Jeep Wrangler TJ. Manual - part 425

PISTON RINGS

DESCRIPTION

SPECIFICATION

Metric

Standard

Ring Gap

Top

Compression

Ring

0.25 - 0.51 mm

0.0098 - 0.020

in.

Wear Limit

0.8 mm

0.031 in.

2nd
Compression
Ring

0.23 - 0.48 mm

0.009 - 0.018 in.

Wear Limit

0.8 mm

0.031 in.

Oil Control Steel
Rails

0.25 - 0.64 mm

0.0098 - 0.025

in.

Wear Limit

1.00 mm

0.039 in.

Compression
Rings

0.030 - 0.080

mm

0.0011 - 0.0031

in.

Wear Limit

0.10 mm

0.004 in.

Ring Side
Clearance - Oil
Ring Pack

0.012 - 0.178

mm

0.0004 - 0.0070

in.

Ring Width -
Compression
Rings

1.47 - 1.50 mm

0.057 - 0.059 in.

Ring Width - Oil
Ring Pack

2.72 - 2.88 mm

0.107 - 0.1133

in.

CONNECTING ROD

DESCRIPTION

SPECIFICATION

Metric

Standard

Bearing
Clearance

0.025 - 0.071

mm

0.0009 - 0.0027

in.

Wear Limit

0.075 mm

0.003 in.

Bore Diameter -
Piston Pin

20.96 - 20.98

mm

0.8252 - 0.8260

in.

Bore Diameter -
Crankshaft End

53.007 - 52.993

mm

2.0868 - 2.0863

in.

Side Clearance

0.13 - 0.38 mm

0.005 - 0.015 in.

Wear Limit

0.40 mm

0.016 in.

Weight - Total
(Less Bearing)

565.8 grams

19.96 oz.

CRANKSHAFT

DESCRIPTION

SPECIFICATION

Metric

Standard

Connecting Rod
Journal
Diameter

49.984 - 50.000

mm

1.968 - 1.9685

in.

Main Bearing
Journal
Diameter

59.992 - 60.008

mm

2.362 - 2.3625

in.

Journal
Out-of-Round
(Max.)

0.0035 mm

0.0003 in.

Journal Taper
(Max.)

0.007 mm

0.0001 in.

End Play

0.09 - 0.24 mm

0.0035 - 0.0094

in.

Wear Limit

0.38 mm

0.015 in.

Main Bearing
Diametrical
Clearance

0.018 - 0.062

mm

0.0007 - 0.0024

in.

HYDRAULIC LASH ADJUSTER

DESCRIPTION

SPECIFICATION

Metric

Standard

Body Diameter

15.901 - 15.913

mm

0.626 - 0.6264

in.

Plunger Travel
Minimum (Dry)

3.0 mm

0.118 in.

CYLINDER HEAD CAMSHAFT BEARING BORE

DIAMETER

DSECRIPTION

SPECIFICATION

Metric

Standard

Journals No.1 -
6

26.020 - 26.041

mm

1.024 - 1.025 in.

TJ

ENGINE 2.4L

9 - 15

ENGINE 2.4L (Continued)

CAMSHAFT

DESCRIPTION

SPECIFICATION

Metric

Standard

Journal
Diameter No. 1
- 6

25.976 - 25.995

mm

1.022 - 1.023 in.

Bearing
Clearance -
Diametrical

0.025 - 0.065

mm

0.0009 - 0.0025

in.

End Play

0.05 - 0.17 mm

0.0019 - 0.0066

in.

Lift (Zero Lash)

Intake

8.25 mm

0.324 in.

Exhaust

6.60 mm

0.259 in.

Intake Valve
Timing*

Closes (ABDC)

44.3°

Opens (ATDC)

6.2°

Duration

218.1°

Exhaust Valve
Timing*

Closes (ATDC)

0.8°

Opens (BBDC)

39.9°

Duration

220.7°

Valve Overlap

5.4°

*
All reading in crankshaft degrees at 0.5 mm (0.019
in.) valve lift.

CYLINDER HEAD

DESCRIPTION

SPECIFICATION

Metric

Standard

Material

Cast Aluminum

Gasket
Thickness
(Compressed)

0.71 mm

0.028 in.

VALVE SEAT

DESCRIPTION

SPECIFICATION

Metric

Standard

Angle

44.5 - 45°

Seat Diameter -
Intake

34.37 - 34.63

mm

1.353 - 1.363 in.

Seat Diameter -
Exhaust

27.06 - 27.32

mm

1.065 - 1.075 in.

Runout (Max.)

0.05 mm

0.002 in.

Valve Seat
Width - Intake
and Exhaust

0.9 - 1.3 mm

0.035 - 0.051 in.

Service Limit -

Intake

2.0 mm

0.079 in.

Service Limit -

Exhaust

2.5 mm

0.098 in.

VALVE GUIDE

DESCRIPTION

SPECIFICATION

Metric

Standard

Diameter I.D.

5.975 - 6.000

mm

0.235 - 0.236 in.

Guide Bore
Diameter

11.0 - 11.02

mm

0.4330 - 0.4338

in.

Guide Height
(spring seat to
guide tip)

13.25 - 13.75

mm

0.521 - 0.541 in.

9 - 16

ENGINE 2.4L

TJ

ENGINE 2.4L (Continued)

VALVES

DESCRIPTION

SPECIFICATION

Metric

Standard

Face Angle -
Intake and
Exhaust

44.5 - 45°

Head Diameter
- Intake

34.67 - 34.93

mm

1.364 - 1.375 in.

Head Diameter
- Exhaust

28.32 - 28.52

mm

1.114 - 1.122 in.

Valve Length
(Overall)

Intake

112.76 - 113.32

mm

4.439 - 4.461 in.

Exhaust

110.89 - 111.69

mm

4.365 - 4.397 in.

Valve Stem
Diameter

Intake

5.934 - 5.952

mm

0.2337 - 0.2344

in.

Exhaust

5.906 - 5.924

mm

0.2326 - 0.2333

in.

VALVE MARGIN

DESCRIPTION

SPECIFICATION

Metric

Standard

Intake

1.2 - 1.7 mm

0.047 - 0.066 in.

Service Limit

0.95 mm

.0037 in.

Exhaust

0.985 - 1.315

mm

0.038 - 0.051 in.

Service Limit

1.05 mm

.039 in.

VALVE STEM TIP HEIGHT

DESCRIPTION

SPECIFICATION

Metric

Standard

Intake

48.04 mm

1.891 in.

Exhaust

47.99 mm

1.889 in.

VALVE STEM TO GUIDE CLEARANCE

DESCRIPTION

SPECIFICATION

Metric

Standard

Intake

0.048 - 0.066

mm

0.0018 - 0.0025

in.

Max. Allowable

0.076 mm

0.003 in.

Service Limit

0.25 mm

0.010 in.

Exhaust

0.0736 - 0.094

mm

0.0029 - 0.0037

in.

Max. Allowable

0.101 mm

0.004 in.

Service Limit

0.25 mm

0.010 in.

VALVE SPRINGS

DESCRIPTION

SPECIFICATION

Metric

Standard

Free Length
(Approx.)

49.2 mm

1.937 in.

Nominal Force
(Valve Closed)

334 ±17 N @

38.0 mm

75.08 ±3.8 lbs.

@ 1.496 in.

Nominal Force
(Valve Open)

598 ±30N @

29.75 mm

134 ±6.7 lbs. @

1.171 in.

Installed Height

38.00 mm

1.496 in.

Number of Coils

6.9

Wire Diameter

3.61 mm

0.142 in

OIL PUMP

DESCRIPTION

SPECIFICATION

Metric

Standard

Clearance Over
Rotors (Max.)

0.10 mm

0.004 in.

Cover Out-of-Flat
(Max.)

0.025 mm

0.001 in.

Inner Rotor
Thickness (Min.)

10.699 mm

0.421 in.

Outer Rotor
Thickness (Min.)

10.699 mm

0.421 in.

Outer Rotor
Clearance (Max.)

0.039 mm

0.015 in.

Outer Rotor
Diameter (Min.)

85.924 mm

3.383 in.

Tip Clearance
Between Rotors
(Max.)

0.20 mm

0.008 in.

TJ

ENGINE 2.4L

9 - 17

ENGINE 2.4L (Continued)

OIL PRESSURE

DESCRIPTION

SPECIFICATION

Metric

Standard

At Curb Idle
Speed*

25 kPa

4 psi

At 3000 rpm

170 - 550 kPa

25 - 80 psi

CAUTION:
*If pressure is ZERO at curb idle, DO NOT run engine
at 3000 rpm.

SPECIFICATIONS - TORQUE

DESCRIPTION

N·m

Ft.

Lbs.

In.

Lbs.

Bolts, Balance Shaft
Carrier to Block

54

40

-

Fastener - Double Ended,
Balance Shaft Gear
Cover

12

-

105

Bolt, Balance Shaft
Sprocket

28

-

250

Bolts, Balance Shaft
Chain Tensioner

12

-

105

Bolts, Balance Shaft
Carrier Cover

12

-

105

Bolt, Camshaft Sprocket

115

85

-

Bolts, Connecting Rod
Cap

27 +

1

⁄

4

turn

20

+

1

⁄

4

turn

-

Bolts, Crankshaft Main
Bearing Cap/Bedplate

M8 Bolts

28

-

250

M11 Bolts

75

55

-

Crankshaft Damper

136

100

-

Bolts, Cylinder Head

(Refer to 9 - ENGINE/

CYLINDER HEAD -

INSTALLATION)

DESCRIPTION

N·m

Ft.

Lbs.

In.

Lbs.

Bolts, Cylinder Head
Cover

12

-

105

Flex Plate to Crankshaft

95

70

-

Flywheel Mounting Bolts

81

60

-

Bolts, Engine Mount
Bracket Right

61

45

-

Bolts, Engine Mounting

(Refer to 9 ENGINE/

ENGINE MOUNTING)

Bolts, Exhaust Manifold to
Cylinder Head

23

-

200

Bolts, Exhaust Manifold
Heat Shield

12

-

105

Bolts, Intake Manifold -
Lower

28

-

250

Oil Filter

20

15

-

Bolts, Oil Pan

12

-

105

Plug, Oil Pan Drain

27

20

-

Bolts, Oil Pump to Block

28

-

250

Bolts, Oil Pump Cover
Plate

12

-

105

Bolt, Oil Pump Pick-up
Tube

28

20

-

Cap - Oil Pump Relief
Valve

41

30

-

Spark Plugs

18

13

-

Bolts, Timing Belt Covers

- Front Covers to Rear

Covers

12

-

105

- Rear Cover

12

-

105

Bolts, Timing Belt
Tensioner Assembly

61

45

-

9 - 18

ENGINE 2.4L

TJ

ENGINE 2.4L (Continued)