Jeep engines performance manual blueprinting racing secrets

- - Part Number: P5007161 $30.00 ,

Many part numbers are listed in this book for reference. They may not be currently available. For part numbers with the letter P prefix, refer to the latest Mopar Performance F’arts Catalog. For part numbers without the letter P prefix, contact your local Chrysler-Plymouth- Dodge-Jeep dealer. Mopar Performance Parts Technical Assistance Hotline 1-248-969-1 690 Monday through Friday 8:OO a.m. - 12:OO p.m. 1:00 p.m. - 5:OO p.m. (EST) .. . T -117

Acknowledgements The information presented in this book was compiled from various sources. Much of it has come from DaimlerChrysler Engineering, the DaimlerChrysler Service Manual Department, and the Walter P. Chrysler Museum, and reflects not only our experience with performance research and development, but our racing involvement as well. To this I must add my appreciation for the tremendous job that our independent testing facilities have done relative to the information contained in this manual. I would also like to acknowledge my coworkers at Mopar Performance Parts, as well as our friends at Arrow Racing Engines, McCormack Motorsports, modis Solutions, and the Adair Printing Company. Without them, this manual would not be possible. Finally, I give my sincere thanks to our many Mopar racers, race teams, and enthusiasts for their loyalty and continued support. This book has been created especially for you. - L. S. Shepard l- -lI1

Content Overview Introduction Welcome ......................... 3 Overview ......................... 3 Chapter 1: Jeep History Jeep History ....................... 7 Chapter 2: 2.5L Power Tech In- Line 4 Introduction ....................... 27 Block ............................ 29 Crankshaft ........................ 33 Connecting Rods ................... 42 Pistons and Rings ................... 45 Cylinder Head ...................... 53 Camshaft and Valve Gear ............. 57 Oiling System ...................... 70 Fuel Delivery and Fuel Injection Systems ... 76 Exhaust System .................... 84 Ignition System ..................... 87 Engine Assembly ................... 93 1990, 2.5L Engine Specifications ........ 93 1990, 2.5L Engine Torque Specifications ..................... 96 1999, 2.5L Engine Specifications ........ 97 1999, 2.5L Engine Torque Specifications .................... 100 Chapter 3: 2.46L In- Line 4 Block .......................... 104 Crankshaft ..................... 105 Connection Rods ................... 109 Pistons and Rings .................. 111 Cylinder Head ..................... 112 Camshaft and Valve Gear ............. 116 Oiling System ..................... 120 Engine Assembly .................. 121 2.46L Engine General Specifications ..................... 121 2.46L Engine General Torque Specifications ..................... 124 Chapter 4: 4.0L Power Tech In- Line 6 Introduction ....................... 129 Block ........................... 130 Crankshaft ....................... 137 Connecting Rods ................... 148 Pistons and Rings .................. 152 Cylinder Head ..................... 162 Camshaft and Valve Gear ............ 176 Oiling System ..................... 206 Cooling System .................... 214 induction System ................... 222 Fuel Delivery System ................ 227 Exhaust System ................... 234 Ignition System .................... 238 Starting System .................... 247 Engine Assembly .................. 250 1989, 4.0L Engine Specifications ........ 272 1989, 4.0L Engine Torque Specifications ..................... 276 1999, 4.0L Engine Specifications ........ 277 1999, 4.0L Engine Torque Specifications ..................... 280 Chapter 5: 4.2L In- Line 6 Introduction ....................... 283 Block ........................... 284 Crankshaft ....................... 286 Piston and Connecting Rod Assembly .... 292 Cylinder Head ..................... 298 Camshaft and Valve Gear ............ 302 Oiling System ..................... 308 Induction System ................... 312 Ignition System .................... 327 Engine Assembly .................. 333 1981, 4.2L Engine Specifications ........ 333 1981. 4.2L Engine Torque Specifications ..................... 335 .. T -7 7 * - .. .

1990. 4.2L Engine Specifications ........ 336 Specifications ..................... 340 Introduction ....................... 343 Crankshaft ....................... 344 Timing Drive System ............... 344 Rod Assembly .................... 345 Cylinder Heads ................... 346 Oiling System .................... 348 Cooling System ................... 350 Starting System .................... 355 Charging System .................. 357 Intake Manifold ................... 358 Fuel Delivery System ............... 358 Module (PCM) .................... 361 Ventilation (PCV) System ............ 364 Exhaust System ................... 365 Ignition System ................... 365 Troubleshooting ................... 366 1999, 4.7L Engine Specifications ........ 370 Specifications ..................... 372 Introduction ....................... 375 Block ........................... 377 Crankshaft ....................... 380 Piston and Connecting Rod Assembly .... 388 Cylinder Heads .................... 394 Oiling System ..................... 406 Cooling System .................... 413 Induction System ................... 414 Fuel Delivery System ................ 421 Exhaust System ................... 424 1990. 4.2L Engine Torque Chapter 6: 4.7L Power Tech V - 8 Block .......................... 344 Piston and Connecting Camshaft and Valve Gear ............ 346 Powertrain Control Positive Crankcase 1999. 4.7L Engine Torque Chapter 7: 360 AMC V - 8 Camshaft and Valve Gear ............ 397 Ignition System .................... 425 Engine Assembly .................. 435 Specifications ..................... 435 Specifications ..................... 438 Specifications ..................... 440 Specifications ..................... 442 Specifications ..................... 444 Specifications ..................... 448 Off-Road Driving ................... 451 Tread Lightly! ..................... 453 Jeep Jamborees ................... 455 Camp Jeep ....................... 460 Getting Started in Racing ............. 464 Contingency ...................... 468 Safety and the Performance Advantage ... 469 Personal Safety .................... 471 Body and Chassis Safety ............. 471 Engine and Drivetrain Safety Safety Checklist ................... 476 Drag Racing ...................... 477 Vehicle in Stages .................. 482 Recommendations .................. 482 Suspension Upgrades ............... 484 Tires ........................... 485 Information and Sources ............. 487 Additional Sources .................. 491 1971. 304-360 AMC V-8 Engine 1971. 304-360 AMC V-8 Engine Torque 1981. 304-360 AMC V-8 Engine 1981. 304-360 AMC V-8 Engine Torque 1990. 360 AMC V-8 Engine 1990. 360 AMC V-8 Engine Torque Chapter 8: Off - Roading and Racing .......... 474 Building Your Performance Mopar Performance Parts Engine Package Mopar Performance Parts Chapter 9: Additional Information Racing Formulas ................... 494 Body and Engine Types .............. 496 Conversion Table .................. 497 Chrysler-Plymouth-Dodge-Jeep Metric to English .. T - 7 1 .

CONTENTS i Contents Introduction WELCOME .............................. 3 OVERVIEW ............................. 3 Chapter 1: Jeep History JEEP HISTORY ............ 7 ............ 7 .................... 10 The Great Out .................... 11 Beyond the Quad ..................... 12 Kaiser-Jeep .......................... 13 Birth of the Sport Utility Vehicle ...... 15 American Motor Corporation (A ...... 16 1984 Cherokee Redefines the SUV ........ 18 Enter the Wrangler ..................... 20 Chrysler Corporation Buys AMC ......... 21 DaimlerChrysler and Beyond ............ 23 Additional Jeep Information ............. 24 Chapter 2: 2.5L Power Tech In- line 4 Introduction 2.5L ENGINE GENERAL SPECIFICATIONS ............ ........ 27 Block DISASSEMBLY AND ASSEMBLY PROCEDURES ........... 29 ........... 30 ............ 3 1 Cylinder Bore Reconditioning Short Block Assembly .................. 32 Crankshaft INTRODUCTION ....................... 33 CRANKSHAFT MAIN BEARINGS ......... 33 Removal ........... . . 33 ............. 34 .................... 34 Main Bearing-to-Journal Clearance Crankshaft Installed .................... 34 Main Bearing Journal Diameter Crankshaft Removed ................... 35 Installation ........ ......... 35 Crankshaft End Play ................... 36 ENGINE DAMPER ....................... 36 Removal ............................ 36 Installation ........................... 36 VIBRATION DAMPER .................... 37 Removal ............................ 37 Installation .......................... 37 TIMING CASE C Removal ... Installation ........................... 38 TIMING CHAIN AND SPROCKETS ......... 39 Removal ............................ 39 Installation .......................... 39 TIMING CASE COVER OIL SEAL REPLACEMENT ................... 40 ............ 40 ............. 41 REAR MAIN OIL SEAL ................... 41 Removal ...... .................. 41 Installation ........................... 41 Timing Case Cover Removed Timing Case Cover Installed Connecting Rods INTRODUCTION ........................ 42 BASIC PREPARATION ................... 42 RODRATIO . . ............ 42 INSPECTION ........................... 42 MEASURING BEARING-TO-JOURNAL 44 MEASURING SIDE CLEARANCE ........... 44 Pistons and Rings PISTONS ................ ........... 45 ....... 45 PISTON AND CONNECTING ROD ASSEMBLY ............................ 46 Removal ............................ 46 Installation .......................... 47 Piston Ring Fitting Piston Ring Fitting (Coated Pistons Only) . . SO Ring Gap Orientation ................ so PISTON PIN ........................... 51 ................... 51 Removal . Inspection ........................... 51 Installation ........................... 52 Piston Fitting (Non-Coated P Piston Fitting (Coated Pistons Only) (Non-Coated Pistons Only) .............. 48 .. T .. ll 1 . ..

ii MOPAR PERFORMANCE PARTS Cylinder Head INTRODUCTION ............. .53 REMOVAL AND INSTALLATION PROCEDURES ........................ .53 .................... 53 tion ............... .54 .................... 54 CYLINDER HEAD COVER . . Removal .................. Installation ...... ......... .56 Inspection .......................... .56 Camshaft and Valve Gear CAMSHAFT ........................... .57 Removal ............................ 58 Installation ..................... 58 CAMSHAFT PIN REPLACEMENT ......... .60 Removal ............................ 60 Installation ..................... 60 Inspection .......................... .58 VALVES AND VALVE SPRINGS Removal - Cylinder Head Removed ...... .61 Removal - Cylinder Head NOT Removed ............ ....... .62 Cleaning ......... ........... .62 Inspection .......................... .63 Valve Refacing .... ............. 63 Valve Spring Tension Test .............. .63 Installation- Cylinder Head Removed ..... .63 Installation - Cylinder Head NOT Removed ......... ........... .64 VALVE TIMING ........................ .65 VALVE STEM OIL SEALS ................ .65 VALVE GUIDES ........................ .65 Valve Stem-to-Guide Clearance Measurement ............... .66 VALVE SEATS ................ .66 Valve Seat Refacing .................. .66 ROCKER ARMS ..................... 67 ..................... 67 Cleaning and Inspection ................ .68 Installation ... .................... 68 PUSHRODS .... ...................... 68 HYDRAULIC LIFTERS (TAPPETS) ......... .68 Disassembly and Cleaning .... ...... .69 Assembly ....... ......... .69 Installation .......................... .69 Removal ................ Oiling System INTRODUCTION ....................... .70 Oil Pressure Requirements ............. .70 ........................ .... Removal ................ 72 ....................... 72 OILPUMP ............................. 73 Removal .................... Gear End Clearance Measurements Gear-to-Body Clearance Measureme Disassembly ................... Assembly .................... Installation ................... Fuel Delivery and Fuel Injection Systems MULTI-POINT FUEL INJECTION (MPI) SYSTEM .............................. .76 Powertrain Control Module (PCM) ....... .76 PCM Inputs ........................ .77 PCM Outputs ........... Modes of Operation ........... Throttle Body ............. Fuel RaiVFuel Damper ................. .78 Fuel Pressure Regulator ................ .78 Racing Modifications .................. .79 Crankcase Ventilation System ........... .79 ........ .79 Electronic Control Unit (ECU) .......... .80 ECU Inputs .............. 80 ECU Outputs ........................ .80 Modes of Operation ................... .8 1 Throttle Body ........................ .8 1 FUEL PUMP .................. ...... .81 FUEL FILTER .......................... .8 1 INTAKE MANIFOLD .................... .81 Removal ............................ 81 Installation ................. 82 AIR FILTERS .... .............. 83 THROTTLE BODY (SINGLE POINT) FUEL INJECTION (TBI) ...... ... TBI Fuel Pump ................... .... Exhaust System EXHAUST SYSTEM ............... Exhaust Gas Recirculation (EGR) ... Exhaust System Troubleshooting Chart Exhaust System Torque Specifications ..... .85 EXHAUST MANIFOLD .............. 86 Removal ............................ 86 Installation .......................... .86 .... .85 l- -1-1 ._

CONTENTS iii Ignition System THROTTLE BODY FUEL INJECTION (TBI) IGNITION SYSTEM ..................... .87 MULTI-POINT FUEL INJECTION (MPI) IGNITION SYSTEM ......... Camshaft Position Sensor . Distributor ..... .......... Distributor Cap ............. 88 Distributor Rotor Ignition Coil ........................ .89 SPARK PLUGS . . ......... .89 Gap Adjustment ...................... .89 Installation .......................... .90 STARTER MOTOR .............. Operation ........... Removal .................... Installation .......................... .9 1 MOPAR PERFORMANCE PARTS ELECTRONIC IGNITION COMPONENTS ... .92 Engine Assembly 1990,2.5L ENGINE SPECIFICATIONS . . 1990,2.5L ENGINE TORQUE SPECIFICATIONS ...................... .96 1999,2.5L ENGINE SPECIFICATIONS ...... .97 1999,2.5L ENGINE TORQUE SPECIFICATIONS ..................... .lo0 Chapter 3: 2.46L In-Line 4 Block ................................... 104 Crankshaft ............... .......... .lo5 INTRODUCTION ...................... .lo5 CRANKSHAFT MAIN BEARINGS ........ .lo5 Removal . ...................... 105 Installation .... .............. 105 CRANKSHAFT (FRONT) OIL SEAL REPLACEMENT- COVER INSTALLED .... ,105 REAR MAIN BEARING OIL SEAL ........ .lo6 Removal ...................... 106 Installation ...... ........ .lo6 VIBRATION DAMPER .................. .lo6 Removal ........................ Installation ......................... .lo6 TIMING CASE COVER ..... ....................... 106 ...................... 106 TIMING CHAIN ....................... .lo7 Removal ........................... 107 Installation ......................... .lo7 Connecting Rods PISTON AND CONNECTING ROD ASSEMBLY ...................... ,109 Removal ........................... 109 Installation ......................... .lo9 CONNECTING ROD BEARINGS ......... ,110 Removal ........................... .I 10 Installation ......................... .l 10 Pistons and Rings ........................ .l 11 Cylinder Head REMOVAL AND REPLACEMENT PROCEDURES .......... Cleaning and Inspection .... CYLINDER HEAD COVER ...... .115 Removal .............. Installation ..... ... Camshaft and Valve Gear .......... CAMSHAFT .......... ,116 Installation ... VALVE SPRING AND OIL DEFLECTOR .... .118 Removal.. .... .... 118 Installation ....... ........ 118 ROCKER ARM ASSEMBLY ............... 118 Removal ........ .... Installation ... ................... 119 Cleaning and Inspection ...... HYDRAULIC VALVE TAPPETS (LIFTERS) . ......................... 119 Removal ............................ 119 Installation .......................... 119 Oiling System OILPAN .............................. 120 Removal ........................... 120 Installation ......................... .120 OIL PUMP 120 Removal ........................... 120 Installation ................... ... ,120 .................... T -7 n ._

iv MOPAR PERFORMANCE PARTS Engine Assembly 2.46L ENGINE GENERAL SPECIFICATIONS ....................... 121 2.46L ENGINE GENERAL TORQUE SPECIFICATIONS ....................... 124 Chapter 4: 4.0L Power Tech In- line 6 Introduction .............................. 129 Block INTRODUCTION ....................... 130 Build Date Code ..................... 130 Oversize and Undersize Component Codes .................... 13 1 Block Harness ....................... 131 Rough Bored Blocks .................. 131 ....... 13 1 Block-to-Head Distortion ............... 131 Sonic Testing ........................ 132 Core Shift .......................... 132 Surfacing (“Decking”) ................. 133 Honing ............................. 133 Boring and Milling Specifications ........ 134 Cylinder Bore Measurements ............ 134 CYLINDER BLOCK PREPARATION Stress Relieving ...................... 132 CYLINDER BLOCK ASSEMBLY Head Bolts ............... Bottoming Taps ........... Main Bearing Bores ........ Deck Height .............. Dowel Pins .............. Rear Main Bearing Oil Seal . . Deburring ................ Tappet Bores ............. Notching the Cylinder Bore for CC’ing the Block .......... Camshaft Bearings ......... Connecting Rod Clearance ... ......... 134 ......... 134 ......... 134 ......... 134 ......... 135 ......... 135 ......... 135 ......... 135 ......... 135 ......... 135 ......... 135 ......... 135 ADDITIONAL CYLINDER BLOCK PREPARATION AND ASSEMBLY TIPS ..... 135 MAINCAPS ........................... 136 FREEZE PLUGS ........................ 136 Crankshaft INTRODUCTION ....................... 137 Balanced and Unbalanced Crankshafts ..... 137 Crank Bolt .......................... 137 BASIC PREPARATION ................... 137 SPECIAL CRANKSHAFT PROCEDURES ... 138 ...... 138 Measuring Main Bearing Clearances Top Dead Center (TDC) ................ 139 Mallory Metal ..... ............... 140 Tuff-Triding and Nitriding .............. 141 4.2L Engine Crankshaft Installation ....... 141 MAIN JOURNALS ...................... 141 MAIN BEARINGS ...................... 141 Main Bearing Material .... Removal .............. Inspection .......................... 142 Fitting ............................. 142 Installation .......................... 142 Main Bearing Fitting Chart ............. 144 Crankshaft End Play .................. 145 REAR MAIN OIL SEAL .................. 145 Removal ........................... 145 Installation .......................... 145 VIBRATION DAMPER ................... 145 Vibration Damper Failure ............... 146 Vibration Damper Performance Tips ...... 146 Removal ........................... 146 Installation .......................... 147 TIMING CHAIN AND SPROCKETS ........ 147 Installation Tips ...................... 147 Connecting Rods INTRODUCTION ....................... 148 BASIC CONNECTING ROD PREPARATION AND INSTALLATION TIPS ............... 148 SPECIAL CONNECTING ROD INSTALLATION PROCEDURES ........... 149 Rod Ratio ........................... 149 Measuring Side Clearance .............. 149 Cap Alignment ........ 149 ............ Connecting Rod Bolt Protectors .......... 150 ALUMINUM CONNECTING RODS ........ 150 CONNECTING ROD BEARINGS .......... 151 Installation ..... .................. 151 Measuring Connecting Rod Bearing Clearance .................... 151 Pistons and Rings PISTONS .............................. 152 Piston Compression Ratio Ratings ........ 152 Piston Shape ........................ 153 Piston-to-Head Clearance ............... 153 Valve-to-Piston Clearance .............. 153 Piston Race Preparation ................ 153 Reversing Pistons With Offset Pins ....... 154 CC’ing the Block ..................... 154 l- -1 1 ..

CONTENTS V COMPRESSION RATIO .................. 154 Measuring 1/2" Down Fill Volume ........ 155 PISTON RINGS ........................ 155 Basic Piston Ring Preparation ........... 156 PISTON PIN ........................... 156 Removal ........................... 156 Inspection .......................... 156 Installation .......................... 156 Offset Pins .......................... 157 Pin Coatings ......................... 157 Pin Oiling .......................... 157 PISTON AND CONNECTING ROD ASSEMBLY ....................... 158 Removal ........................... 158 Inspection .......................... 159 Cylinder Bore Measurement ............. 159 Fitting Pistons- Bore Gauge Method ...... 159 Piston Size Chart ..................... 159 Fitting Rings ........................ 159 Installation .......................... 160 Cylinder Head INTRODUCTION ....................... 162 SELECTION ........................... 162 CYLINDER HEAD REMOVAL AND INSTALLATION PROCEDURES ........... 163 Removal ........................... 163 Cleaning and Inspection ................ 164 Preparation .......................... 164 Installation .......................... 165 CYLINDER HEAD PERFORMANCE AND ASSEMBLY TIPS ................... 166 Alignment .......................... 166 Piston-to-Head Clearance ............... 166 Oil Restriction ....................... 166 Valve-to-Valve Clearance ............... 166 Measuring Cylinder Head Combustion Chamber Volume ..................... 166 Block-to-Head Distortion ............... 167 Spring Seats and Valve Guides ........... 168 Diagnosing Valve Seat Insert Failure ...... 168 Aluminum Head Threads ............... 169 Weeping ............................ 169 PORTED CYLINDER HEAD .............. 170 Swirl Ports .......................... 170 Porting ............................. 171 Flow Bench ......................... 171 Evaluating Cylinder Head Air Flow ....... 172 Oversize Valve Seats and Guides ......... 174 CYLINDER HEAD COVER ............... 175 Removal ........................... 175 Cleaning and Inspection ................ 175 Installation .......................... 175 Camshaft and Valve Gear CAMSHAFT ........................... 176 CAMSHAFT SELECTION ................ 177 Racing Camshaft Selection .............. 177 CAMSHAFT REMOVAL AND INSTALLATION PROCEDURES ........... 178 Removal ........................... 178 Inspection .......................... 178 Installation .......................... 178 CAMSHAFT INSTALLATION TIPS ......... 179 CAMSHAFT INSTALLATION TROUBLESHOOTING ................... 180 SPECIAL CAMSHAFT THEORIES ......... 180 Camshaft Duration .................... 180 Camshaft Centerline ................... 181 Calculating Duration at Fifty ............ 184 Base Circle ......................... 184 VALVE GEAR .......................... 185 General Valve Gear ................... 186 Valve Gear Selection .................. 186 VALVE GEAR PERFORMANCE AND ASSEMBLY TIPS ....................... 186 SPECIAL VALVE GEAR THEORIES ........ 187 Valve Gear Oiling .................... 187 Valve Train Geometry ................. 188 Dynamics ........................... 188 VALVES ............................... 188 Stainless Steel Valves .................. 190 Valve Grinding (Valve Job) ............. 190 Valve Timing ........................ 192 Polished Valve Stems .................. 193 Valve Stem Lash Caps ................. 193 VALVE STEM OIL SEALS ................ 193 VALVE GUIDES ........................ 194 Valve Stem-to-Guide Clearance Measurement ........................ 194 VALVE SEATS .......................... 194 Valve Seat Refacing ................... 194 VALVE SPRINGS ....................... 195 Big Camshaft Valve Spring Considerations ................. 196 Valve Spring Installation Performance Tips ..................... 196 ... l- - T I 7 .

Jeep engines performance manual blueprinting racing secrets

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