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Tech Specs

Injectors

Some of those specs that are hard to find in any workshop manual.The following is a list of the injectors used on the 4.0L since 1987 along with their rated static flow:Model Year, ...Part #, ......Colour, .....Fuel Pressure, ...Static Flow,'87-'90, ........53003956, ...Black, ........39psi, .................18.6lb/hr '91-'93, ........33007127, ...Brown, .......39psi, .................21.0lb/hr '94-'95, ........53030343, ...Tan, ...........39psi, .................21.0lb/hr '96-'99, ........53030778, ...Grey, .........49psi, .................23.2lb/hr '00-'01, ........04854181, ...Blue tip, .....49psi, .................22.5lb/hr The injector flow rate varies as the square root of the pressure drop across the injector. The stock '91-'95 4.0 injectors are rated at 22lb/hr @ 43psi fuel pressure, so at 39psi they flow ( sq. rt.(39/43) x 22.0 =21.0 ).For stock/modified 4.0 engines or stroker build-ups the following injectors can be installed. The flowrates are:Ford Motorsport 19.0lb/hr @ 39psi (Part no. FMS-M9593-C302)Ford Motorsport 24.0lb/hr @ 39psi (Part no. FMS-M9593-A302)Ford Motorsport 30.0lb/hr @ 39psi (Part no. FMS-M9593-B302)Chevy LT1 24.0lb/hr @ 43.5psi (Part no. 17124248)Chevy LT4 28.0lb/hr @ 43.5psi (Part no. 17124251)'98 Chevy LS1 25.2lb/hr @ 58.0psi (Part no. 12533952)'99-'00 Chevy LS1 26.2lb/hr @ 58.0psi (Part no. 12456154)'01-'02 Chevy LS1/LS6 28.6lb/hr @ 58.0psi (Part no. 12482704)Accel 19.2lb/hr @ 44.1psi (ACC-150119)Accel 21.1lb/hr @ 44.1psi (ACC-150121)Accel 24.4lb/hr @ 44.1psi (ACC-150124)Accel 25.6lb/hr @ 44.1psi (ACC-150126)Accel 29.4lb/hr @ 44.1psi (ACC-150130)The '95 Jeep 5.2 ZJ/Dodge 5.9 injectors (Part no. 53030262) are rated to flow 24.6lb/hr at 39psi.The selection of injector size will depend on the estimated horsepower output, brake specific fuelconsumption BSFC (assume 0.5), no. of cylinders, and the injector duty cycle (assume 80% or 0.8). Theformula is:

Page 1 of 6Tech Specs5/10/2009http://www.jeep4.0performance.4mg.com/tech_specs.html

Injector size (lb/hr) = (horsepower x 0.5)/(no.of cylinders x 0.8)

Cylinder head

The stock cylinder head is cast iron and weighs 60lb. The valve head diameter is 1.91" intake/1.50"exhaust. Casting numbers are as follows:Year............Casting No1987-90......26861991-95......71201996-99......06302000-01......0331Cylinder head flow figures (cfm) at 25inH2O pressure drop are:Non-HO head #2686Valve lift (in)..... 0.2 ... 0.3 ... 0.4 ... 0.5 ... 0.6Intake flow.... 122.0 168.0 186.0 189.0 192.0Exhaust flow....88.0 114.0 130.0 134.0 138.0Ported non-HO head #2686Valve lift (in)..... 0.2 ... 0.3 ... 0.4 ... 0.5 ... 0.6Intake flow.... 124.0 183.0 197.0 207.0 216.0Exhaust flow....87.0 113.0 138.0 153.0 159.0HO head #7120 & #0630Valve lift (in)... 0.1 ... 0.2 ... 0.3 ... 0.4 ... 0.5 ... 0.6Intake flow.... 66.0 128.0 179.0 206.0 209.0 209.0Exhaust flow. 55.0 100.0 120.0 136.0 141.0 141.2HO head #0331Valve lift (in)..... 0.2 ... 0.3 ... 0.4 ... 0.5 ... 0.6Intake flow.... 114.0 165.0 194.0 199.0 205.0Exhaust flow....94.0 117.0 126.0 130.0 133.0Ported big valve 2.02/1.60 HO headValve lift (in)... 0.1 ... 0.2 ... 0.3 ... 0.4 ... 0.5Intake flow.... 73.9 142.4 197.8 229.8 247.0Exhaust flow. 65.3 114.0 135.9 146.3 157.1The early '87-'90 non-HO heads have low intake ports that flow rather poorly. The later HO heads havehigher intake ports that flow more air by allowing a straighter shot into the cylinders. The '91-'95 HOheads with casting no.7120 have the highest intake and exhaust port airflows, especially at lower valvelifts where it is most important, and are the best for performance. The '96-'99 0630 heads are almost

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identical except that they don't have a port for the coolant temp. gauge sending unit. The '00 and later HO heads with casting no.0331 have smaller exhaust ports to produce a faster warm-up of the catalyticconverter and improve emissions, but performance also suffers because the ports don't flow as well asthose of the 7120 and 0630 castings.The exhaust ports flow relatively poorly compared to the intake ports on all the 4.0 heads so this enginewould perform better with a dual pattern cam that has more exhaust valve opening duration and lift thanthe intake.The intake ports of the HO head are rectangular and measure 1.625" x 1.375", while the exhaust portsare elliptical and measure only 1.375" x 1.250". The port cross-sectional areas are 2.234 and 1.350 sq.inches respectively. For good street performance, it is recommended that the port c/s area should beabout 85% of the valve head area. Therefore it should be 2.435 sq. in. for the intake ports and 1.502 sq.in. for the exhaust ports. The stock port c/s areas therefore need to be enlarged by 9.0% for the intakeand 11.3% for the exhaust. The ports should be matched to the intake and exhaust manifold runners tosmoothen airflow and prevent power-robbing turbulence.For those who would like to undertake a DIY head porting job, theStandard Abrasives DIY Head PortingGuideis a must read.

Head gaskets

The compressed thicknesses of the following gaskets for the 4.0 engine are:Stock 4.0 (all years) 53020754AB----0.051"Mopar Performance P4529242 / Victor Reinz Dana 5713----0.043"Corteco 20667CS '87-'95, Corteco 20871 '96-'06 ----0.051"Fel-Pro 9076PT----0.043"Fel-Pro 9076PT1----0.051"Fel-Pro 530SD----0.051"

Pistons

The pin heights and dish volumes of pistons available for the 4.0 engine are:Stock 4.0 cast aluminium '87-'93 #83500251, '94-'95 #4773157, '96-'06 #4798329----1.601" 13.1ccKeith-Black Silvolite (UEM) cast aluminium 2228/2228c, 2229/2229c----1.581" 12.2ccKeith-Black Silvolite (UEM) hypereutectic 3238hc/3243hc, 3241hc/3242hc----1.592" 14.1ccSealed Power (Sterling) hypereutectic H802CP/H825CP----1.592" 15.1ccSealed Power (Sterling) cast aluminium 677P/677CP----1.585" 17.5ccSealed Power (Sterling) cast aluminium 525P/525CP----1.580" 17.5ccKeith-Black Silvolite (UEM) forged stroker 944----1.353" 21.7cc

NEW

Keith-Black Silvolite (UEM) forged stroker 945----1.353" 11.4cc

NEW

Intake manifold

The '91-'99 intake manifold is aluminium and has equal length 24cm (9.5") long runners. The runnersare rectangular with internal dimensions of 1.625" x 1.375" and a cross sectional area of 2.234 sq. in.(14.4 sq. cm). The '00-'06 intake manifold has smaller diameter curved runners with internal dimensionsof 1.53" x 1.26" and a cross sectional area of 1.928 sq. in. (12.4 sq. cm), and is clearly designed toproduce more torque at lower rpm. The distance from the intake valve to the port opening is 3.5" (9cm),making the total distance 13" (33cm) from the manifold plenum wall to the intake valve.

Page 3 of 6Tech Specs5/10/2009http://www.jeep4.0performance.4mg.com/tech_specs.html