Jeep Wrangler TJ. Manual — part 425
PISTON RINGS
DESCRIPTION
SPECIFICATION
Metric
Standard
Ring Gap
Top
Compression
Ring
0.25 - 0.51 mm
0.0098 - 0.020
in.
Wear Limit
0.8 mm
0.031 in.
2nd
Compression
Ring
0.23 - 0.48 mm
0.009 - 0.018 in.
Wear Limit
0.8 mm
0.031 in.
Oil Control Steel
Rails
0.25 - 0.64 mm
0.0098 - 0.025
in.
Wear Limit
1.00 mm
0.039 in.
Compression
Rings
0.030 - 0.080
mm
0.0011 - 0.0031
in.
Wear Limit
0.10 mm
0.004 in.
Ring Side
Clearance - Oil
Ring Pack
0.012 - 0.178
mm
0.0004 - 0.0070
in.
Ring Width -
Compression
Rings
1.47 - 1.50 mm
0.057 - 0.059 in.
Ring Width - Oil
Ring Pack
2.72 - 2.88 mm
0.107 - 0.1133
in.
CONNECTING ROD
DESCRIPTION
SPECIFICATION
Metric
Standard
Bearing
Clearance
0.025 - 0.071
mm
0.0009 - 0.0027
in.
Wear Limit
0.075 mm
0.003 in.
Bore Diameter -
Piston Pin
20.96 - 20.98
mm
0.8252 - 0.8260
in.
Bore Diameter -
Crankshaft End
53.007 - 52.993
mm
2.0868 - 2.0863
in.
Side Clearance
0.13 - 0.38 mm
0.005 - 0.015 in.
Wear Limit
0.40 mm
0.016 in.
Weight - Total
(Less Bearing)
565.8 grams
19.96 oz.
CRANKSHAFT
DESCRIPTION
SPECIFICATION
Metric
Standard
Connecting Rod
Journal
Diameter
49.984 - 50.000
mm
1.968 - 1.9685
in.
Main Bearing
Journal
Diameter
59.992 - 60.008
mm
2.362 - 2.3625
in.
Journal
Out-of-Round
(Max.)
0.0035 mm
0.0003 in.
Journal Taper
(Max.)
0.007 mm
0.0001 in.
End Play
0.09 - 0.24 mm
0.0035 - 0.0094
in.
Wear Limit
0.38 mm
0.015 in.
Main Bearing
Diametrical
Clearance
0.018 - 0.062
mm
0.0007 - 0.0024
in.
HYDRAULIC LASH ADJUSTER
DESCRIPTION
SPECIFICATION
Metric
Standard
Body Diameter
15.901 - 15.913
mm
0.626 - 0.6264
in.
Plunger Travel
Minimum (Dry)
3.0 mm
0.118 in.
CYLINDER HEAD CAMSHAFT BEARING BORE
DIAMETER
DSECRIPTION
SPECIFICATION
Metric
Standard
Journals No.1 -
6
26.020 - 26.041
mm
1.024 - 1.025 in.
TJ
ENGINE 2.4L
9 - 15
ENGINE 2.4L (Continued)
CAMSHAFT
DESCRIPTION
SPECIFICATION
Metric
Standard
Journal
Diameter No. 1
- 6
25.976 - 25.995
mm
1.022 - 1.023 in.
Bearing
Clearance -
Diametrical
0.025 - 0.065
mm
0.0009 - 0.0025
in.
End Play
0.05 - 0.17 mm
0.0019 - 0.0066
in.
Lift (Zero Lash)
Intake
8.25 mm
0.324 in.
Exhaust
6.60 mm
0.259 in.
Intake Valve
Timing*
Closes (ABDC)
44.3°
Opens (ATDC)
6.2°
Duration
218.1°
Exhaust Valve
Timing*
Closes (ATDC)
0.8°
Opens (BBDC)
39.9°
Duration
220.7°
Valve Overlap
5.4°
*
All reading in crankshaft degrees at 0.5 mm (0.019
in.) valve lift.
CYLINDER HEAD
DESCRIPTION
SPECIFICATION
Metric
Standard
Material
Cast Aluminum
Gasket
Thickness
(Compressed)
0.71 mm
0.028 in.
VALVE SEAT
DESCRIPTION
SPECIFICATION
Metric
Standard
Angle
44.5 - 45°
Seat Diameter -
Intake
34.37 - 34.63
mm
1.353 - 1.363 in.
Seat Diameter -
Exhaust
27.06 - 27.32
mm
1.065 - 1.075 in.
Runout (Max.)
0.05 mm
0.002 in.
Valve Seat
Width - Intake
and Exhaust
0.9 - 1.3 mm
0.035 - 0.051 in.
Service Limit -
Intake
2.0 mm
0.079 in.
Service Limit -
Exhaust
2.5 mm
0.098 in.
VALVE GUIDE
DESCRIPTION
SPECIFICATION
Metric
Standard
Diameter I.D.
5.975 - 6.000
mm
0.235 - 0.236 in.
Guide Bore
Diameter
11.0 - 11.02
mm
0.4330 - 0.4338
in.
Guide Height
(spring seat to
guide tip)
13.25 - 13.75
mm
0.521 - 0.541 in.
9 - 16
ENGINE 2.4L
TJ
ENGINE 2.4L (Continued)
VALVES
DESCRIPTION
SPECIFICATION
Metric
Standard
Face Angle -
Intake and
Exhaust
44.5 - 45°
Head Diameter
- Intake
34.67 - 34.93
mm
1.364 - 1.375 in.
Head Diameter
- Exhaust
28.32 - 28.52
mm
1.114 - 1.122 in.
Valve Length
(Overall)
Intake
112.76 - 113.32
mm
4.439 - 4.461 in.
Exhaust
110.89 - 111.69
mm
4.365 - 4.397 in.
Valve Stem
Diameter
Intake
5.934 - 5.952
mm
0.2337 - 0.2344
in.
Exhaust
5.906 - 5.924
mm
0.2326 - 0.2333
in.
VALVE MARGIN
DESCRIPTION
SPECIFICATION
Metric
Standard
Intake
1.2 - 1.7 mm
0.047 - 0.066 in.
Service Limit
0.95 mm
.0037 in.
Exhaust
0.985 - 1.315
mm
0.038 - 0.051 in.
Service Limit
1.05 mm
.039 in.
VALVE STEM TIP HEIGHT
DESCRIPTION
SPECIFICATION
Metric
Standard
Intake
48.04 mm
1.891 in.
Exhaust
47.99 mm
1.889 in.
VALVE STEM TO GUIDE CLEARANCE
DESCRIPTION
SPECIFICATION
Metric
Standard
Intake
0.048 - 0.066
mm
0.0018 - 0.0025
in.
Max. Allowable
0.076 mm
0.003 in.
Service Limit
0.25 mm
0.010 in.
Exhaust
0.0736 - 0.094
mm
0.0029 - 0.0037
in.
Max. Allowable
0.101 mm
0.004 in.
Service Limit
0.25 mm
0.010 in.
VALVE SPRINGS
DESCRIPTION
SPECIFICATION
Metric
Standard
Free Length
(Approx.)
49.2 mm
1.937 in.
Nominal Force
(Valve Closed)
334 ±17 N @
38.0 mm
75.08 ±3.8 lbs.
@ 1.496 in.
Nominal Force
(Valve Open)
598 ±30N @
29.75 mm
134 ±6.7 lbs. @
1.171 in.
Installed Height
38.00 mm
1.496 in.
Number of Coils
6.9
Wire Diameter
3.61 mm
0.142 in
OIL PUMP
DESCRIPTION
SPECIFICATION
Metric
Standard
Clearance Over
Rotors (Max.)
0.10 mm
0.004 in.
Cover Out-of-Flat
(Max.)
0.025 mm
0.001 in.
Inner Rotor
Thickness (Min.)
10.699 mm
0.421 in.
Outer Rotor
Thickness (Min.)
10.699 mm
0.421 in.
Outer Rotor
Clearance (Max.)
0.039 mm
0.015 in.
Outer Rotor
Diameter (Min.)
85.924 mm
3.383 in.
Tip Clearance
Between Rotors
(Max.)
0.20 mm
0.008 in.
TJ
ENGINE 2.4L
9 - 17
ENGINE 2.4L (Continued)
OIL PRESSURE
DESCRIPTION
SPECIFICATION
Metric
Standard
At Curb Idle
Speed*
25 kPa
4 psi
At 3000 rpm
170 - 550 kPa
25 - 80 psi
CAUTION:
*If pressure is ZERO at curb idle, DO NOT run engine
at 3000 rpm.
SPECIFICATIONS - TORQUE
DESCRIPTION
N·m
Ft.
Lbs.
In.
Lbs.
Bolts, Balance Shaft
Carrier to Block
54
40
-
Fastener - Double Ended,
Balance Shaft Gear
Cover
12
-
105
Bolt, Balance Shaft
Sprocket
28
-
250
Bolts, Balance Shaft
Chain Tensioner
12
-
105
Bolts, Balance Shaft
Carrier Cover
12
-
105
Bolt, Camshaft Sprocket
115
85
-
Bolts, Connecting Rod
Cap
27 +
1
⁄
4
turn
20
+
1
⁄
4
turn
-
Bolts, Crankshaft Main
Bearing Cap/Bedplate
M8 Bolts
28
-
250
M11 Bolts
75
55
-
Crankshaft Damper
136
100
-
Bolts, Cylinder Head
(Refer to 9 - ENGINE/
CYLINDER HEAD -
INSTALLATION)
DESCRIPTION
N·m
Ft.
Lbs.
In.
Lbs.
Bolts, Cylinder Head
Cover
12
-
105
Flex Plate to Crankshaft
95
70
-
Flywheel Mounting Bolts
81
60
-
Bolts, Engine Mount
Bracket Right
61
45
-
Bolts, Engine Mounting
(Refer to 9 ENGINE/
ENGINE MOUNTING)
Bolts, Exhaust Manifold to
Cylinder Head
23
-
200
Bolts, Exhaust Manifold
Heat Shield
12
-
105
Bolts, Intake Manifold -
Lower
28
-
250
Oil Filter
20
15
-
Bolts, Oil Pan
12
-
105
Plug, Oil Pan Drain
27
20
-
Bolts, Oil Pump to Block
28
-
250
Bolts, Oil Pump Cover
Plate
12
-
105
Bolt, Oil Pump Pick-up
Tube
28
20
-
Cap - Oil Pump Relief
Valve
41
30
-
Spark Plugs
18
13
-
Bolts, Timing Belt Covers
- Front Covers to Rear
Covers
12
-
105
- Rear Cover
12
-
105
Bolts, Timing Belt
Tensioner Assembly
61
45
-
9 - 18
ENGINE 2.4L
TJ
ENGINE 2.4L (Continued)
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