Jeep XJ. Manual — part 312
DESCRIPTION
SPECIFICATION
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
240.03 to 240.18 mm
(9.450 to 9.456 in.)
Deck Clearance (Below
Block)
0.546 mm (0.0215 in.)
Cylinder Bore Diameter
Standard
98.45 to 98.48 mm
(3.8759 to 3.8775 in.)
Taper
0.025 mm (0.001 in.)
Out-ofRound
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.)
Flatness Max.
0.20 mm max. for total
length
(0.008 in. max. for total
length)
Main Bearing Bore
Diameter
68.3514 to 68.3768 mm
(2.691 to 2.692 in.)
CONNECTING ROD
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.)
DESCRIPTION
SPECIFICATION
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.)
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 inch)
Bend (Max.)
0.002 mm per mm
(0.002 in. per inch.)
CYLINDER COMPRESSION PRESSURE
Pressure Range
827 to 1,034 kPa
(120 to 150 psi)
Max. Variation Between
Cylinders
206 kPa (30 psi)
CYLINDER HEAD
Combustion Chamber
55.22 to 58.22 cc
(3.37 to 3.55 cu. in.)
Valve Guide I. D.
(Integral)
7.95 to 7.97 mm
(0.313 to 0.314 in.)
Valve Stem-to-Guide
0.025 to 0.076 mm
Clearance
(0.001 to 0.003 in.)
Valve Seat Angle
Intake
44.5°
Exhaust
44.5°
Valve Seat Width
1.02 to 1.52 mm
(0.040 to 0.060 in.)
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.)
9 - 116
4.0L ENGINE
XJ
SPECIFICATIONS (Continued)
DESCRIPTION
SPECIFICATION
Flatness Max.
0.20 mm - max. for total
length
(0.008 in. max. for total
length)
ROCKER ARMS, PUSH RODS & TAPPETS
Rocker Arm Ratio
1.6:1
Push Rod Length
244.856 to 245.364 mm
(Pink)
(9.640 to 9.660 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.)
VALVES
Valve Length (Overall)
Intake
122.479 to 122.860 mm
(4.822 to 4.837 in.)
Exhaust
122.860 to 123.241 mm
(4.837 to 4.852 in.)
Valve Stem Diameter
7.899 to 7.925 mm
(0.311 to 0.312 in.)
Stem-to-Guide Clearance
0.025 to 0.076 mm
(0.001 to 0.003 in.)
Valve Head Diameter
Intake
48.387 to 48.641 mm
(1.905 to 1.915 in.)
Exhaust
37.973 to 38.227 mm
(1.495 to 1.505 in.)
Valve Face Angle
Intake
46.5°
Exhaust
46.5°
Tip Refinishing (Max.
Allowable)
0.25 mm (0.010 in.)
DESCRIPTION
SPECIFICATION
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 lbf. @ 1.64 in.)
Valve Open
898.6 to 969.7 N @
30.89 mm
(202 to 218 lbf @ 1.216
in.)
Inside Diameter
21.0 mm to 21.51 mm
(0.827 to 0.847 in.)
Installed Height
41.656 mm (1.64 in.)
PISTONS
Weight (Less Pin)
417 to 429 grams
(14.7 to 15.1 oz.)
Piston Pin Bore
(Centerline
40.61 to 40.72 mm
to Piston Top)
(1.599 to 1.603 in.)
Piston-to-Bore Clearance
0.018 to 0.038 mm
(0.0008 to 0.0015 in.)
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.)
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.)
XJ
4.0L ENGINE
9 - 117
SPECIFICATIONS (Continued)
DESCRIPTION
SPECIFICATION
Piston Ring Groove
Diameter
No.1 Compression Ring
88.39 to 88.65 mm
(3.48 to 3.49 in.)
No.2 Compression Ring
87.63 to 87.88 mm
(3.45 to 3.46 in.)
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-to-Pin Connecting
Rod (Press Fit)
8.9 kN (2000 lbf.)
OIL PUMP
Gear-to-Body Clearance
0.051 to 0.102 mm
(Radial)
(0.002 to 0.004 in.)
Gear-to-Body Clearance
(Radial) Preferred
0.051 mm (0.002 in.)
Gear End Clearance
0.051 to 0.152 mm
Plastigage
(0.002 to 0.006 in.)
Gear End Clearance
Plastigage (Preferred)
0.051 mm (0.002 in.)
Gear End Clearance
0.1016 to 0.2032 mm
Feeler Gauge
(0.004 to 0.008 in.)
Gear End Clearance
Feeler Gauge (Preferred)
0.1778 mm (0.007 in.)
Oil Pressure
At Idle Speed
89.6 kPa (13 psi)
At 1600 rpm & Higher
255 to 517 kPa
(37 to 75 psi)
Oil Pressure Relief
517 kPa (75 psi)
TORQUE SPECIFICATIONS
4.0L ENGINE
DESCRIPTION
N·m
Ft.
In.
Lbs.
Lbs.
A/C Compressor—Bolts
28
—
250
Block Heater—Nut
2
—
16
Camshaft Sprocket—Bolt
68
50
—
Camshaft Thrust Plate to
Cylinder Block—Screws
24
18
—
Clutch Cover to Flywheel—
Bolts
54
40
—
Coil Bracket to Block—Bolts
22
—
192
Connecting Rod—Nuts
45
33
—
Cylinder Block—Drain Plugs
34
25
—
Cylinder Head—Bolts
135
100
—
Cylinder Head Cover—Bolts
10
—
85
Distributor Clamp—Bolts
23
—
204
Engine Mounts—Front
Support Bracket Bolts
61
45
—
Support Cushion Bolts/Nuts
41
30
—
Support Cushion Bracket
Bolts
54
40
—
Support Cushion Bracket Stud
Nuts
41
30
—
Support Cushion Thru-Bolt
65
48
—
Engine Mounts—Rear
Crossmember to Sill Bolts—
(Automatic)
41
30
—
Insulator Stud Assembly—Nut
41
30
—
Support Cushion/
Crossmember—
Nuts
22
—
192
Support Cushion/Bracket—
Nuts
(Manual)
75
55
—
Transmission Support
Bracket—Bolt
(Manual)
46
34
—
Transmission Support Bracket/
Cushion—Bolt (4WD Auto)
75
55
—
Transmission Support Adaptor
Bracket—Bolts (2WD Auto)
75
55
—
Exhaust Manifold/Pipe—Nuts
27
20
—
9 - 118
4.0L ENGINE
XJ
SPECIFICATIONS (Continued)
DESCRIPTION
N·m
Ft.
In.
Lbs.
Lbs.
Intake/Exhaust Manifold
Fasteners #1-5
33
24
—
Fasteners #6 and 7
14
—
126
Fasteners #8-11
33
24
—
Flywheel to Converter
Housing—Bolts
38
28
—
Flywheel to Crankshaft—Bolts
143
105
—
Front Cover to Block—Bolts
1/4-20
7
—
60
5/16-18
22
—
192
Fuel Rail—Bolts/Stud
12
—
108
Generator—Bolts
57
42
—
Generator Bracket to
Engine—Bolts
47
35
—
Idler Pulley to Cylinder
Head—Bolt
47
35
—
Main Bearing Cap—Bolts
108
80
—
Oil Filter
18
—
156
Oil Filter Connector to
Adaptor
47
35
—
Block
68
50
—
Adaptor Bolts
102
50
—
Oil Galley—Plug
41
30
—
Oil Pan—Bolts
1/4-20
9.5
—
84
5/16-18
15
—
132
Oil Pan—Drain Plug
34
25
—
Oil Pump
Mounting Bolts
23
—
204
Cover Bolts
8
—
70
Rocker Arm Assembly to
Cylinder
Head—Capscrews
30
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
23
17
—
SPECIAL TOOLS
4.0L ENGINE
Valve Spring Compressor Tool MD-998772A
Timing Case Cover Alignment and Seal installation
Tool 6139
Vibration Damper Removal Tool 7697
Hydraulic Valve Tappet Removal/Installation Tool
C-4129–A
XJ
4.0L ENGINE
9 - 119
SPECIFICATIONS (Continued)
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