Jeep Wrangler TJ. Manual — part 442
CONNECTING RODS
DESCRIPTION
SPECIFICATION
Metric
Standard
Bearing
Clearance
0.025 - 0.076
mm
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
mm
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
mm
6.123 - 6.127 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.
CRANKSHAFT
DESCRIPTION
SPECIFICATION
Metric
Standard
Main Bearing
Journal
Diameter
No. 1-6
63.489 - 63.502
mm
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
mm
0.0015 - 0.0065
in.
Connecting Rod
Journal
Diameter
53.17 - 53.23
mm
2.0934 - 2.0955
in.
CAMSHAFT
DESCRIPTION
SPECIFICATION
Metric
Standard
Hydraulic
Tappet
Clearance
Zero Lash
Bore Diameter
26.02 - 26.04
mm
1.0245 - 1.0252
in.
Bearing Journal
Diameter
No. 1
51.54 - 51.56
mm
2.029 - 2.030 in.
No. 2
51.28 - 51.31
mm
2.019 - 2.020 in.
No. 3
51.03 - 51.05
mm
2.009 - 2.010 in.
No. 4
50.78 - 50.80
mm
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°
TJ
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
TJ
ENGINE 4.0L (Continued)
OIL PRESSURE
SPECIFICATION
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.
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
—
DESCRIPTION
N·m
Ft.
In.
Lbs.
Lbs.
Transmission Support Adaptor
Bracket—Bolts (2WD Auto)
75
55
—
Exhaust Manifold/Pipe—Nuts
27
20
—
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
—
TJ
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
TJ
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