| Pressure At 3500 Rev/Min (Hot) | 1.5-3.0 Bar (21.75-43.5 psi) | ||
| Relief Valve Opening Pressure | 4.0 Bar (58 psi) | ||
| Low Oil Pressure Switch Opening Pressure | 0.2-0.6 Bar (3.0-8.8 psi) | ||
| Crankshaft | |||
| Main Journal Diameter | 61.9875-62.0125 mm (2.4404-2.4414 in) | ||
| Crankpin Journal Diameter | 53.99-54.01 mm (2.125-2.131 in) | ||
| End Float | 0.020 - 0.250 mm (0.0008 - 0.0098 in) | ||
| Main Bearings | |||
| Quantity | 6 (5 Main, 1 Thrust) | ||
| Pistons Type | |||
| Graphite | Compound skirt with combustion chamber in crown | ||
| Clearance In Cylinder Bore. Measured At Bottom Of Skirt, 90° To Gudgeon Pin | 0.172-0.206 mm (0.007-0.008 in) | ||
| Diameter (Measured At Right Angles To Gudgeon Pin And 40.0 Mm (1.5 In) From Bottom Of Skirt) | 84.270-85.254 mm (3.321-3.361 in) | ||
| Gudgeon Pins | Fully floating, offset towards piston thrust side | ||
| Piston Rings | |||
| Type | 2 compression, 1 oil control | ||
| Upper Compression Ring | Barrel edge, chrome plated | ||
| Lower Compression Ring | Taper faced | ||
| Oil Control Ring | Bevelled ring with spring | ||
| New Ring To Groove Clearance | |||
| Upper Compression | Not measured | ||
| Lower Compression | 0.050-0.082 Mm (0.002-0.003 In) | ||
| Oil Control | 0.050-0.082 Mm (0.002-0.003 In) | ||
| Piston Ring Fitted Gap In Cylinder Bore | |||
| Upper Compression | 0.30-0.45 Mm (0.0118-0.0177 In) | ||
| Lower Compression | 0.40-0.60 Mm (0.0157-0.0236 In) | ||
| Oil Control | 0.25-0.40 Mm (0.0098-0.0157 In) | ||
| Camshaft | |||
| Bearings | 6 | ||
| Drive | Duplex chain | ||
| End Float | 0.06-0.16 Mm (0.002-0.006 In) | ||
| Tappets | |||
| Type | Hydraulic lash adjusters With followers | ||
GENERAL DATA - ENGINE
FUEL SYSTEM
| Application | Description |
|---|---|
| Type | Multiport injection from pressure regulated, returnless supply |
| Pump | Electric submersible |
| Regulated Pump Output Pressure | 3.5 Bar (50.75 psi) |
| Fuel Pump Delivery | 120 Liters/Hr (211 Pints/Hr) (234 Us Pints/Hr) |
| Filter | In-line canister |
| Air Filter | Mann And Hummell P0036 |
GENERAL DATA - FUEL SYSTEM
COOLING SYSTEM
| Application | Description | |
|---|---|---|
| Type | Pressurized, Spill Return, Thermostatically Controlled Water And Antifreeze Mixture. Vertical Flow Radiator With Remote Header Tank And Pump Assisted | |
| Cooling Fans | 9 Blade Axial Flow On Viscous Coupling And 11 Blade Axial Flow Electric | |
| Electric Cooling Fan Switching Points | ||
| For A/C System | ||
| On | When Vehicle Speed Is 50 Mph (80 Km/H) Or Less And Ambient Temperature Is 28 °C (82 °F) Or More | |
| Off | When Vehicle Speed Increases To (62.5 Mph (100 Km/H) Or Ambient Temperature Decreases To 25 °C (77 °F) | |
| For Engine Cooling During Normal Running | ||
| On | 100 °C (212 °F) | |
| Off | 94.5 °C (202 °F) | |
| For Engine Cooling At Ignition Off (To Counteract Heat Soak) | ||
| On | If, Within 10 Seconds Of Ignition Off, Intake Air Temperature Is 60 °C (140 °F) Or More And Engine Coolant Temperature Is 110 °C (230 °F) Or More | |
| Off | After 10 Minutes Or If Engine Coolant Temperature Decreases To 100 °C (212 °F) | |
| Coolant Pump | Centrifugal Impeller, Belt Driven From Crankshaft | |
| Coolant Pump Drive Ratio | 1.293 : 1 | |
| Coolant Pump Output At 1000 Rev/Min | 10 Liters/Min (2.64 Us Galls/Min) At 0.7 Bar (10 Lbf.In2) | |
| Thermostat | Waxstat With Pressure Relief Valve | |
| Thermostat Operating Temperature | ||
| Initial Opening | 82 °C (179 °F) | |
| Fully Open | 96 °C (204 °F) | |
| Expansion Tank Cap Relief Valve - System Operating Pressure | 1.4 Bar (20 Lbf.In2) | |
GENERAL DATA - COOLING SYSTEM
CLUTCH
| Application | Description | |
|---|---|---|
| Type | Diaphragm Spring, Hydraulically Operated With Self-Centering, Preloaded Release Bearing | |
| Clutch Plate Friction Material | APTEC 385 | |
| Drive Plate Diameter | 267 Mm (10.5118 In) | |
| Pressure Plate Diameter | 268 Mm (10.5512 In) | |
| Clutch Plate Thickness (Clamped State) | ||
| New | 8.4-8.9 Mm (0.33-0.35 In) | |
| Service Limit | 7.1 Mm (0.28 In) | |
| Rivet Depth | ||
| New | 1.73 Mm (0.07 In) | |
| Service Limit | 0.25 Mm (0.01 In) | |
| Clutch Plate Runout | ||
| New | 0.5 Mm (0.02 In) | |
| Service Limit | 0.5 Mm (0.02 In) | |
GENERAL DATA - CLUTCH
MANUAL TRANSMISSION - R380
| Application | Description | |
|---|---|---|
| Type | Single helical constant mesh | |
| Gears | 5 forward, 1 reverse, all synchromesh | |
| Gear Ratios: V8 Petrol | ||
| First | 3.321:1 | |
| Second | 2.132:1 | |
| Third | 1.397:1 | |
| Fourth | 1.0:1 | |
| Fifth | 0.732:1 | |
| Reverse | 3.536:1 | |
| Baulk Ring Clearance | ||
| New | 0.500 mm (0.0197 in) | |
| Service limit | 0.500 mm (0.0197 in) | |
| Selector fork pad widths - minimum | 6.5 mm (0.255 in) | |
| First gear end float | ||
| New | 0.050 - 0.200 mm (0.0020 - 0.0079 in) | |
| Service limit | 0.327 mm (0.0129 in) | |
| Second gear end float | ||
| New | 0.040 - 0.210 mm (0.0016 - 0.0083 in) | |
| Service limit | 0.337 mm (0.0133 in) | |
| Third gear end float | ||
| New | 0.110 - 0.210 mm (0.0043 - 0.0083 in) | |
| Service limit | 0.337 mm (0.0133 in) | |
| Adjust fifth / reverse hub - shim to | ||
| New | 0.005 - 0.055 mm (0.0002 - 0.0022 in) | |
| Service limit | 0.055 mm (0.0022 in) | |
| Reverse gear idler shaft clearance | ||
| New | 0.040 - 0.380 mm (0.0016 - 0.0150 in) | |
| Service limit | 0.380 mm (0.0150 in) | |
| Mainshaft end float | ||
| New | 0.000 - 0.050 mm (0.0000 - 0.0020 in) | |
| Service limit | 0.000 - 0.050 mm (0.0000 - 0.0020 in) | |
| Layshaft end float | ||
| New | 0.000 - 0.050 mm (0.0000 - 0.0020 in) | |
| Service limit | 0.000 - 0.050 mm (0.0000 - 0.0020 in) | |
GENERAL DATA - MANUAL TRANSMISSION - R380
TRANSFER CASE - LT230SE
| Application | Description | |
|---|---|---|
| Type | LT230SE, Two Speed Reduction With Front And Rear Drives | |
| Reduction ratios | ||
| High range | 1.211 : 1 | |
| Low range | 3.32 : 1 | |
| Low Range Gear To High/Low Range Hub Clearance | 0.05 to 0.15 mm (0.002 to 0.006 in) | |
| High Range Gear To High/Low Range Hub Clearance | 0.05 to 0.15 mm (0.002 to 0.006 in) | |
| Mainshaft Input Gear Bearing Pre-Load | 0.05 mm (0.002 in) | |
| Intermediate Gear Bearing Pre-Load | Torque Intermediate Shaft Nut To 88 Nm (65 lbf.ft) | |
GENERAL DATA - TRANSFER CASE - LT230SE
AUTOMATIC TRANSMISSION - ZF4HP22/24
| Application | Description | |
|---|---|---|
| Type | ZF4HP22, electro-hydraulic shift control with fluid torque converter | |
| Gears | 4 forward, 1 reverse | |
| Gear ratios | ||
| First | 2.480:1 | |
| Second | 1.480:1 | |
| Third | 1.000:1 | |
| Fourth | 0.728:1 | |
| Reverse | 2.086:1 | |
| Torque converter lock-up | Engaged in third and fourth gears above 72 km/h (45 mph) | |
| Input shaft axial end-float | 0.2 to 0.4 mm (0.008 to 0.016 in) | |
GENERAL DATA - AUTOMATIC GEARBOX - ZF4HP22/24
REAR AXLE
| Application | Description |
|---|---|
| Type | Solid axle casing incorporating a spiral bevel differential and drive shafts |
| Reduction ratio | 3.538:1 |
GENERAL DATA - REAR AXLE
FRONT AXLE
| Application | Description |
|---|---|
| Type | Solid axle casing incorporating spiral bevel differential and drive shafts with constant velocity joints. |
| Reduction ratio | 3.538:1 |
GENERAL DATA - FRONT AXLE
STEERING
| Applications | Description | |
|---|---|---|
| Type | Hydraulically assisted worm and roller | |
| Steering Wheel Turns Lock To Lock | 3.5 | |
| Steering Wheel Diameter | 400 mm (15.7 in) | |
| Turning Circle, Curb To Curb | 11.9 meters (39.1 feet) | |
| PAS pump | Hobourn Automotive Ltd. Series 500, belt driven | |
| Pas Pump Pressure - Engine At Idle With Steering At Full Lock | 21 to 62 bar (305 to 900 lbf/in2 | |
| Delivery Pressure (Nominal) | 100 bar (1450 lbf.in2) 8.5 liters/min (15.1 pints/min) (18.1 US pints/min) | |
| Steering Geometry | ||
| Camber Angle - Front, Up To VIN 2A 754807 - Unladen Condition | 10' +/- 30' | |
| Camber Angle - Front, From VIN 2A 754808 - unladen condition | +20' +/- 30' | |
| Camber Angle - Rear - Unladen Condition | 10' +/- 30' | |
| Cross Camber - Front And Rear | 45' (Maximum) | |
| Castor Angle - Unladen Condition | 3° 45' +/- 45' | |
| Cross Castor | 1° (Maximum) | |
| Toe Out - Front | 0° 10' +/- 0° 10' (total) | |
| Toe In - Rear | + 0° 5' +/- 0° 15' (total) | |
| Thrust Angle | 0° +/- 20' | |
| Swivel Pin Inclination | 13° 11' | |
GENERAL DATA - STEERING
Note. Measurements taken at EEC curb weight.
SUSPENSION
| Applications | Description | |
|---|---|---|
| Type - Front | Beam axle with coil springs, longitudinal radius arms, Panhard rod, twin tube dampers and either anti-roll bar or active cornering enhancement (ACE) | |
| Nominal height from hub center to wheel arch (not liner)* | 500 +/- 15 mm (19.7 +/- 0.6 in) | |
| Front road spring color codes | ||
| V8 LHS | Pink/orange | |
| V8 RHS - LHD | Pink/orange | |
| Rear road spring color codes | ||
| 5 seat, LHS | Purple | |
| 5 seat, RHS - LHD | Purple | |
| 5 seat, RHS - RHD | Purple/purple | |
| 7 seat, LHS - LHD | Grey/blue | |
| 7 seat, LHS - RHD | Grey/green | |
| 7 seat, RHS - LHD | Grey/blue | |
| 7 seat, RHS - RHD | Grey/white | |
| Bump stop height (top of bump stop to axle bracket) | 44.5 mm (1.75 in) | |
| Anti-roll bar diameter - front | ||
| With ACE fitted | 35 mm (1.38 in) | |
| Without ACE | 30 mm (1.18 in) | |
| Type - Rear | Beam axle with coil or air springs, longitudinal radius arms, Watts linkage, twin tube dampers and either anti-roll bar or active cornering enhancement (ACE) | |
| Nominal height from hub center to wheel arch (not liner) (1) | ||
| Coil spring | 483 +/- 15 mm (19.0 +/- 0.6 in) | |
| Air spring | 473 +/- 15 mm (18.6 +/- 0.6 in) | |
| Road spring color code | Purple (all models) | |
| Bump stop height (top of bump stop to axle bracket) | ||
| Coil spring | 71.5 mm (2.8 in) | |
| Air spring | 61.5 mm (2.4 in) | |
| Anti-roll bar diameter - rear | ||
| With ACE fitted | 35 mm (1.38 in) | |
| Without ACE - SLS fitted | 29 mm (1.14 in) | |
| Without ACE - SLS not fitted | 5-seats = 19 mm (0.75 in) 7-seats = 16 mm (0.63 in) | |
| (1) Measurement taken with vehicle at unladen weight. . | ||
| (1) | Measurement taken with vehicle at unladen weight. |
GENERAL DATA - SUSPENSION
BRAKES
| Application | Description | |
|---|---|---|
| Type | Servo assisted, diagonally split hydraulic on outboard discs, with four channel electronic control ABS | |
| Disc diameter | ||
| Front | 297.0 - 297.4 mm (11.693 - 11.709 in) | |
| Rear | 303.8 - 304.2 mm (11.961 - 11.976 in) | |
| Front disc minimum thickness | ||
| New | 24.9 - 25.1 mm (0.980 - 0.988 in) | |
| Service limit | 22.0 mm (0.866 in) | |
| Rear disc minimum thickness | ||
| New | 12.5 - 12.7 mm (0.492 - 0.500 in) | |
| Service limit | 11.7 mm (0.461 in) | |
| Maximum disc runout | 0.15 mm (0.006 in) | |
| Minimum pad material thickness | 2.0 mm (0.079 in) | |
| Handbrake | Cable operated drum on transfer box rear output shaft | |
GENERAL DATA - BRAKES
WHEELS & TIRES
| Application | Description | ||
|---|---|---|---|
| Wheel size | |||
| Steel | 7J x 16 | ||
| Alloy | 7J x 16; 8J x 16; 8J x 18 | ||
| Tyre size | |||
| With 7J x 16 wheels | 235/70 R16 Wrangler HP 105H; 235/70 R16 Michelin XPC * 105H | ||
| With 8J x 16 wheels | 255/65 R16 Wrangler HP 109H; 255/65 R16 Michelin XPC * 109H | ||
| With 8J x 18 wheels | 255/55 R18 Wrangler HP 109H | ||
| Tyre Pressures | |||
| All tires - normal operating conditions | |||
| Front | Up to 03MY - 1.9 Bar (28 lbf.in2) From 03MY - 2.1 Bar (30 lbf.in2) | ||
| Rear | 2.6 Bar (38 lbf.in2) | ||
| All tires-vehicle at GVW | |||
| Front | Up to 03MY - 1.9 Bar (28 lbf.in2) From 03MY - 2.1 Bar (30 lbf.in2) | ||
| Rear | 3.2 Bar (46 lbf.in2) | ||
GENERAL DATA - WHEELS & TIRES
AIR CONDITIONING
| Application | Description | |
|---|---|---|
| Type | CFC free, sealed closed loop | |
| Compressor | ||
| Displacement | 177.7 cm3/rev (10.84 in3/rev) | |
| Relief valve operating pressure | 34.3 to 41.4 bar (497 to 600 lbf.in2) | |
| Refrigerant oil quantity | 180ml (6.3 fl.oz) | |
| Dual pressure switch operating pressures (nominal) | ||
| Low pressure switch Opens | 2.0 bar (29.0 lbf.in2), pressure decreasing | |
| Low pressure switch Closes | 2.3 bar (33.4 lbf.in2), pressure increasing | |
| High pressure switch Opens | 32 bar (464 lbf.in2), pressure increasing | |
| High pressure switch Closes | 26 bar (377 lbf.in2), pressure decreasing | |
GENERAL DATA - AIR CONDITIONING
ELECTRICAL
| Applications | Description | |
|---|---|---|
| System | 12 volt, negative earth | |
| Battery | ||
| Type | Delco Freedom | |
| Capacity | 72 amp hour | |
| Alternator | ||
| Type | Bosch NC65/130 | |
| Maximum output | 130 amp | |
| Starter motor | ||
| Type | Nippon Denso | |
| Power | 1.8 kW | |
GENERAL DATA - ELECTRICAL
The following illustration indicates the general position of each earth point and earth header on the vehicle
Scheme 19
DIMENSIONS
| Applications | Description |
|---|---|
| Overall length - including towing hitch | 4715 mm (185.6 in) |
| Overall length - including spare wheel | 4705 mm (185.24 in) |
| Overall width (excluding mirrors) | 1885 mm (74.2 in) |
| Overall height - Open sunroof (1) | 2015 mm (79.3 in) |
| Overall height (without roof bars) (1) | 1940 mm (76.40 in) |
| Minimum ground clearance (1) | 253.5 mm (10.0 in) |
| Wheelbase | 2540 mm (100.00 in) |
| Turning circle (kerb to kerb) | 11.9 meters (39.1 feet) |
| Track - front | 1540 mm (60.63 in) |
| Track - rear | 1560 mm (61.42 in) |
| (1) Measurement taken with vehicle at unladen weight. | |
| (1) | Measurement taken with vehicle at unladen weight. |
GENERAL DATA - DIMENSIONS