Content .. 440 441 442 443 ..

Jeep Wrangler TJ. Manual - part 442

CONNECTING RODS

DESCRIPTION

SPECIFICATION

Metric

Standard

Bearing

Clearance

0.025 - 0.076

0.001 - 0.003 in.

Preferred

0.044 - 0.050

0.0015 - 0.0020

Side Clearance

0.25 - 0.48 mm

0.010 - 0.019 in.

Piston Pin Bore

Diameter

.023.59 - 23.62

0.9288 - 0.9298

in.

Bearing Bore

( Less Bearings)

56.08 -

56.09mm

2.2080 - 2.2085

in.

Total Weight

(Less Bearing)

663 - 671

grams

23.39 - 23.67

oz.

Length ( Center

To Center)

155.52 - 155.62

6.123 - 6.127 in.

Twist ( MAX.)

0.002 mm per

0.002 in. per

inch

Bend (MAX.)

0.002 mm per

0.002 in. per

inch.

CRANKSHAFT

DESCRIPTION

SPECIFICATION

Metric

Standard

Main Bearing

Journal

Diameter

No. 1-6

63.489 - 63.502

2.499 - 2.500 in.

No. 7

63.449 - 63.487

2.498 - 2.499 in.

Bearing

Clearance

0.03 - 0.06 mm

0.001 - 0.0025

in.

Preferred

0.051 mm

0.002 in.

Out of Round

(MAX)

0.013 mm

0.0005 in.

Taper (MAX)

0.013 mm

0.0005 in.

End Play

0.038 - 0.165

0.0015 - 0.0065

in.

Connecting Rod

Journal

Diameter

53.17 - 53.23

2.0934 - 2.0955

in.

CAMSHAFT

DESCRIPTION

SPECIFICATION

Metric

Standard

Hydraulic

Tappet

Clearance

Zero Lash

Bore Diameter

26.02 - 26.04

1.0245 - 1.0252

in.

Bearing Journal

Diameter

No. 1

51.54 - 51.56

2.029 - 2.030 in.

No. 2

51.28 - 51.31

2.019 - 2.020 in.

No. 3

51.03 - 51.05

2.009 - 2.010 in.

No. 4

50.78 - 50.80

1.999 - 2.000 in.

Base Circle

Runout (MAX)

0.033 mm

0.001 in.

Valve Lift

Intake

10.350 mm

0.4075 in.

Exhaust

10.528 mm

0.4145 in.

VALVE TIMING

DESCRIPTION

SPECIFICATION

Intake

Opens (BTDC)

12.4°

Closes (ABDC)

60.9°

Duration

253.3°

Exhaust

Opens (BBDC)

49.8°

Closes (ATDC)

29.2°

Duration

259.0°

Valve Overlap

41.6°

ENGINE 4.0L

9 - 83

ENGINE 4.0L (Continued)

VALVES

DESCRIPTION

SPECIFICATION

Face Angle

46.5°

Head Diameter

Intake

48.38 - 48.64 mm

(1.905 - 1.915 in.)

Exhaust

37.97 - 38.22 mm

(1.495 - 1.505 in.)

Length (Overall)

Intake

122.47 - 122.86 mm

(4.822 - 4.837)

Exhaust

122.86 - 123.24 mm

(4.83 - 4.85 in.)

Stem Diameter

7.89 - 7.92 mm

(0.311 - 0.312 in.)

Stem - to - Guide
Clearance

0.025 - 0.076 mm

(0.001 - 0.003 in.)

Tip Refinishing (Max.
Allowable)

0.025 mm (0.010 in.)

VALVE SPRING

DESCRIPTION

SPECIFICATION

Free Length (Approx)

47.65 mm (1.876 in.)

Spring Force (Valve
Closed)

Intake and Exhaust

316.0 - 351.0 N @ 41.65
mm
(71.0 - 79.0 lbs. @ 1.64
in.)

Spring Force (Valve
Open)

Intake and Exhaust

898.6 - 969.7 N @ 30.89
mm
(202.0 - 218.0 lbs. @
1.216 in.)

Wire Diameter (Inside)

21.0 - 21.51 mm

Intake and Exhaust

(0.827 - 0.847 in.)

Installed Height (Spring
Seat to Bottom of
Retainer)

41.65 mm (1.64 in.)

CYLINDER HEAD

DESCRIPTION

SPECIFICATION

Combustion Chamber

55.22 - 58.22 cc

(3.37 - 3.55 cu. in.)

Valve Seat Angle

44.5°

Valve Seat Runout (MAX)

0.064 mm (0.0025 in.)

Valve Seat Width

1.02 - 1.52 mm

(0.040 - 0.060 in.)

Valve Guide I. D

(Integral)

7.95 - 7.97 mm

(0.313 - 0.314 in.)

Valve Stem to Guide

Clearance

0.025 - 0.076 mm

(0.001 - 0.003 in.)

Cylinder Head Warpage

(Flatness)

0.03 mm per 25 mm

(0.001 in. per 1 in.)

0.05 mm per 152 mm

(0.002 in. per 6 in.)

Flatness (MAX)

0.20 mm - max for total

length

OIL PUMP

DESCRIPTION

SPECIFICATION

Gear to Body Clearance

(Radial)

0.051 - 0.102 mm

(0.002 - 0.004 in.)

Gear to Body Clearance

(Radial Preferred)

0.051 mm

(0.002 in.)

Gear End Clearance

(Plastigage)

0.051 - 0.152 mm

(0.002 - 0.006 in.)

Gear End Clearance

(Plastigage Preferred)

.051 mm (.002 in.)

Gear End Clearance

(FeelerGauge)

0.1016 - 0.2032 mm

(0.004 - 0.008 in.)

Gear End Clearance

(FeelerGauge Preferred)

0.1778 mm (0.007 in.)

9 - 84

ENGINE 4.0L

ENGINE 4.0L (Continued)

OIL PRESSURE

SPECIFICATION

At Curb Idle Speed*

89.6 kPa (13 psi)

@ 1600 and Higher Rpm

255 - 517 kPa (37 - 75

psi)

Oil Pressure Relief

517 kPa (75 psi.)

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

TORQUE - 4.0L ENGINE

DESCRIPTION

N·m

Ft.

In.

Lbs.

A/C Compressor—Bolts

—

250

Block Heater—Nut

—

Camshaft Sprocket—Bolt

—

Camshaft Thrust Plate to

Cylinder Block—Screws

—

Clutch Cover to Flywheel—Bolts

—

Coil Bracket to Block—Bolts

—

192

Connecting Rod—Nuts

—

Cylinder Block—Drain Plugs

—

Cylinder Head—Bolts

135

100

—

Cylinder Head Cover—Bolts

—

Distributor Clamp—Bolts

—

204

Engine Mounts—Front

Support Bracket Bolts

—

Support Cushion Bolts/Nuts

—

Support Cushion Bracket Bolts

—

Support Cushion Bracket Stud

Nuts

—

Support Cushion Thru-Bolt

—

Engine Mounts—Rear

Crossmember to Sill Bolts—

(Automatic)

—

Insulator Stud Assembly—Nut

—

Support Cushion/Crossmember—

Nuts

—

192

Support Cushion/Bracket—Nuts

(Manual)

—

Transmission Support Bracket

—Bolt (Manual)

—

Transmission Support Bracket/

Cushion—Bolt (4WD Auto)

—

DESCRIPTION

N·m

Ft.

In.

Lbs.

Transmission Support Adaptor

Bracket—Bolts (2WD Auto)

—

Exhaust Manifold/Pipe—Nuts

—

Intake/Exhaust Manifold

Fasteners #1-5

—

Fasteners #6 and 7

—

126

Fasteners #8-11

—

Flywheel to Converter Housing—
Bolts

—

Flywheel to Crankshaft—Bolts

143

105

—

Front Cover to Block—Bolts

1/4-20

—

5/16-18

—

192

Fuel Rail—Bolts/Stud

—

108

Generator—Bolts

—

Generator Bracket to Engine—
Bolts

—

Idler Pulley to Cylinder Head—
Bolt

—

Main Bearing Cap—Bolts

108

—

Oil Filter

—

156

Oil Filter Connector to

Adaptor

—

Block

—

Adaptor Bolts

102

—

Oil Galley—Plug

—

Oil Pan—Bolts

1/4-20

9.5

—

5/16-18

—

132

Oil Pan—Drain Plug

—

Oil Pump

Mounting Bolts

—

204

Cover Bolts

—

Rocker Arm Assembly to Cylinder

Head—Capscrews

—

Spark Plugs

—

Starter Motor—Mounting Bolts

—

Thermostat Housing—Bolts

—

156

Throttle Body—Bolts

—

Vibration Damper—Bolt

108

—

Water Pump to Block—Bolts

—

ENGINE 4.0L

9 - 85

ENGINE 4.0L (Continued)

AIR CLEANER ELEMENT

REMOVAL

(1) Loosen air tube clamp at housing cover (Fig. 7).
(2) Disconnect air tube at cover.
(3) Pry back the clips retaining air cleaner cover to

air cleaner housing.

(4) Lift cover up to expose air cleaner element.
(5) Remove air cleaner element.
(6) Clean inside of air cleaner housing and its

cover before installing new element.

INSTALLATION

(1) Install air cleaner element into housing.
(2) Install housing cover to housing. Be sure cover

is properly seated to air cleaner housing.

(3) Connect air tube at cover.

AIR CLEANER HOUSING

REMOVAL

(1) Loosen air tube clamp at housing cover.
(2) Disconnect air tube at cover. (Fig. 8)
(3) Pry back the clips retaining air cleaner cover to

air cleaner housing.

(4) Lift cover up to expose air cleaner element.
(5) Remove air cleaner element.

(6) Remove the air inlet duct.
(7) Lift up and remove the air cleaner housing.
(8)

INSTALLATION

(1) Push down on the air cleaner housing to lock in

place.

(2) Install the air inlet tube.
(3) Install the air cleaner element.
(4) Pry back the clips retaining air cleaner cover to

air cleaner housing. (Fig. 8)

(5) Install the air cleaner housing cover. Be sure

cover is properly seated.

(6) Install the air out let tube.

CYLINDER HEAD

DESCRIPTION

The cylinder head is made of cast iron containing

twelve valves made of chrome plated heat resistant
steel, valve stem seals, springs, retainers and keep-
ers. The cylinder head and valve seats can be resur-
faced for service purposes.

The valve guides are integral to the cylinder head,

They are not replaceable. However, they are service-
able.

Fig. 7 AIR CLEANER ELEMENT

1 - COVER
2 - CLAMP
3 - AIR TUBE
4 - HOUSING
5 - FILTER

Fig. 8 AIR CLEANER ELEMENT

1 - COVER
2 - CLAMP
3 - AIR TUBE
4 - HOUSING
5 - FILTER

9 - 86

ENGINE 4.0L

Content .. 440 441 442 443 ..