Jeep Wrangler TJ. Manual — part 438
(13) Install pick-up tube and oil pan (Refer to 9 -
ENGINE/LUBRICATION/OIL
PAN
-
INSTALLA-
TION).
(14) Fill engine crankcase with proper oil to cor-
rect level.
BALANCE SHAFT CARRIER
DESCRIPTION
The 2.4L engine is equipped with two nodular cast
iron balance shafts installed in a cast aluminum car-
rier attached to the lower cylinder block (Fig. 118).
OPERATION
The balance shafts are driven by the crankshaft
via a roller chain and sprockets. The balance shafts
are connected by helical gears. The dual counter
rotating shafts decrease second order vertical shak-
ing forces caused by component movement.
REMOVAL
(Refer to 9 - ENGINE/VALVE TIMING/BALANCE
SHAFT - REMOVAL)
INSTALLATION
(Refer to 9 - ENGINE/VALVE TIMING/BALANCE
SHAFT - INSTALLATION)
BALANCE SHAFT CHAIN
REMOVAL
(Refer to 9 - ENGINE/VALVE TIMING/BALANCE
SHAFT - REMOVAL)
INSTALLATION
(Refer to 9 - ENGINE/VALVE TIMING/BALANCE
SHAFT - INSTALLATION)
Fig. 118 Balance Shafts and Carrier Assembly
1 - SPROCKET
7 - GEARS
2 - TENSIONER
8 - GEAR COVER
3 - PLUG
9 - CHAIN COVER
4 - CARRIER
10 - SPROCKET
5 - REAR COVER
11 - GUIDE
6 - BALANCE SHAFTS
12 - CHAIN
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ENGINE 2.4L
9 - 67
BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued)
ENGINE 4.0L
TABLE OF CONTENTS
page
page
ENGINE 4.0L
. . . . . . . . . . . . . . . 70
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION . . . . . . . . . . . 71
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE . . . . . . . . . . . 71
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL . . . . . . . . . . . . . 74
DIAGNOSIS AND TESTING—CYLINDER
COMPRESSION PRESSURE . . . . . . . . . . . . . 76
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE . . . . . . 76
PLACE GASKETS . . . . . . . . . . . . . . . . . . . . . 77
STANDARD PROCEDURE - HYDROSTATIC
LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
ENGINE ASSEMBLY (SHORT BLOCK) . . . . . . 78
DAMAGED OR WORN THREADS . . . . . . . . . 78
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . 78
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
. . . . . . . . . . . . . . . . . . . . . . . . . 80
. . . . . . . . . . . . . . . . . . . . . . . . 81
. . . . . . . . . . . . . . . . 85
AIR CLEANER ELEMENT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
. . . . . . . . . . . . . . . . . . . . . . . . . 86
AIR CLEANER HOUSING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
. . . . . . . . . . . . . . . . . . . . . . . . . 86
CYLINDER HEAD
. . . . . . . . . . . . . . . . . . . . . . . . . 86
DIAGNOSIS AND TESTING - ENGINE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
. . . . . . . . . . . . . . . . . . . . . . . . . . 88
. . . . . . . . . . . . . . . . . . . . . . . . . 88
CYLINDER HEAD COVER(S)
. . . . . . . . . . . . . . . . . . . . . . . . . 90
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
. . . . . . . . . . . . . . . . . . . . . . . . . . 90
. . . . . . . . . . . . . . . . . . . . . . . . . 90
INTAKE/EXHAUST VALVES & SEATS
. . . . . . . . . . . . . . . . . . . . . . . . . 91
STANDARD PROCEDURE - VALVE SERVICE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
. . . . . . . . . . . . . . . . . . . . . . . . . 93
ROCKER ARM / ADJUSTER ASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . 94
. . . . . . . . . . . . . . . . . . . . . . . . . . . 94
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
. . . . . . . . . . . . . . . . . . . . . . . . . . 94
. . . . . . . . . . . . . . . . . . . . . . . . . 95
VALVE STEM SEALS
. . . . . . . . . . . . . . . . . . . . . . . . . 95
VALVE SPRINGS
. . . . . . . . . . . . . . . . . . . . . . . . . 96
STANDARD PROCEDURE - VALVE SPRING
. . . . . . . . . . . . . . . . . . . . . . . 96
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
. . . . . . . . . . . . . . . . . . . . . . . . . 97
ENGINE BLOCK
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
. . . . . . . . . . . . . . . . . . . . . . . . . . 98
CAMSHAFT & BEARINGS (IN BLOCK)
. . . . . . . . . . . . . . . . . . . . . . . . . 98
. . . . . . . . . . . . . . . . 99
INSTALLATION - CAMSHAFT BEARINGS
CONNECTING ROD BEARINGS
CRANKSHAFT
. . . . . . . . . . . . . . . . . . . . . . . . 103
CRANKSHAFT MAIN BEARINGS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
. . . . . . . . . . . . . . . . . . . . . . . . . 107
. . . . . . . . . . . . . . . . . . . . . . . . 107
CRANKSHAFT OIL SEAL - FRONT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
. . . . . . . . . . . . . . . . . . . . . . . . 109
CRANKSHAFT OIL SEAL - REAR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
. . . . . . . . . . . . . . . . . . . . . . . . 109
9 - 68
ENGINE 4.0L
TJ
HYDRAULIC LIFTERS
. . . . . . . . . . . . . . . . . . . . . . . . 110
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
. . . . . . . . . . . . . . . . . . . . . . . . . . . 110
. . . . . . . . . . . . . . . . . . . . . . . . . . 110
. . . . . . . . . . . . . . . . . . . . . . . . 111
PISTON & CONNECTING ROD
. . . . . . . . . . . . . . . . . . . . . . . . 111
STANDARD PROCEDURE - PISTON FITTING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
. . . . . . . . . . . . . . . . . . . . . . . . 113
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
VIBRATION DAMPER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
. . . . . . . . . . . . . . . . . . . . . . . . 117
STRUCTURAL SUPPORT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
. . . . . . . . . . . . . . . . . . . . . . . . 117
FRONT MOUNT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
. . . . . . . . . . . . . . . . . . . . . . . . 119
REAR MOUNT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
. . . . . . . . . . . . . . . . . . . . . . . . 119
LUBRICATION
. . . . . . . . . . . . . . . . . . . . . . . . 120
. . . . . . . . . . . . . . . . . . . . . . . . . . 120
DIAGNOSIS AND TESTING - ENGINE OIL
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 122
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
OIL
STANDARD PROCEDURE - ENGINE OIL
. . . . . . . . . . . . . . . . . . . . . . . . . . . 123
OIL FILTER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
. . . . . . . . . . . . . . . . . . . . . . . . 124
OIL PAN
. . . . . . . . . . . . . . . . . . . . . . . . 124
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
. . . . . . . . . . . . . . . . . . . . . . . . 125
ENGINE OIL PRESSURE SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . 126
. . . . . . . . . . . . . . . . . . . . . . . . . . 126
OIL PUMP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
. . . . . . . . . . . . . . . . . . . . . . . . 126
VALVE TIMING
STANDARD PROCEDURE - VALVE TIMING
TIMING BELT / CHAIN COVER(S)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
. . . . . . . . . . . . . . . . . . . . . . . . 127
TIMING BELT/CHAIN AND SPROCKETS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
. . . . . . . . . . . . . . . . . . . . . . . . 129
INTAKE MANIFOLD
. . . . . . . . . . . . . . . . . . . . . . . . 129
DIAGNOSIS AND TESTING - INTAKE
. . . . . . . . . . . . . . . . . 129
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
. . . . . . . . . . . . . . . . . . . . . . . . 130
EXHAUST MANIFOLD
. . . . . . . . . . . . . . . . . . . . . . . . 131
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
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ENGINE 4.0L
9 - 69
ENGINE 4.0L
DESCRIPTION
DESCRIPTION - ENGINE BLOCK
The cylinder block is a cast iron inline six cylinder
design. The cylinder block is drilled forming galleries
for both oil and coolant (Fig. 1).
DESCRIPTION - ENGINE
The 4.0 Liter (242 CID) six-cylinder engine is an
In-line, lightweight, overhead valve engine.
This engine is designed for unleaded fuel. The
engine cylinder head has dual quench-type combus-
tion chambers that create turbulence and fast burn-
ing of the air/fuel mixture. This results in good fuel
economy.
The cylinders are numbered 1 through 6 from front
to rear. The firing order is 1-5-3-6-2-4 (Fig. 2).
The crankshaft rotation is clockwise, when viewed
from the front of the engine. The crankshaft rotates
within seven main bearings. The camshaft rotates
within four bearings.
BUILD DATE CODE
The engine Build Date Code is located on a
machined surface on the right side of the cylinder
block between the No.2 and No.3 cylinders (Fig. 3).
The digits of the code identify:
• 1st Digit—The year (0 = 2000).
• 2nd & 3rd Digits—The month (01 - 12).
• 4th & 5th Digits—The engine type/fuel system/
compression ratio (MX = A 4.0 Liter (242 CID) engine
with a multi-point fuel injection system).
• 6th & 7th Digits—The day of engine build (01 -
31).
(1) FOR EXAMPLE: Code * 001MX12 * identifies
a 4.0 Liter (242 CID) engine with a multi-point fuel
injection system, and built on January 12, 2000.
Fig. 1 4.0L Cylinder Block with Main Bearing Caps
and Cap Brace
1 - BLOCK
2 - MAIN BEARING CAP BRACE
Fig. 2 Engine Firing Order
Fig. 3 Build Date Code Location
1 - YEAR
2 - MONTH
3 - DAY
9 - 70
ENGINE 4.0L
TJ
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