You are on page 1of 18

4.0L 6-CYL - VIN [M] & 4.

2L 6-CYL - VIN [C]
1988 Jeep Cherokee

1988 ENGINES Chrysler Motors 4.0L & 4.2L 6-Cylinder Jeep; Cherokee, Comanche, Wagoneer, Wrangler

ENGINE CODING ENGINE IDENTIFICATION
NOTE: For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL INFORMATION section.

The Vehicle Identification Number (VIN) is located on upper left side of dash and is visible through windshield. The fourth character identifies the engine size. The tenth character identifies the model year. ENGINE IDENTIFICATION CODES TABLE Application

4.0L 6-Cylinder MPFI ........................ 4.2L 6-Cylinder 2-Bbl. ......................

Some engines are produced at factory with oversize or undersize components. These engines are identified by a letter code stamped on a boss between ignition coil and distributor. Letters are decoded as follows: * * * * "B" indicates oversize. "C" indicates oversize. "M" indicates undersize. "P" indicates undersize. all cylinder bores are .010" (.25 mm) all camshaft bearing bores are .010" (.25 mm) all main bearing journals are .010" (.25 mm) all connecting rod journals are .010" (.25 mm)

WARNING: Fuel system is under pressure. Use care when removing fuel lines to prevent personal injury. Removal 1) Disconnect negative battery cable. Remove air inlet from throttle plate assembly. Disconnect throttle, cruise control and throttle valve (A/T models) cables (if equipped). 2) Disconnect and mark all vacuum and electrical connectors

                                                                                        ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡ ¡¡¡¡¡¡¡¡ ¡¡ ¡¡¡¡ ¡                                                                                          ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡ ¡¡¡¡¡¡¡¡ ¡¡ ¡¡¡¡ ¡ 
SPECIAL ENGINE MARKS REMOVAL & INSTALLATION ENGINE REMOVAL
See ENGINE REMOVAL in this section.

VIN Code M C

INTAKE & EXHAUST MANIFOLD (4.0L)

Reverse removal procedures for remaining components. Mark and disconnect all vacuum hoses. Disconnect EGR tube fittings. 3) Install new "O" rings on fuel line connectors prior to installation. Ensure "CLICK" sound is heard when installing fuel lines. Remove power steering pump and bracket from intake manifold. remove PCV hose from manifold. Disconnect oxygen sensor. disconnect throttle valve rod. Apply anti-seize to oxygen sensor threads prior to installation. Remove fuel rail and injector assembly. Drain cooling system. 1: Manifold Tightening Sequence (4. 4) Remove intake manifold heat shield.from intake manifold. INTAKE & EXHAUST MANIFOLD (4. Disconnect fuel lines at fuel rail. 1. see TORQUE SPECIFICATIONS TABLE in this article. On all models.2L) Removal 1) Remove air cleaner. Remove coolant hoses from intake . Install exhaust and intake manifolds and loosely install bolts. Use caution as these fuel lines are under pressure. Tighten bolts to specification. Disconnect exhaust pipe from manifold. 2) Disconnect throttle cable at bellcrank. Tighten manifold bolts in proper sequence see Fig. On A/T models. 3) Loosen drive belt tensioner and remove drive belt. Fuel lines are removed by squeezing the 2 retaining tabs against the fuel line and pulling the fuel line from the connector. Fig. Remove fuel rail retaining bolts. 2) Tighten EGR tube bolts. Remove retaining bolts and remove manifolds. Disconnect fuel line at carburetor. This indicates that fuel lines are properly seated. Tighten to specifications. Install EGR tube between manifolds. ventilation hoses and electrical connectors at intake manifold.0L) Courtesy of Chrysler Motors. Installation 1) Install new gasket.

Inspection Inspect cylinder head for cracks or damage. 2) Apply anti-seize to oxygen sensor threads prior to installation. Fig. 3) Remove EGR tube fittings from manifolds. Install exhaust manifold and loosely install bolts. See COOLING SYSTEM AIR PURGE under WATER PUMP in this article.2L) Courtesy of Chrysler Motors. Repair . 2: Manifold Tightening Sequence (4. 3) Remove the rocker arms and the push rods. Remove cylinder head. Remove oxygen sensor (if equipped). Remove exhaust manifold. See the following: * * INTAKE & EXHAUST MANIFOLD (4. See ROCKER ARMS & BRIDGE. See Fig. Install intake manifold. CYLINDER HEAD Removal 1) Disconnect negative battery cable. Tighten bolts to specification. Remove cylinder head bolts. Remove valve cover bolts. Disconnect and mark spark plug wires.manifold. Remove intake manifold. Remove power steering pump and A/C compressor and mounting brackets (if equipped). Disconnect hoses at thermostat housing. Remove intake and exhaust manifolds. If exhaust manifold requires removal. Reverse removal procedure for remaining components.0L).2L). INTAKE & EXHAUST MANIFOLD (4. 4) Remove intake manifold bolts. 2) Disconnect and mark all hoses and electrical connections at cylinder head. Drain cooling system. 2. check cylinder head for warpage in several areas. Remove spark plugs. Tighten bolts to specification in proper sequence. disconnect exhaust pipe from manifold. Using straightedge. Installation 1) Install new gasket. Fill and purge cooling system.

Fig. Install new gasket with the word "TOP" upward. Tighten bolts to specification.m) on 4. Valve Arrangement E-I-I-E-I-E-E-I-E-I-I-E (Front-to-rear). (136 N. 2) Install cylinder head. Install valve cover and new gasket. 5) Refill and purge cooling system. (115 N. Install rocker arm components in original location. (136 N. Installation 1) Ensure all gasket surfaces are clean. See Fig.m) on 4. Remove valve cover. 11) to 110 ft. lbs. 11 prior to installation. See Fig.m) on 4. 3: Cylinder Head Bolt Tightening Sequence Courtesy of Chrysler Motors.or replace cylinder head if warpage exceeds . ROCKER ARMS & BRIDGE Removal 1) Remove PCV valve hose at valve cover. 2) Remove rocker arm assemblies and push rods.002" (. Remove cruise control servo (if equipped). 11 head bolt to 100 ft. 4) Reverse removal procedure for remaining components.0L or 85 ft. Components must be installed in original location. 3) Tighten all bolts in sequence (except No. Valve Guide Valve guides are not replaceable. Alternately loosen each rocker arm bolt one turn at a time.0L or 75 ft. Install head bolts. Apply sealant to both sides of new cylinder head gasket.2L models. See COOLING SYSTEM AIR PURGE under WATER PUMP in this article. (149 N. valve guides must be reamed to accommodate oversized stem valves. Install valve cover and new gasket. Mark components for reassembly. If clearance is excessive. lbs. Tighten No. Installation Reverse removal procedure. Apply sealing compound to threads of cylinder head bolt No.2L. lbs. Tighten bolts to specification. lbs.05 mm) per each 6" (152 mm) or damage exists. 3.m) on 4. Clean carbon from combustion chambers and tops of pistons. Ensure all holes are aligned. . 3.

999-23. Remove front cover. Tighten bolts to specification. 2) Using Puller (J-21719-01). Tighten bolts to specification. Remove oil pan-to-front cover bolts. Replace lifters as an assembly if damaged. Remove cover-to-block retaining bolts. Mark lifter location for reassembly reference. Check cylinder block lifter bore diameter. fan and hub assembly.9055-. See CYLINDER HEAD. Apply sealant to the joint area of oil pan and cylinder block. 3) Cut oil pan gasket tabs even with face of cylinder block. Place Front Cover Seal Installer (J-22248) in front cover seal area. Remove pulley from vibration damper. Reverse removal procedure for remaining components. Install all retaining bolts. Pry seal from front cover. Installation Soak lifter assembly in engine oil prior to installation. ENGINE FRONT COVER Removal 1) Disconnect negative battery cable. Inspection Inspect lifter and camshaft mating surfaces for wear. Installation 1) Ensure all gasket surfaces are clean. Internal components cannot be interchanged. Use . Remove gasket from oil pan. See FRONT COVER OIL SEAL in this article.29 mm. Reverse removal procedure for installation. Lubricate vibration damper retaining bolt with oil prior to installation. Remove drive belts. Apply engine oil on seal-to-oil pan contact areas.2L the information is not available from manufacturer. Replace front section of oil pan seal with similar section fabricated from new seal. Install gasket on cylinder block. remove lifter. Remove alternator and A/C compressor bracket (if equipped). Apply sealing compound on both sides of front cover gasket. HYDRAULIC VALVE LIFTER Removal Remove cylinder head. Replace parts as necessary.0L the Valve Spring Installed Height Specification is 1. Install lifter in original location. Pry crankshaft oil seal from cover.VALVE SPRING Valve springs can be removed without removing cylinder head. FRONT COVER OIL SEAL 1) Remove vibration damper. Valve Spring Installed For 4.625 inches or 41. Lifter bore diameter should be within . 2) Coat seal with RTV sealant and place in position. remove vibration damper and key.025 mm). 3) Place front cover on cylinder block. 4) Install front cover oil seal. Ensure oil slinger is installed on crankshaft. Using Lifter Remover/Installer (J-21884). Remove front cover seal installer.9065" (22. For the 4. Remove vibration damper retaining bolt and washer. Remove tabs.

Remove engine front cover. Remove oil slinger. Install camshaft sprocket bolt. 3) Install key in crankshaft (if removed). 4. See Fig. 4. 2) Remove camshaft sprocket bolt. Tap seal into front cover. 4: Timing Chain & Sprocket Alignment Courtesy of Chrysler Motors. Install vibration damper. Install new front cover oil seal. Reverse removal procedure for remaining components. Tighten to specification. Installation Install timing chain and sprockets.care not to damage seal area. Lightly coat crankshaft with oil. Tighten bolts to specification. Rotate crankshaft until timing marks on sprockets are aligned. CAMSHAFT . Remove timing chain and both sprockets as an assembly. Lubricate vibration damper bolt with oil. Lightly coat seal contact area of vibration damper with oil. Ensure timing marks are aligned. See Fig. TIMING CHAIN & SPROCKET Removal 1) Drain cooling system. See ENGINE FRONT COVER in this article. Fig. Place front cover seal installer on front of crankshaft. Install retaining bolt and washer. 2) Apply sealant to seal outer diameter. Position new seal on Front Cover Seal Installer (J-22248) with lip facing outward. Remove radiator.

Remove radiator. Installation 1) Ensure ring end gap and side clearance are within specification. Position ring end gaps at specified areas. Carefully remove camshaft. PISTON & ROD NOTE: Mark piston cylinder location for reassembly reference. Installation Lubricate camshaft and install into place. Oil squirt holes in connecting rod must face camshaft side of engine. Replace if not within specification. Reverse removal procedure to complete installation. Install pistons in original cylinder location. Remove oil pan. 5. CAUTION: Arrows on top of piston must point toward front of engine. Remove bearing cap. Remove fuel pump (if equipped with mechanical pump). Install rings on piston.Removal 1) Drain cooling system. See ENGINE SPECIFICATIONS tables. See Fig. ignition wires and distributor. 3) Remove engine front cover. Ring gaps may vary 20 degrees from positions illustrated. See CYLINDER HEAD in this article. Inspection Inspect camshaft for flaking. Remove front bumper and grille (if necessary). 2) Remove cylinder head. Camshaft Bearing Replace camshaft bearings using camshaft bearing remover/installer. Remove hydraulic lifters. 2) Mark connecting rod and piston for cylinder identification. Use care not to damage camshaft bearings. Removal 1) Remove cylinder head. See CYLINDER HEAD in this article. lobe wear or worn bearing journals. Discharge A/C system if necessary. See OIL PAN REMOVAL at end of ENGINE section. Using Lifter Remover/Installer (J-21884). Remove ridge or deposits from cylinder bore. Tighten bolts to specification. Ensure oil holes are aligned after installation. Remove A/C condenser and receiver assembly (if equipped). remove lifters. OIL PAN See OIL PAN REMOVAL at end of ENGINE section. See ENGINE FRONT COVER in this article. . Remove piston and rod assembly. See ENGINE SPECIFICATIONS tables. Remove timing chain and sprockets. Mark lifter location for reassembly reference.

5: Positioning Piston Ring Gaps Courtesy of Chrysler Motors 2) Lubricate piston assembly and cylinder block.Fig. Install piston assembly. Arrows on top of piston must face toward front of engine and connecting rod oil squirt hole should face camshaft side of .

02) Piston Pin Bore Diameter ..8775 (98. Piston pin cannot be reused after removal. ......... 3..7533 (95.... 6.........632-23. See Fig........... Fitting Pistons 1) Determine cylinder taper.. ..488) 4. See CYLINDER...... NOTE: Rod must be positioned on the piston so the oil squirt hole faces the camshaft side of the engine when piston is installed with arrow toward the front of the engine...095) Pin Bore .. Replace components if not within specification. wear and out-of-roundness and piston clearance. Press piston pin from piston... Insert piston pin through the upper piston pin bore and into connecting rod pin bore..083-56.... ..616) Cylinder Bore Diameter 4..644) Piston-to-Cylinder Clearance ....334) Out-of-Round .. For cylinder specifications.... CYLINDER... Note location of piston pin through gauge window.......                                                                                                                                   ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡                                                                                                                        ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡  PISTON PIN In.. see CYLINDER.252-95......... Place assembly on support... Mark fitted piston for cylinder location.. piston bore and connecting rod bores.. Inspection Measure piston pin diameter.043) NOTE: Removal Position piston on Support (J-21872-1).9308-............ See Fig... .. Pin Pilot (J-21872-2) and Driver (J-21872-3) on an arbor press.... Installation 1) Insert pin pilot through piston and connecting rod.. Check oil clearance and connecting rod side play clearance......... Reverse removal procedure for remaining components...9288-. Compare reading to cylinder bore to determine clearance...0L ........022-.2L .. If taper or out-of-roundness are not within specification. 6...... PISTON & ROD SPECIFICATIONS table........engine.....427-98.......... ..591-23... Tighten bolts to specification. Piston pin should gravity-fall through the piston at room temperature......001 (.. hone or bore cylinders for installation of new pistons..001 (.7501-3...02) Taper .. .9309 (23.... 2..2080-2..9304-...2085 (56...... NOTE: Piston and pin must be at standard room temperature when measuring fit..9298 (23. 2) Measure piston at right angle of the piston pin at the center line of the pin.9313 (23.. ......8751-3........ (mm) Note direction of arrows on piston and oil squirt hole in connecting rod location prior to removal..642-23. 3) Install bearings.......0017 (.0009-.655) Piston Pin Diameter . 3... PISTON & ROD SPECIFICATIONS TABLE Application Connecting Rod Crankshaft Bore .......... PISTON & ROD SPECIFICATIONS table.

3) Piston pin installation requires a 2000 lb. .792 mm). ¢ . Remove piston and connecting rod. Replace connecting rod if noticeably less effort is encountered.Fig. 2) Position driver inside pin. Pin should be centered in rod 0312" (. Using arbor press. (906 kg) press fit. press pin through rod and piston bores until pilot indexes with mark on support. 6: Piston Pin Removal & Installation Courtesy of Chrysler Motors.

Reverse removal procedure for remaining components.02 mm) difference in size. Tighten bolts to specification. Install bearings. Mark bearing cap and connecting rod. Installation 1) Note color code on edge of bearings removed. Check crankshaft end play. different sized upper and lower bearings may be installed to obtain correct oil clearance. Tighten bolts to specification. Removal Remove oil pan. Replace bearings as necessary to obtain correct clearance. NOTE: Crankshaft main bearing journal diameters are indicated by a color code. Rotate crankshaft to ensure freedom of movement. 2) If required. Using Plastigage method. Rotate crankshaft to remove bearings. Check rod side play. Tighten bolts to specification. See OIL PAN REMOVAL at end of ENGINE section. Check oil clearance after bearing installation.ROD BEARING NOTE: Crankshaft journal diameters are indicated by a color coded mark placed on the adjacent counterweight or cheek toward the flanged (rear) end of crankshaft. . See CRANKSHAFT END PLAY in this article. odd sized bearings must all be uniform in location (upper or lower). Installation 1) Note color code on edge of bearings removed. check bearing clearances. NOTE: If different sized bearings are used. check bearing clearances. 3) Tighten bolts to specification.001" (. MAIN BEARING Removal Remove oil pan. Bearings are available in standard and undersize applications. Check oil clearance after bearing installation. 2) Replace bearings as necessary to obtain correct clearance.001" (. Note color code on edge of bearing. Ensure main bearing caps are marked for location. See OIL PAN REMOVAL at end of ENGINE section. Remove bearing cap.02 mm). Push piston and rod assembly up to remove upper bearing. Note color code to determine proper bearing usage. different sized upper and lower bearings may be installed to obtain correct oil clearance. DO NOT use bearings with a thickness difference exceeding . Color code is placed on the adjacent cheek toward the flanged (rear) end of crankshaft for all except the rear main. Rear main is color coded on the rear flange. Rotate crankshaft to position rod to be serviced at bottom of stroke. NOTE: Avoid combining bearing inserts in excess of . If required. Install bearings. Reverse removal procedure for remaining components. Rotate crankshaft to ensure freedom of movement. Remove bearing cap with bearing. Bearings are available in standard and undersize application. Ensure caps are installed in original location with arrow on cap facing toward front of engine. Using Plastigage method. Note color code to determine proper bearing usage.

4) Install rear main bearing cap. 7: Installing Rear Main Bearing Oil Seal Courtesy of Chrysler Motors. See Fig. Ensure no sealer is applied on seal lip. WATER PUMP .Crankshaft End Play 1) Using dial indicator. 2) Replace thrust bearing if required. Remove seal from bearing cap. Lightly coat all seal lips with engine oil. Note direction of seal lip installation. See ENGINE SPECIFICATIONS table. Recheck end play. 3) Install lower seal into bearing cap with lip facing toward front of engine. Coat seal-to-block contact areas with liquid soap. When replacing thrust bearing. REAR MAIN OIL SEAL Removal 1) Remove oil pan. check crankshaft end play. Loosen all remaining main bearing cap bolts. Inspect crankshaft thrust surfaces or thrust bearing for wear if not within specification. pry crankshaft forward then reward prior to tightening main bearing cap to specification. Installation 1) Clean crankshaft seal surface. Install upper seal into block with lip facing toward front of engine. Remove rear main bearing cap. CAUTION: DO NOT apply Silicone sealer on cap-to-block contact surfaces. 7. Ensure seal is firmly seated in bearing cap. Remove seal. 2) Using a brass drift. tap upper seal around crankshaft until seal protrudes enough to permit removal with pliers. See Fig. See OIL PAN REMOVAL in this section. Tighten main bearing cap bolts to specification. Apply liquid soap on seal-tocap contact surfaces. Sealer should only be applied to chamfered edges only. 7. Fig. Apply Silicone sealer to chamfered edges of bearing cap. Replace crankshaft if not within specification. 2) Apply Silicone sealer on both sides of lower seal tabs.

2L) or 5 qts. Remove fan shroud. Oil is supplied through the full-flow oil filter and into an internal oil passage.2L with oil filter change. ENGINE OILING SYSTEM Engine lubrication is provided by the distributor driven gear-type oil pump. LUBRICATION CRANKCASE CAPACITY Crankcase capacity for 4.Removal Drain cooling system. Cooling System Air Purge (Vehicles W/Coolant Recovery) Fill system to proper level. Place heater control to "HEAT" position and temperature control to "WARM" or "HIGH" position. Disconnect radiator and heater hoses from pump. Operate engine to normal operating temperature with radiator cap removed. Minimum oil pressure should be 13 psi (.0L is 5 1/2 qts. Tighten bolts to specification. Place heater control to "HEAT" position and temperature control to "WARM" or "HIGH" position. Remove power steering bracket from water pump. Fill and purge air from cooling system. NOTE: It may be necessary to remove heater hose to remove trapped air if system cannot be purged using following procedures. Ensure pump turns freely. Remove water pump and gasket. Reverse removal procedures. Valve is nonadjustable and serviced as an assembly. OIL PRESSURE REGULATOR VALVE Oil pressure regulator valve is located in pump body. Oil is supplied to rocker arms from the hydraulic lifters and through the push rods. Remove fan assembly. Add coolant to recovery bottle. Install coolant caps. (5. Installation Ensure gasket surfaces are clean. Remove £ £ .6-5. Install water pump. NOTE: For further information on cooling systems. Shut off engine and allow system to cool. Repeat procedure to obtain correct coolant level. Remove electric cooling fan (if equipped). OIL PUMP Removal Remove oil pan. Cooling System Air Purge (Vehicles W/O Coolant Recovery) Fill system to proper level.9 kg/cm ) at 600 RPM. see appropriate article in the ENGINE COOLING section. Add necessary coolant and install radiator cap. Remove drive belt(s). NORMAL OIL PRESSURE Normal oil pressure should be 37-75 psi (2. Oil is then routed to camshaft and crankshaft bearings. Operate engine to normal operating temperature. Internal passage provides oil to the lifter bores. (4.3 kg/cm ) maximum above 1600 RPM.7L) for 4. See OIL PAN REMOVAL in this section.

install pick-up pipe. Apply Permatex No.oil pump retaining bolts. Tighten bolts to specification.. See OIL PUMP SPECIFICATIONS table.. Place straightedge across gears and pump body. Different diameter valves may be used. CAUTION: DO NOT move oil pick-up pipe in pump body. Tighten retaining bolts to specification. ensure replacement valve is the same diameter as that removed.. 2 to pick-up pipe prior to installation. Ensure pick-up pipe support bracket is aligned with pump cover bolt.002-... determine thickness feeler gauge which fits snugly between straightedge and gears.004 (.. Repair as necessary if not within specifications. (mm) .. Apply Loctite on pump cover area.. 3) Install oil pump and new gasket...004-. Disassembly & Inspection 1) Disassemble pump. 8: Exploded View of Oil Pump Assembly Courtesy of Chrysler Motors. Fig. Gear-to-Body Clearance .. See Fig..10-. If oil pick-up pipe is moved. Install cover and bolts. insert feeler gauge between gear tooth and inner wall of pump body to check gear-to-body clearance. Replace components if wear or binding exists. Check pressure regulator valve for wear or binding in pump body.05-. Reassembly & Installation 1) Reverse procedures for reassembly and installation. Using Pipe Installer (J-21882). OIL PUMP SPECIFICATIONS TABLE Application Gear End Clearance . pick-up pipe must be replaced to ensure an airtight seal.008 (. Using feeler gauge.. 8. Use feeler gauge and straightedge to check gear end clearance.. Check pump gears for freedom of rotation. 3) Compare measurements to specification.. 2) Fill gear cavity with petroleum jelly prior to installing cover. 2) With gears installed in pump body. Rotate gears and measure clearance at each gear tooth.                                                                                                       ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡                                                                                                        ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡  TORQUE SPECIFICATIONS TABLE In..20) .10) . CAUTION: If pressure regulator valve is replaced.

...................................................... 20 (27) Cylinder Head Bolt 4........ 23 (31) Exhaust Manifold Bolts 6-7 ...... 23 (31) Main Bearing Cap Bolt Step 1 .................. ( 1) 80 (109) Water Pump Bolts ..... 40 (54) Step 2 .. 17 (23) Oxygen Sensor ......... 30 (41) 4.......... 10 (14) Long ..................................... 20 (27) Intake & Exhaust Manifold Bolt 4....................................................................................... 84 (9) 5/16" X 18 ............... 60 (7) Studs ............................................ 70 (95) Step 3 ............................................. 55 (5) (1) .........................................................2L .............................................m)                                                                                                                       ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡  In.................................................... (N................... 17 (23) Exhaust Manifold Bolts 8-11 .......... 33 (45) Crankshaft Pulley-to-Damper Bolt ..... 35 (47) Rocker Arm Bolt ..2L No..... 13 (18) INCH Lbs.........0L No..........m) Engine Front Cover Bolt . 192 (22) Oil Pan Bolt 1/4" X 20 .... 23 (31) Exhaust Manifold Bolts 12-13 ......................TORQUE SPECIFICATIONS TABLE Application Camshaft Sprocket Bolt ............................. 100 (135) All Others ................. 85 (115) Exhaust Pipe-to-Manifold Bolt .... 11 ..........................0L Displacement                                                                                                                       ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡                                                                                                                        ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡  ENGINE SPECIFICATIONS GENERAL ENGINE SPECIFICATIONS Ft.............. 75 (102) All Others ........................ 80 (109) Oil Pump Attaching Bolt Short . 20 (27) Fan & Hub Bolt ....... Lbs.. 11 .................. 19 (26) Vibration Damper Bolt ........................................ 132 (15) Oil Pump Cover Bolt .................................Clean and lubricate with oil prior to tightening......................... 80 (109) Connecting Rod Cap Nut ............................ (N..................................... 105 (142) Fuel Rail Bolt ............0L Exhaust Manifold Bolts 1-5 ............. (mm) ...... 70 (8) Valve Cover Bolt ........ 110 (149) 4...... GENERAL SPECIFICATIONS TABLE Application 4............... 18 (24) Flywheel-to-Crankshaft Bolt .............................................................

08) Valve Lift ...............001-..................................312 (7......... 45 Seat Angle .... ...001-.... ...............................................5 Seat Width ... 1... 242 Liters .....424 (10........................92) Stem Clearance ............................2:1 Bore ...3725 (9.................................... . 112 @ 3000 Torque Ft...............424 (10........................ 44 Seat Angle .............. ............4) Stroke ....................... 4.............060 (1...46) Stem Clearance .........001-................ 9.......29) 4.........060 (1.....................03-....50 (38...52) Stem Diameter . 1.. 220 @ 2500 Compression Ratio ................ 210 @ 2000 Compression Ratio .. In...... .....312 (7............. ( 1) ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤                                                                                                                       ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡  VALVE SPECIFICATIONS                                                                                                                       ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡  In...52) Stem Diameter ..... ..........060 (1...003 (............. .........405 (10.. ...........................02-1......................................... ..............................6-35..@RPM ..76) Valve Spring Height Installed ....... 44................405 (10. ...29) Valve Spring Height Installed ..91 (48.8) Face Angle ....... 3... 45 Seat Angle ....... HP@RPM ........5 Seat Width ....... ..Cu...... Lbs...... 1. 3..060 (1....08) Valve Lift ... 2-Bbl..... 1......76) Exhaust Head Diameter .03-.............................................08) Valve Lift ......9) VALVES SPECIFICATIONS TABLE Application 4.....040-.............................................003 (........46) Stem Clearance ........02-1........78-1............75 (95.... . 3......................................44-9......................... (mm) .625 (41............003 (...........0 Fuel System ... In......................2:1 Bore ..............3-45........... 44................................. 173 @ 2500 Torque Ft............ .. ........0L Intake Head Diameter ..90 (98..............92) Stem Clearance ..41 (35... ..........02-1...... 44....5) Face Angle ..............2L Intake Head Diameter .........................3715-................................. 29 Seat Angle .........52) Stem Diameter .. Lbs....................88 (98....040-................ 3.... 1.02-1............ 4..... 258 Liters ....52) Stem Diameter ..........2 Fuel System ..3725 (9.......3) Stroke ........................001-..................79 (45.... 9...003) Valve Lift ..44-9..2L Displacement Cu.....3715-....................040-....03-...................003 (..........51) Face Angle ........03-....5 Seat Width ....29) Exhaust Head Diameter ......................@RPM ....... ....40-1........040-.44 (87........... .............................. 30 Seat Width .10) Face Angle .........4) 4... MPI HP@RPM .......... .......................

...... 2 End Gap ..0L Pressure (1)                                                                                                                       ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡  PISTON/PIN/RING SPECIFICATIONS                                                                                                                       ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡                                                                                                                        ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡  BEARING SPECIFICATIONS In.......64) Side Clearance ..........019-2....65) Connecting Rod Bearings Journal Diameter ....0032 (........... .....253 (6.. 3 End Gap ........ (mm)                                                                                                                       ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡                                                                                                                        ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡  CAMSHAFT SPECIFICATIONS In..03-...25-....0010-......03-.5001 (63......4996-2....064) Thrust Bearing .....48) CAMSHAFT TABLE Application Clearance .77-50........009-2......0003-. 2....003 (... 2....... (mm)                                                                                                                       ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡                                                                                                                        ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡  VALVE SPRING SPECIFICATIONS In.56) No..............010-........08) Side Play ..... No.......... . 1....43) Journal Diameter No............03-..003 (.... Press Fit Rings Ring No....0025 (..03-51...25-....... .......013) Rod Fit ............ ..010-.. ...043) Pins Piston Fit ....029-2... 2............. ......0009-..001-....023-...........05) No..80) VALVE SPRINGS TABLE Application 4..043-... .0005 (.081) Ring No.(1) ..008-.................0015-.999-2............. (mm)                                                                                                                       ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡  In.......0017 (. (mm) ........... ...020 (51....54-51....... 1 & No... ........................50) Clearance .........51) Side Clearance ...28-51...... 2.030 (51.. .020 (... 2 .............010 (51...001-..019 (.25-.0934-2.....001-. 4 ..Specification not provided from manufacturer...010-..........17-53..025 (.................020) CRANKSHAFT MAIN & CONNECTING ROD BEARINGS TABLE Application Main Bearings Journal Diameter .......... PINS & RINGS TABLE Application Piston Clearance .0955 (53...008 (..31) No.... 3 Crankshaft End Play ......08) Lobe Lift ................ 3 ..... 1 .......23) Clearance ..000 (50.. PISTONS.49-63...0065 (.038-1....03-.... 2........ ..... .0017-.............

.. @ In..Valve Closed ...... 188-202 @ 1........ 1.....2L Pressure (1) Valve Closed ...23) 4........99 (50.............5) Valve Open ......5) Valve Open ... 66-74 @ 1.. (Kg @ mm)......................5) (1) .......625 (30-34 @ 45...41 (85-92 @ 35.                                                                                                                       ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡  ..Lbs..48) Free Length ............... 1.... 64-72 @ 1...79 (29-33 @ 45..8) Free Length . 205-220 @ 1..20 (91-100 @ 30......82 (46..