Jeep Wrangler TJ. Manual — part 424
• High speed power tool with an abrasive pad or a
wire brush.
NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.
Only use the following for cleaning gasket surfaces:
(Fig. 3)
• Solvent or a commercially available gasket
remover
• Plastic or wood scraper.
• Drill motor with 3M Roloc™ Bristle Disc (white
or yellow).
CAUTION: Excessive pressure or high RPM (beyond
the recommended speed), can damage the sealing
surfaces. The mild (white, 120 grit) bristle disc is
recommended. If necessary, the medium (yellow, 80
grit) bristle disc may be used on cast iron surfaces
with care.
MEASURING BEARING CLEARANCE USING
PLASTIGAGE
Engine crankshaft bearing clearances can be deter-
mined by use of Plastigage or equivalent. The follow-
ing is the recommended procedure for the use of
Plastigage:
(1)
Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(2) Place a piece of Plastigage across the entire
width of the bearing shell in the cap approximately
6.35 mm (1/4 in.) off center and away from the oil
holes (Fig. 4). (In addition, suspected areas can be
checked by placing the Plastigage in the suspected
area). Torque the bearing cap bolts of the bearing
being checked to the proper specifications.
(3)
Remove the bearing cap and compare the
width of the flattened Plastigage with the metric
scale provided on the package. Locate the band clos-
est to the same width. This band shows the amount
of clearance in thousandths of a millimeter. Differ-
ences in readings between the ends indicate the
amount of taper present. Record all readings taken.
Compare clearance measurements to specs found in
engine specifications (Refer to 9 - ENGINE - SPECI-
FICATIONS). Plastigage generally is accompa-
nied by two scales. One scale is in inches, the
other is a metric scale.
NOTE: Plastigage is available in a variety of clear-
ance ranges. Use the most appropriate range for
the specifications you are checking.
(4) Install
the
proper
crankshaft
bearings
to
achieve the specified bearing clearances. (Refer to 9 -
ENGINE/ENGINE
BLOCK/CRANKSHAFT
MAIN
BEARINGS - STANDARD PROCEDURE) (Refer to 9
- ENGINE/ENGINE BLOCK/CONNECTING ROD
BEARINGS - STANDARD PROCEDURE)
FORM-IN-PLACE GASKETS AND SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when
applying
form-in-place
gaskets
to
assure
obtaining the desired results. Do not use form-in-
place gasket material unless specified. Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopar
t
Engine RTV GEN II, Mopar
t ATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPAR
t ENGINE RTV GEN II is used to seal
components exposed to engine oil. This material is a
specially designed black silicone rubber RTV that
retains adhesion and sealing properties when exposed to
engine oil. Moisture in the air causes the material to
cure. This material is available in three ounce tubes
and has a shelf life of one year. After one year this
material will not properly cure. Always inspect the
package for the expiration date before use.
MOPAR
t ATF RTV is a specifically designed
black silicone rubber RTV that retains adhesion and
sealing properties to seal components exposed to
automatic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
Fig. 4 Plastigage Placed in Lower Shell - Typical
1 - PLASTIGAGE
TJ
ENGINE 2.4L
9 - 11
ENGINE 2.4L (Continued)
MOPAR
t GASKET MAKER is an anaerobic type
gasket material. The material cures in the absence of
air when squeezed between two metallic surfaces. It
will not cure if left in the uncovered tube. The
anaerobic material is for use between two machined
surfaces. Do not use on flexible metal flanges.
MOPAR
t BED PLATE SEALANT is a unique
(green-in-color) anaerobic type gasket material that
is specially made to seal the area between the bed-
plate and cylinder block without disturbing the bear-
ing clearance or alignment of these components. The
material cures slowly in the absence of air when
torqued between two metallic surfaces, and will rap-
idly cure when heat is applied.
MOPAR
t GASKET SEALANT is a slow drying,
permanently soft sealer. This material is recom-
mended for sealing threaded fittings and gaskets
against leakage of oil and coolant. Can be used on
threaded and machined parts under all tempera-
tures. This material is used on engines with multi-
layer
steel
(MLS)
cylinder
head
gaskets.
This
material also will prevent corrosion. Mopar
t Gasket
Sealant is available in a 13 oz. aerosol can or 4oz./16
oz. can w/applicator.
SEALER APPLICATION
Mopar
t Gasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
Mopar
t Engine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
Mopar
t Gasket Sealant in an aerosol can should be
applied using a thin, even coat sprayed completely
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the
sealing surfaces. Material in an aerosol can should be
used on engines with multi-layer steel gaskets.
REMOVAL - ENGINE ASSEMBLY
(1) Disconnect the battery negative cable.
(2) Remove hood. Mark hood hinge location for
reinstallation.
(3) Remove air cleaner assembly.
(4) Remove radiator core support bracket.
(5) Remove fan shroud with electric fan assembly.
(6) Remove drive belt.
NOTE: It is NOT necessary to discharge the A/C
system to remove the engine.
(7) Remove A/C compressor and secure away from
engine with lines attached.
(8) Remove
generator
and
secure
away
from
engine.
NOTE: Do NOT remove the phenolic pulley from the
P/S pump. It is not required for P/S pump removal.
(9) Remove
power
steering
pump
with
lines
attached and secure away from engine.
(10) Drain cooling system.
(11) Remove coolant bottle.
(12) Disconnect the heater hoses from the engine.
(13) Disconnect heater hoses from heater core and
remove hose assembly.
(14) Disconnect throttle and speed control cables.
(15) Remove upper radiator hose from engine.
(16) Remove lower radiator hose from engine.
(17) Disconnect the engine to body ground straps
at the left side of cowl.
(18) Disconnect the engine wiring harness at the
following points:
• Intake air temperature (IAT) sensor
• Fuel Injectors
• Throttle Position (TPS) Switch
• Idle Air Control (IAC) Motor
• Engine Oil Pressure Switch
• Engine Coolant Temperature (ECT) Sensor
• Manifold Absolute Pressure MAP) Sensor
• Camshaft Position (CMP) Sensor
• Coil Over Plugs
• Crankshaft Position Sensor
(19) Remove coil over plugs.
(20) Release fuel rail pressure.
(21) Remove fuel rail and secure away from
engine.
(22) Remove the PCV hose.
(23) Remove the breather hoses.
(24) Remove the vacuum hose for the power brake
booster.
(25) Disconnect knock sensors.
(26) Secure the left and right engine wiring har-
nesses away from engine.
(27) Raise vehicle.
(28) Disconnect oxygen sensor wiring.
9 - 12
ENGINE 2.4L
TJ
ENGINE 2.4L (Continued)
(29) Disconnect crankshaft position sensor.
(30) Disconnect the engine block heater power
cable, if equipped.
(31) Disconnect the front propshaft at the front
differential and secure out of way.
(32) Remove the starter.
(33) Remove the ground straps from the engine
(34) Disconnect the exhaust pipes at the manifold.
(35) Remove the structural cover, if equipped.
(36) Remove torque convertor bolts, and mark
location for reassembly.
(37) Remove transmission bellhousing to engine
bolts.
(38) Loosen left and right engine mount thru bolts.
NOTE: It is not necessary to completely remove
engine mount thru bolts, for engine removal.
(39) Lower the vehicle.
(40) Support the transmission with a suitable jack.
(41) Connect a suitable engine hoist to the engine.
CAUTION: The 2.4L engine with manual transmis-
sions, can be removed without removing the man-
ual transmission. Use caution when attempting this
procedure as the clearance is tight.
(42)
Remove engine from vehicle.
INSTALLATION - ENGINE ASSEMBLY
(1) Position the engine in the vehicle.
CAUTION: Use caution when installing 2.4L engine
into vehicle equipped with manual transmission, as
clearance is tight.
(2) Install both left and right side engine mounts
into the frame mounts.
(3) Raise the vehicle.
(4) Install the transmission bellhousing to engine
mounting bolts. Tighten the bolts to 41 N·m (30 ft.
lbs.).
(5) Tighten the engine mount thru bolts.
(6) Install the torque convertor bolts.
(7) Connect the ground straps on the left and right
side of the engine.
(8) Install the starter.
(9) Connect the crankshaft position sensor.
(10) Install the engine block heater power cable, if
equipped.
CAUTION: The structural cover requires a specific
torque sequence. Failure to follow this sequence
may cause severe damage to the cover.
(11) Install the structural cover.
(12) Install the exhaust pipe.
(13) Connect the oxygen sensors.
(14) Lower vehicle.
(15) Connect the knock sensors.
(16) Connect the engine to body ground straps.
(17) Install the power brake booster vacuum hose.
(18) Install the breather hoses.
(19) Install the PCV hose.
(20) Install the fuel rail.
(21) Install the coil over plugs.
(22) Reconnect the engine wiring harness at the
following points:
• Intake air temperature (IAT) sensor
• Fuel Injectors
• Throttle Position (TPS) Switch
• Idle Air Control (IAC) Motor
• Engine Oil Pressure Switch
• Engine Coolant Temperature (ECT) Sensor
• Manifold Absolute Pressure MAP) Sensor
• Camshaft Position (CMP) Sensor
• Coil Over Plugs
• Crankshaft Position Sensor
(23) Connect lower radiator hose.
(24) Connect upper radiator hose.
(25) Connect throttle and speed control cables.
(26) Install the heater hose assembly.
(27) Install coolant recovery bottle.
(28) Install the power steering pump.
(29) Install the generator.
(30) Install the A/C compressor.
(31) Install the drive belt.
(32) Install the fan shroud with the electric fan
assembly.
(33) Install the radiator core support bracket.
(34) Install the air cleaner assembly.
(35) Refill the engine cooling system.
(36) Install the hood.
(37) Check and fill engine oil.
(38) Connect the battery negative cable.
(39) Start the engine and check for leaks.
TJ
ENGINE 2.4L
9 - 13
ENGINE 2.4L (Continued)
SPECIFICATIONS
SPECIFICATIONS - 2.4L ENGINE
GENERAL SPECIFICATIONS
DESCRIPTION
SPECIFICATION
Type
In-Line OHV, DOHC
Number of
Cylinders
4
Firing Order
1-3-4-2
Compression
Ratio
9.5:1
Max. Variation
Between
Cylinders
25%
Metric
Standard
Displacement
2.4 Liters
148 cu. in.
Bore
87.5 mm
3.445 in.
Stroke
101.0 mm
3.976 in.
Compression
Pressure
1172-1551 kPa
170-225 psi
CYLINDER BLOCK
DESCRIPTION
SPECIFICATIONS
Metric
Standard
Cylinder Bore
Diameter
87.4924 -
87.5076 mm
3.4446 - 3.4452
in.
Out-of-Round
(Max.)
0.051 mm
0.002 in.
Taper (Max.)
0.051 mm
0.002 in.
PISTONS
DESCRIPTION
SPECIFICATION
Metric
Standard
Piston Diameter
87.456 - 87.474
mm
3.4431 -3.4439
in.
Clearance @
24.6 mm (0.551
in.) from bottom
of skirt
0.018 - 0.0516
mm
0.0007 - 0.0020
in.
Weight
345 - 355
grams
12.17 - 12.52
oz.
Land Clearance
(Diametrical)
0.563 - 0.621
mm
0.022 - 0.024 in.
Piston Length
66.25 mm
2.608 in.
Piston Ring
Groove Depth
No. 1
3.946 -
4.045mm
0.155 - 0.159 in.
Piston Ring
Groove Depth
No. 2
4.555 - 4.680
mm
0.179 - 0.184 in.
Piston Ring
Groove Depth
No. 3
4.108 - 4.220
mm
0.162 - 0.166 in.
PISTON PINS
DESCRIPTION
SPECIFICATION
Metric
Standard
Clearance in
Piston
0.005 - 0.018
mm
0.0002 - 0.0008
in.
Clearance in
Connecting Rod
Interference
Diameter
21.998 - 22.003
mm
0.8660 - 0.8662
in.
End Play
None
Length
72.75 - 73.25
mm
2.864 - 2.883 in.
9 - 14
ENGINE 2.4L
TJ
ENGINE 2.4L (Continued)
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