Jeep XJ. Manual — part 297
DESCRIPTION
SPECIFICATION
Stem to Guide Clearance
0.025 - 0.076 mm
(0.001 - 0.003 in.)
ValveFace Angle
Intake
46.5°
Exhaust
46.5°
Valve Head Diameter
Intake
48.387 - 48.641 mm
(1.905 - 1.915 in.)
Exhaust
37.973 - 38.227 mm
(1.495 - 1.505 in.)
Tip Refinishing (Max
Alowable)
0.25 mm (0.010 in.)
VALVE SPRINGS
Free Length (Approx.)
47.65 mm (1.876 in.)
Spring Load
Valve Closed
316 to 351 N @ 41.656
mm
(71 to 79 Lbs. @ 1.64
in.)
Valve Open
898.6 to 969.7 N @
30.89 mm
(202 to 218 Lbs. @ 1.216
in.)
Inside Diameter (Top)
21.0 mm to 21.51 mm
(0.827 to 0.847 in.)
Installed Height
41.656 mm (1.640 in.)
CRANKSHAFT
End Play
0.038 to 0.165 mm
(0.0015 to 0.0065 in.)
Main Bearing Journal
Diameter
63.489 to 63.502 mm
(2.4996 to 2.5001 in.)
DESCRIPTION
SPECIFICATION
Main Bearing Journal
Width
No. 1
27.58 to 27.89 mm
(1.086 to 1.098 in.)
No. 2
32.28 to 32.33 mm
(1.271 to 1.273 in.)
No. 3-4-5
30.02 to 30.18 mm
(1.182 to 1.188 in.)
Main Bearing Clearance
0.03 to 0.06 mm
(0.001 to 0.0025 in.)
Main Bearing Clearance
(Preferred)
0.051 mm
(0.002 in.)
Connecting Rod Journal
Diameter
53.17 to 53.23 mm
(2.0934 to 2.0955 in.)
Connecting Rod Journal
Width
27.18 to 27.33 mm
(1.070 to 1.076 in.)
Out of Round - Max
0.013 mm (0.0005 in.)
Taper - Max
0.013 mm (0.0005 in.)
CYLINDER BLOCK
Deck Height
236.73 mm (9.320 in.)
Deck Clearance
0.000 mm (0.000 in.)
Cylinder Bore Diameter—
Standard
98.45 to 98.48 mm
(3.8759 to 3.8775 in.)
Cylinder Bore Diameter—
Taper (Max)
0.025 mm
(0.001 in.)
Out of Round (Max)
0.025 mm
(0.001 in.)
Tappet Bore Diameter
23.000 to 23.025 mm
(0.9055 to 0.9065 in.)
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.)
9 - 56
2.5L ENGINE
XJ
SPECIFICATIONS (Continued)
DESCRIPTION
SPECIFICATION
Flatness Max
0.20 mm for total length
(0.008 in. for total length)
Main Bearing Bore
Diameter
68.3514 to 68.3768 mm
(2.691 to 2.692 in.)
CONNECTING RODS
Total Weight (Less
Bearing)
663 to 671 grams
(23.39 to 23.67 oz.)
Length (Center to Center)
155.52 to 155.62 mm
(6.123 to 6.127 in.)
Piston Pin Bore Diameter
23.59 to 23.62 mm
(0.9288 to 0.9298 in.)
Bore (Less Bearings)
56.08 to 56.09 mm
(2.2080 to 2.2085 in.)
Bearing Clearance
0.025 to 0.076 mm
(0.001 to 0.003 in.)
Bearing Clearance
(Preferred)
0.044 to 0.050 mm
(0.0015 to 0.0020 in.)
Side Clearance
0.25 to 0.48 mm
(0.010 to 0.019 in.)
Twist (Max)
0.002 mm per mm
(0.002 in. per in.)
Bend (Max)
0.006 mm per mm
(0.006 in. per inch.)
CYLINDER HEAD
Combustion Chamber
49.9 to 52.9 cc
(3.04 to 3.23 cu. in.)
Valve Guide I. D.
(Integral)
7.95 to 7.97 mm
(0.313 to 0.314 in.)
Valve Seat Angle
Intake
44.5°
Exhaust
44.5°
Valve Seat Width
1.01 to 1.52 mm
(0.040 to 0.060 in.)
DESCRIPTION
SPECIFICATION
Valve Seat Runout
0.064 mm
(0.0025 in.)
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 for total length
(0.008 in. for total length)
ROCKER ARMS, PUSH RODS & TAPPETS
Rocker Arm Ratio
1.6:1
Push Rod Length (Blue)
241.300 to 241.808 mm
(9.500 to 9.520 in.)
Push Rod Diameter
7.92 to 8.00 mm
(0.312 to 0.315 in.)
Hydraulic Tappet
Diameter
22.962 to 22.974 mm
(0.904 to 0.9045 in.)
Tappet to Bore Clearance
0.025 to 0.063 mm
(0.001 to 0.0025 in.)
PISTON
Weight (Less Pin)
417 to 429 grams
(14.7 to 15.1 oz.)
Compression Height
40.61 to 40.72 mm
(1.599 to 1.603 in.)
Piston to Bore Clearance
0.018 to 0.038 mm
(0.0008 to 0.0015 in.)
Piston Ring Groove
Height
Compression Rings
1.530 to 1.555 mm
(0.0602 to 0.0612 in.)
Oil Control Ring
4.035 to 4.060 mm
(0.1589 to 0.1598 in.)
Piston Ring Groove
Diameter
Compression Ring #1
88.39 to 88.65 mm
(3.48 to 3.49 in.)
Compression Ring #2
87.63 to 87.88 mm
(89.66 to 89.92 in.)
XJ
2.5L ENGINE
9 - 57
SPECIFICATIONS (Continued)
DESCRIPTION
SPECIFICATION
Oil Control Ring
89.66 to 89.92 mm
(3.53 to 3.54 in.)
Piston Pin Bore Diameter
23.650 to 23.658 mm
(0.9312 to 0.9315 in.)
Piston Pin Diameter
23.637 to 23.640 mm
(0.9306 to 0.9307 in.)
Piston to Pin Clearance
0.0102 to 0.0208 mm
(0.0005 to 0.0009 in.)
PISTON RINGS
Ring Gap Clearance
Top Compression Ring
0.229 to 0.610 mm
(0.0090 to 0.0240 in.)
2nd Compression Ring
0.483 to 0.965 mm
(0.0190 to 0.0380 in.)
Oil Control Steel Rails
0.254 to 1.500 mm
(0.010 to 0.060 in.)
Ring Side Clearance
Compression Rings
0.042 to 0.084 mm
(0.0017 to 0.0033 in.)
Oil Control Rings
0.06 to 0.21 mm
(0.0024 to 0.0083 in.)
DESCRIPTION
SPECIFICATION
OIL PUMP AND OIL PRESSURE
Gear to Body Clearance
(Radial)
0.051 to 0.102 mm
(0.002 to 0.004 in.)
(Radial Preferred)
0.051 mm
(0.002 in.)
Gear End Clearance—
Plastigage
0.051 to 0.152 mm
(0.002 to 0.006 in.)
Plastigage Preferred
0.051 mm
(0.002 in.)
Feeler Gauge
0.1016 to 0.2032 mm
(0.004 to 0.008 in.)
Feeler Gauge Preferred
0.1778 mm
(0.007 in.)
Min. Pressure (600 rpm)
89.6 kPa
(13 psi)
Min. Pressure at Idle
(800 rpm)
172 to 241 kPa
(25 to 35 psi)
Min. Pressure at 1600
rpm
and Higher
255 to 517 kPa
(37 to 75 psi)
Oil Pressure Relief
517 kPa
(75 psi)
9 - 58
2.5L ENGINE
XJ
SPECIFICATIONS (Continued)
SPECIFICATIONS—TORQUE
TORQUE CHART 2.5L ENGINE
DESCRIPTION
N·m
Ft.
Lbs.
In. Lbs
A/C Compressor Bracket
47
35
—
to Engine—Bolts
A/C Compressor Mounting
Bolts
28
—
250
Block Heater Nut
1.8
—
16
Camshaft Sprocket Bolt
108
80
—
Clutch Cover to Flywheel
Bolts
31
23
—
Connecting Rod Cap Nuts
45
33
—
Cylinder Block Drain Plugs
41
30
—
Cylinder Head Bolts #1–10
149
110
—
& #12–14
Cylinder Head Bolt #11
135
100
—
Cylinder Head Cover Bolts
13
—
115
Dipstick Tube Bracket to
19
—
168
Cylinder Block—Bolt
Distributor Hold-Down
Clamp Bolt
23
—
204
Engine Front Insulator
Bracket—
81
60
—
Bolts
Insulator Bracket—Nuts
47
35
—
Insulator—Through Bolt
81
60
—
Engine Rear Support
Cushion
22
—
192
/Crossmember—Nuts
Support Cushion/Bracket
Nuts
46
34
—
Transmission Support
Bracket—
43
32
—
Bolts
Transmission Support
Bracket
75
55
—
/Cushion—Bolt
Transmission Support
Adaptor
75
55
—
Bracket—Bolts
Exhaust Manifold/Pipe
Nuts
27
20
—
DESCRIPTION
N·m
Ft.
Lbs.
In. Lbs
Exhaust Manifold
Bolt #1
41
30
—
Bolts #2-5
31
23
—
Nuts 6 and 7
14
—
126
Flywheel/Converter
Housing Bolts
38
28
—
Flywheel to Crankshaft
Bolts
143
105
—
Front Cover to Block Bolts
1/4-20
7
—
60
Front Cover to Block
5/16-18
22
—
192
Generator Mounting—
Bolts
57
42
—
Generator Mounting
47
35
—
Bracket to Engine—Bolts
Main Bearing Cap Bolts
108
80
—
Oil Filter Adaptor Bolt
102
75
—
Oil Filter Connector
68
50
—
Oil Filter
18
13
—
Oil Galley Plug
41
30
—
Oil Pan 1/4-20 Bolts
9.5
—
84
Oil Pan 5/16-18 Bolts
15
—
132
Oil Pan Drain Plug
34
25
—
Oil Pressure Sending Unit
15
—
130
Oil Pump Short Attaching
Bolts
23
—
204
Oil Pump Long Attaching
Bolts
23
—
204
Oil Pump Cover Bolts
8
—
70
Rocker Arm—Bolts
28
21
—
Spark Plugs
37
27
—
Starter Motor Mounting
Bolts
45
33
—
Thermostat Housing Bolts
18
—
156
Throttle Body Bolts
10
—
90
Vibration Damper Bolt
108
80
—
Water Pump to Block Bolts
31
23
—
XJ
2.5L ENGINE
9 - 59
SPECIFICATIONS (Continued)
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