Jeep Wrangler JK (07-10) Torque Sheet
Content
FRONT SUSPENSION DESCRIPTION Shock Absorber Upper Nut Shock Absorber Lower Nut Suspension Arm Lower Axle Bracket Nut Suspension Arm Lower Frame Bracket Nut Suspension Arm Upper Axle Bracket Nut/Bolt Suspension Arm Upper Frame Bracket Bolt Stabilizer Bar Retainer Bolts Stabilizer Bar Link Upper Nut Stabilizer Bar Link Lower Bolt Track Bar Frame Bracket Nut Track Bar Axle Bracket Bolt Hub/Bearing Bolts Hub/Bearing Axle Nut Jounce Cup Bolt Drag link to Knuckle (Right Side) Drag link to Knuckle Axle Shaft Nut Wheel speed sensor
N·m 27 76 169 169 102 102 61 102 102 169 169 102 136 42 74 74 136 4-6
Ft. Lbs. 20 56 125 125 75 75 45 75 75 125 125 75 100 31 55 55 100 —
In. Lbs. — — — — — — — — — — — — — — — — — 34-50
REAR SUSPENSION DESCRIPTION Shock Absorber Upper Bolts Shock Absorber Lower Nut Suspension Arm Lower Axle Bracket Nut Suspension Arm Lower Frame Bracket Bolt Suspension Arm Upper Axle Bracket Bolt Suspension Arm Upper Frame Bracket Bolt Stabilizer Bar Retainer Bolts Stabilizer Bar Link Nut/Bolt Stabilizer Bar to Link Nut
N·m 50 76 169 169 169 169 61 102 90
Ft. Lbs. 37 56 125 125 125 125 45 75 66
In. Lbs. — — — — — — — — —
Track Bar Frame Bracket Nut Track Bar Axle Bracket Bolt
169 169
125 125
— —
PROPELLER SHAFT DESCRIPTION Front Shaft - Axle Flange Bolts Front Shaft - Transfer Case Flange Bolts Rear Shaft - Axle Flange Bolts Rear Shaft - Transfer Case Flange Bolts
N·m 110 20 20 20
Ft. Lbs. 81 15 15 15
In. Lbs. -
FRONT AXLE - 186FBI DESCRIPTION Axle Ratio Ring Gear Backlash Pinion Torque To Rotate - Original Bearings Pinion Torque To Rotate - New Bearings Differential Total Torque To Rotate: Pinion Torque To Rotate Plus DESCRIPTION Fill Hole Plug Differential Cover Bolts Bearing Cap Bolts Ring Gear Bolts Pinion Bearing Nut Min - Max Axle Nut Hub Bearing Bolts N·m 34 41 61 108 217 - 542 136 102
SPECIFICATION 3.21, 4.10 0.12 - 0.20 mm (0.005 - 0.008 in.) 1.13 - 2.26 N·m (10 - 20 in. lbs.) 2 - 3.4 N·m (15 - 30 in. lbs.) 0.79 - 1.24 N·m (7 - 11 in. lbs.) Ft. Lbs. 25 30 45 80 160 - 400 100 75 In. Lbs. -
FRONT AXLE - 216FBI DESCRIPTION Axle Ratio Ring Gear Backlash Pinion Torque To Rotate - Original Bearing Pinion Torque To Rotate - New Bearing Total Torque To Rotate: Pinion Torque To Rotate plus DESCRIPTION Fill Plug Differential Cover Bolts Bearing Cap Bolts Pinion Nut Ring Gear Bolts Axle Nut Hub Bearing Bolts N·m 34 41 108 217-271 136 136 102
SPECIFICATION 4.1 0.12 - 0.20 mm (0.005 - 0.008 in.) 1 - 2 N·m (10 - 20 in. lbs.) 2 - 4.5 N·m (20 - 40 in. lbs.) 0.79 - 1.24 N·m (7 - 11 in lbs) Ft. Lbs. 25 30 80 160-200 100 100 75 In. Lbs. -
REAR AXLE - 198RBI DESCRIPTION Axle Ratio Ring Gear Backlash Pinion Torque To Rotate - Original Bearings Pinion Torque To Rotate - New Bearings Total Torque To Rotate: Pinion Torque To Rotate plus DESCRIPTION Differential Cover Bolts Bearing Cap Bolts Ring Gear Bolts Pinion Nut Axle Retainer Nuts N·m 41 77 136 271 - 475 61
SPECIFICATION 4.1 0.12 - 0.20 mm (0.005 - 0.008 in.) 1 - 2 N·m (10 - 20 in. lbs.) 2 - 4 N·m (20 - 35 in. lbs.) 0.79 - 1.24 N·m (7 - 11 in. lbs.) Ft. Lbs. 30 57 100 200 - 350 45 In. Lbs. -
REAR AXLE - 226RBI DESCRIPTION Axle Ratio Ring Gear Backlash Pinion Torque To Rotate - Original Bearings Pinion Torque To Rotate - New Bearings Total Torque To Rotate: Pinion Torque To Rotate plus DESCRIPTION Fill Hole Plug Differential Cover Bolts Bearing Cap Bolts Ring Gear Bolts Pinion Nut Axle Retainer Nuts N·m 34 41 108 136 217 - 271 61
SPECIFICATION 3.21, 4.10 0.12 - 0.20 mm (0.005 - 0.008 in.) 1 - 2 N·m (10 - 20 in. lbs.) 2 - 4.5 N·m (20 - 40 in. lbs.) 0.79 - 1.24 N·m (7 - 11 in. lbs.) Ft. Lbs. 25 30 80 100 160 - 200 45 In. Lbs. -
BRAKE COMPONENTS DESCRIPTION Disc Brake Caliper Type Front Disc Brake Rotor Type Rear Disc Brake Rotor Type Front Disc Brake Rotor Diameter Rear Disc Brake Rotor Diameter Front Ventilated Disc Brake Rotor Rear Solid Disc Brake Rotor Front Ventilated Disc Brake Rotor Rear Solid Disc Brake Rotor Front Ventilated Disc Brake Rotor Rear Solid Disc Brake Rotor Brake Booster Type DESCRIPTION N·m
SPECIFICATION Sliding Ventilated Solid 302 x 28 mm (11.89 x 1.10 in.) 312 x 12 mm (12.28 x 0.472 in.) Max. Runout 0.10 mm (0.0039 in.) Max. Runout 0.102 mm (0.004 in) Max. Thickness Variation 0.009 mm (0.00035 in.) Max Thickness Variation 0.018 mm (0.0007 in) Min. Thickness 22.7 mm (0.8937 in.) Min. Thickness 11.00 mm (0.433 in.) Tandem Diaphragm Ft. Lbs. In. Lbs.
Brake Booster Mounting Nuts Master Cylinder Mounting Nuts Booster Mounting Plate Master Cylinder Brake Lines Front Caliper Adapter Mounting Bolts Rear Caliper Adapter Mounting Bolts Front Caliper Brake Hose Banjo Bolt Rear Caliper Brake Hose Banjo Bolt Front Caliper adapter Rear Caliper adapter Parking Brake Lever Bracket Bolts
25 17 18 19 35 35 31 31 163 75 12
18 13 — 14 26 26 23 23 120 55 9
— 151 159 168 — 220 — — — — —
CLUTCH DESCRIPTION Pressure Plate Bolts 2.8L Pressure Plate Bolts 3.8L Flywheel Bolts - 2.8L Flywheel Bolts - 3.8L Slave Cylinder Nuts Dust Shield Bolts Crossmember Frame Bolts
N·m 31 50 95 81 23 50 41
Ft. Lbs. 23 37 70 60 17 37 30
In. Lbs. -
COOLING SYSTEM DESCRIPTION Bolt, Block Heater Bolts, Condenser to Radiator Electric Fan to Fan Shroud bolts Bolts, Fan Blade Assembly to Viscous Drive - Diesel Viscous Fan Drive Diesel Bolts, Fan Shroud to Radiator Mounting Bolts, Radiator Upper Isolator to Crossmember Bolts, Thermostat Housing-
N·m 2 6 23 50 8 9 28
Ft. Lbs. -
In. Lbs. 17 53
37 -
210 70 80 250
Bolts, Water Pump 3.8L 2.8L
12 23
-
105 200
3.8L ENGINE DESCRIPTION Engine Type Number of Cylinders Displacement 3.8L Bore 3.8L Stroke Compression Ratio 3.8L Firing Order Compression Pressure-Minimum Cylinder Compression (Max. Difference Between Cylinders CYLINDER BLOCK DESCRIPTION Cylinder Bore Diameter (Standard) 3.8L Out of Round (Service Limits) Taper (Service Limits) Lifter Bore Diameter Deck Surface Flatness (Max.) CRANKSHAFT DESCRIPTION Connecting Rod Journal Diameter Main Bearing Journal Diameter Journal Out-of-Round (Max.) Journal Taper (Max.) End Play Wear Limit Main Bearing Diametrical Clearance 1-2-3-4 Wear Limit CONNECTING RODS DESCRIPTION Bearing Clearance Wear Limit Side Clearance Wear Limit PISTONS DESCRIPTION Piston Diameter 3.8L-Measured 33.01 mm (1.30 in) From Piston Top Clearance in Bore @ Size Location (New)
METRIC 60° V-6 Engine 6 3.8 Liters 96.0 mm 87 mm 689.5 kPa -
STANDARD 231 cu. in. 3.779 cu.in. 3.425 in. 9.6:1 1-2-3-4-5-6 100 psi. 0.25
METRIC 95.993-96.007 mm 0.076 mm 0.051 mm 22.980-23.010 mm 0.1 mm METRIC 57.979-58.005 mm 63.993-64.013 mm 0.025 mm 0.025 mm 0.09-0.24 mm 0.381 mm 0.011-0.055 mm 0.076 mm METRIC 0.019-0.065 mm. 0.074 mm 0.13-0.32 mm 0.38 mm METRIC 95.968-95.998 mm. -0.005-0.039 mm
STANDARD 3.7792-3.780 in. 0.003 in. 0.002 in. 0.905-0.906 in. 0.004 in. STANDARD 2.2827-2.2837 in. 2.5194-2.5202 in. 0.001 in. 0.001 in 0.0036-0.0095 in. 0.015 in. 0.0005-0.0022 in. 0.003 in. STANDARD 0.017-0.020 in. 0.003 in. 0.005-0.013 in. 0.015 in. STANDARD 3.778-3.779 in. -0.0002–0.0015 in.
Weight 3.8L PISTON PINS DESCRIPTION Type Clearance in Piston @ 21C (70°F) Clearance in Connecting Rod Diameter Length 3.8L PISTON RINGS DESCRIPTION Ring End Gap Top Compression Ring Second Compression Ring Oil Control (Steel Rails) Wear Limit-Compression Rings Wear Limit-Oil Control Steel Rails Ring Side Clearance Top Compression Ring 3.8L Second Compression Ring 3.8L Oil Ring (Steel Ring) Wear Limit- Top Ring Wear Limit-2nd Ring Wear Limit Oil Ring Pack Ring Width-Top Compression Ring 3.8L Ring Width-2nd Compression Ring 3.8L Ring Width-Oil Ring (Steel Rails) 3.8L CAMSHAFT DESCRIPTION Journal Diameter #1 #2 #3 #4 Bearing Clearance-Diametrical Bearing Clearance (Max.Allowable) End Play Camshaft Bearing Diameter #1 #2 #3 #4
426 ± 5 grams METRIC Press Fit in Rod (Serviced as a Assembly) 0.006-0.019 mm Interference Fit 22.87-22.88 mm 71.25-71.75 mm METRIC 0.18-0.38 mm 0.28-0.57 mm 0.23-0.78 mm 1.0 mm 1.88 mm
15.03 ± 0.1764 oz. STANDARD 0.0002-0.0007 in. 0.9007-0.9009 in. 2.805-2.824 in. STANDARD 0.007-0.015 in. 0.011-0.022 in. 0.009-0.030 in. 0.039 in. 0.074 in.
0.030-0.069 mm 0.041-0.085 mm 0.039-0.200 mm 0.10 mm 0.13 mm 0.266 mm 1.175-1.190 mm 1.46-1.49 mm 0.435-0.510 mm
0.0012-0.0027 in. 0.0016-0.0033 in. 0.0015-0.0078 in. 0.004 in. 0.005 0.009 0.0462-0.0468 0.0575-0.058 in. 0.017-0.020
METRIC 50.724-50.775 mm 50.317-50.368 mm 49.936-49.987 mm 49.530-49.581 mm 0.025-0.101 mm 0.127 mm 0.254-0.508 mm 50.800-50.825 50.393-50.419 mm 50.013-50.038 mm 49.606-49.632 mm
STANDARD 1.997-1.999 in. 1.9809-1.9829 in. 1.9659-1.9679 in. 1.9499-1.9520 in. 0.001-0.004 in. 0.005 in. 0.010-0.020 in. 1.9999-2.0009 in. 1.9839-1.9849 in. 1.9690-1.9699 in. 1.9529-1.954 in.
Exhaust Valve Timing Closes-3.8L (ATDC) Opens-3.8L (BBDC) Duration-3.8L Intake Valve Timing Closes-3.8L (ABDC) Opens-3.8L (ATDC) Duration-3.8L Valve Overlap-3.8L HYDRAULIC LIFTER DESCRIPTION Type Outside Diameter Clearance in Block CYLINDER HEAD DESCRIPTION Gasket Thickness (Compressed) VALVES DESCRIPTION Face Angle-Intake Face Angle-Exhaust Head Diameter-Intake Head Diameter-Exhaust Valve Lift (Zero Lash)-Intake and Exhaust-3.8L Valve Length-Intake Valve Length-Exhaust Valve Stem to Tip Height (valve tip to spring seat washer)-Intake Valve Stem to Tip Height (valve tip to spring seat washer)Exhaust VALVE SEAT DESCRIPTION Angle Run Out (Service Limits) Width-Intake and Exhaust VALVE GUIDE DESCRIPTION Guide Bore Diameter (Std.) VALVE MARGIN DESCRIPTION Intake Exhaust VALVE STEM DIAMETER DESCRIPTION
METRIC Hydraulic Roller 22.949-22.962 mm 0.020-0.061 mm METRIC 0.65-0.75 mm METRIC 47.87-48.13 mm 35.37-35.63 mm 11.0 mm 125.84-126.6 mm 127.20-127.96 48.1-49.7 mm 48.53-50.09 mm
18° 46° 244° 63° 1° 242° 17° STANDARD 0.903-0.904 in. 0.0007-0.0024 in. STANDARD 0.0007-0.0024 in. STANDARD 45-45.5° 45-45.5° 1.88-1.89 in. 1.39-1.40 in. 0.433 in. 4.95-4.98 in. 5.00-5.04 in. 1.89-1.95 in. 1.91-1.97 in.
METRIC 0.0762 mm 1.50-2.00 mm METRIC 6.975-7.00 mm METRIC 0.825-0.973 mm 1.565-1.713 mm METRIC
STANDARD 44.5-45° 0.003 in. 0.057-0.078 in. STANDARD 0.274-0.275 in. STANDARD 0.032-0.038 in. 0.061-0.067 in. STANDARD
Intake (Standard) Exhaust (Standard)
6.935-6.953 mm 6.906-6.924 mm
0.2718-0.2725 in. 0.2718-0.2725 in. STANDARD 0.001-0.0025 in. 0.002-0.0037 in. 0.010 in. 0.016 in.
VALVE STEM TO GUIDE CLEARANCE DESCRIPTION METRIC Intake 0.025-0.065 mm Exhaust 0.059-0.094 mm Max Allowable-Intake (Rocking 0.247 mm Method) Max Allowable-Exhaust 0.414 mm (Rocking Method) PUSH RODS DESCRIPTION Length VALVE SPRING DESCRIPTION Free Length-Type A Free Length-Type B Wire Diameter Type A Wire Diameter Type B Number of Coils Type A Number of Coils Type B Spring Tension (Valve Closed) Type A Spring Tension (Valve Open) Type A Spring Tension (Valve Closed) Type B Spring Tension (Valve Open) Type B Installed Height METRIC 135.438 mm METRIC 51.4 mm 53.4 mm 3.95-4.77 mm 4.19-4.29 mm 7.52 7.25 376.4-424.4 N @ 41.9 mm 863.9-959.9 N @ 41.9 mm 377-423 N @ 41.9 mm 880-962 N @ 30.91 mm 41.1-42.7 mm
STANDARD 5.33 in. STANDARD 2.02 in. 2.10 in. 0.15-0.19 in. 0.16-0.17 in. 84.6-95.6 lbs. @ 1.65 in. 194.2-215.8 lbs. @ 1.65 in. 84.8-95.2 lbs. @ 1.65 in. 197.9-216.3 lbs. @ 122 in. 1.61-1.68 in
LUBRICATION DESCRIPTION METRIC STANDARD At Curb Idle Speed* (Minimum 34.47 kPa 5 psi with engine at operating temperature) At 3000 RPM 205-551 kPa 30-80 psi Oil Filter By-Pass Valve Setting 62-103 kPa 9-15 psi Oil Pressure Switch Actuating 14-28 Kpa 2-4 psi Pressure CAUTION: *If pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm. OIL PUMP DESCRIPTION Clearance Over rotors-Inner and Outer Cover Out-Of-Flat (Max.) Inner Rotor Thickness Outer Rotor Thickness (Min) Outer Rotor Clearance (Max) Outer Rotor Diameter (Min) METRIC 0.10 mm 0.025 mm 7.64 mm 7.64 mm 0.039 mm 79.95 mm STANDARD 0.004 in. 0.001 in. 0.301 in. 0.301 in. 0.015 in. 3.148 in.
Tip Clearance Between Rotors (Max) DESCRIPTION Camshaft Sprocket— Bolt Camshaft Thrust Plate —Bolts Forged Connecting Rod Cap-Nuts Cracked Connecting Rod Cap-Bolts Crankshaft Main Bearing Cap-Bolts Crankshaft Main Bearing Cap Cross Bolts (3.8L) Crankshaft Oil Seal Retainer Rear-Bolts Crankshaft DamperBolt Cylinder Block Drain Plugs Cylinder Head-Bolts Cylinder Head CoverBolts Flex Plate to Crankshaft Engine Mounting Exhaust Manifold-Bolts Intake Manifold Lower-Bolts Intake Manifold Lower Gasket RetainerBolts Intake Manifold UpperBolts Lifter Yoke RetainerBolts Oil Filter Attaching Fitting Oil Cooler Attaching Fitting Oil Filter Oil Filter Adapter-Bolts Oil Gallery Plug Oil Pan—Bolts Oil Pan Drain-Plug Oil Pressure Switch Oil Pump Cover PlateScrews Oil Pump Pick-up Tube-Bolt Oil Dipstick HousingBolts N·m 54 12 54 +¼ turn
0.20 mm Ft. Lbs. 40 — 40 +¼ turn
0.008 in. In. Lbs. — 105 —
41 +¼ turn 61 12 54 20 12 88 23 23 12 12 12 54 27 20 28 27 12 27 23 12 28 48
30 +¼ turn 45 — 40 15 — 65 — — — — — 40 20 15 — 20 — 20 — — — 35
— — 105 — — 105 — 200 200 105 105 105 — — — 250 — 105 — 200 105 250 —
Rocker Arm ShaftBolts Spark Plug Thermostat Housing Timing Chain Case Cover —M8 Bolt —M10 Bolt Water Pump-Bolts Water Pump PulleyBolts
23 16 12 27 54 12 28
— 12 — 20 40 — —
200 — 105 — — 105 250
2.8L Panther Engine Engine Engine Type Displacement Bore Stroke Power (VGT) Torque (ATX) Torque (MTX) Cylinders Injection Order Compression Ratio Maximum compression pressure variation between two cylinders. Vacuum at idle Idle Speed (ATX) Idle Speed (MTX) Maximum RPM in Gear Maximum RPM in neutral Belt tension Thermostat opening Generator Rating Emissions Level Block configuration/Material Cylinder Head Timing System Fuel System Electronic Control Unit Timing System Air Intake Fuel System Emission devices Combustion Cycle Cylinder Compression Difference Between Cylinders Cooling System Turbocharging:
2.8L PANTHER JK 2.8L — 16 Valves 2777 cc 94 100.05 130 kW (177CV)@3800 RPM 400 Nm @ 2000 RPM 410 Nm @ 2000 RPM 4 In line 1–3–4–2 17.0:1 5 bar 680 mm/HG (27.5 In/HG) 760 +/- 50 RPM 875 +/- 50 RPM 4500 RPM ATX 2800 MTX 3500 Automatic Belt Tensioner 80°C +/- 2°C Denso 12V-180A EU4 Open/Cast Iron Dual Overhead Cam Belt CP3.2+ 1,600 bar Fuel Pump, Piezo Injectors EDC 16 Belt Driven DOHC Overhead Camshaft Dry Filter With turbocharger and Charge Air Cooler Direct Fuel Injection Common Rail System Cooled EGR (pneumatic) Electric Intake Throttle Fast Metallic Glow plugs 4 Stroke 5 bar (72.5 psi) Water Cooling Single VGT with REA
Intake Ports Crankshaft Camshafts Intake & Exhaust Valves Intake Manifold Lubrication Engine Rotation 2.8L Panther Engine Specifications Cylinder Head Cylinder head height Cylinder head flatness deformation tolerance Cylinder head gasket thickness 0 Hole 1 Hole 2 Holes Intake Manifold Intake manifold flatness deformation tolerance Exhaust Manifold Exhaust manifold flatness deformation tolerance Tappets Hydraulic tappet outside diameters Valves Intake valve face angle Exhaust valve face angle Intake Valve Head Diameter Exhaust Valve Head Diameter Intake Valve Stem Diameter Exhaust Valve Stem Diameter Intake Valve Guide Stem Clearance Min Max Exhaust Valve Guide Stem Clearance Min Max Valve Springs Free Length Closed Valve Opened Valve Camshafts
Aluminum heads with traditional dual side intake and exhaust ports. One intake port is helical and the other has a directed entry. 8 Counterweights with an incorporated balance shaft gear. 2 overhead camshafts with axial front bearings and identical camshaft caps, finger followers, and hydraulic lifters. Flat with fire deck face. Aluminum, with Cast-in EGR passages, intake mixer, vacuum actuated EGR valve, electric intake throttle and a U-type EGR cooler Pressure Lubricated By Rotary Pump Clockwise Viewed From Front Cover
135.5 mm (5.334 in.) 0.075 mm (0.003 in.) 1.10 mm ( 0.043 in) 1.20 mm (0.047 in) 1.30 mm (0.051 in) 0.075 mm (0.003 in.) 0.075 mm (0.003 in.) 11.994 mm +/- 0.06 mm (0.472 in +/- 0.002) 45°30' 45°30' 32 mm (1.25 in.) 29.4 mm (1.15 in.) 5.97 mm (0.235 in.) 5.96 mm (0.235 in.) 0.030 mm (0.0012 in.) 0.060 mm (0.0024 in.) 0.040 mm (0.0016 in.) 0.070 mm (0.0028 in.) 50.8 mm (2 in.) 38 mm (1.49 in.) 29 mm (1.14 in.)
Camshaft End Play Max Min Outer Journal Diameter (at crankshaft) Inner Journal Diameter (at cylinder head) Crankshaft Journal Clearance. Max Min Connecting Rods Connecting Rod Diameter (Small End) Connecting Rod Diameter (Large End) Piston Pin Diameter Length Crankshaft End Play Bearing Selection Engine Block Cylinder Bore Internal Diameter Cylinder Bore Taper Cylinder Bore Out-Of-Round Fuel System Injection Pressure High Pressure Pump ECU Injectors Glow Plugs Make/Type Voltage Lubrication System Oil Pump Outer Rotor End Play Min Max Oil Pump Inner Rotor End Play Max Min Oil Pump Outer Rotor to Body Diameter Clearance Max Min Oil Pressure Relief Valve Opening Pressure Oil Pressure Valve Spring Free Length
0.350 mm (0.013 in.) 0.150 mm (0.006 in.) 25.95 mm +/– 0.01 mm (1.021 mm +/- .0004 in) 26.00 mm +/– 0.015 mm (1.027 mm +/- .0006 in) 0.075 mm (0.003 in.) 0.030 mm (0.0012 in) 32 mm (1.26 in.) 57.563 mm ( 2.266 in.) 32 mm (1.26 in.) 70.7 mm - 71.00 mm (2.78 in — 2.79 in.) 0.1 mm — 0.33 mm (0.004 in. — 0.013 in.)
94 mm (3.700 in.) TBD 0.007 mm (0.0003 in.) CRS 3.0 — 1600 Bar CP3.2+ EDC16CP31 Piezo CRI 3.0 Bosch / GLP2 4.4V
0.01 (0.0004 in.) 0.09 (0.0036 in.) 0.01 mm (0.0004 in.) 0.09 mm (0.0036 in.)
0.130 mm (0.052 in.) 0.230 mm (0.0091 in) 5 Bar 46.8 mm (1.84 in)
Minimum Oil Pressure (Warm) at Idle at 3800 RPM Cooling System Thermostat Opening Temperature Engine Oil Coolant ENGINE BLOCK DESCRIPTION Lower Oil Pan Upper Oil Pan (m6 bolt) Upper Oil Pan (m8 bolt) Oil Pickup Tube Oil Drain Plug Balance Shaft Main Bearing Caps Connecting Rod Caps Dipstick Tube (sump) Dipstick Tube (block) Oil Cooler Coolant Line Transmission adapter bolts (hex head) Transmission adapter bolts (Allen Head) Oil Jet Engine Mount Bolts Oil Filter Cap Oil Pressure Sensor Air Temp/Pressure sensor CYLINDER HEAD DESCRIPTION Cylinder Head Bolt Cylinder Head Cover Vacuum Tube Fuel Rail Fuel Injector Lines at the injector Fuel injector lines at the fuel rail High Pressure Fuel Feed Line at the Fuel Rail
0.7 Bar 2.5 Bar 80°C (176°F)
N·m 15 15 32 15 54 32 11 33 15 15 78 11 12 25 14 12
Ft. Lbs. 12 12 23 12 40 23 8 24 12 12 57 8 9 18.4 10 9
In. Lbs. 133 133 283 133 478 283 97 292 133 133 690 97 106 221 124 106
N·m 11 11 24 28 20 20
Ft. Lbs. 8 8 18 20 15 15
In. Lbs. 97 97 18 247 177 177
High Pressure Fuel Feed Line at the High Pressure Pump High Pressure Fuel Line Bracket bolt Fuel injector Glow Plugs EGR Throttle Assembly Exhaust Manifold Camshaft Sprocket Camshaft Cap Front Camshaft Journal Intake Manifold FRONT ENGINE DESCRIPTION Outer Front Cover (upper) Outer Front Cover (lower) Inner Front Cover Front Cover Crankshaft Sprocket Crankshaft Pulley Front Engine Lifting Bracket Accessory Drive Idler Pulley CMP sensor Water Pump Timing Belt Tensioner REAR ENGINE DESCRIPTION Rear Cover Rear Lifting Bracket Crankshaft Sensor CKP Cover Plate Trans Adapter Plate (allen bolts) Trans Adapter Plate (hex bolt) ACCESSORY DRIVE DESCRIPTION Power Steering Pump Pulley Power Steering Pump Generator Generator Bracket A/C Compressor A/C Compressor Bracket Turbocharger
28 15 33 14 11 35 64 11 11 25 N·m 11 11 11 15 100 + 75° 32 45 45 11 32 20 N·m 15 45 11 15 79 45
20 11 24 10 8 29 47 8 8 19 Ft. Lbs. 8 8 8 12 74+ 75° 23 33 33 8 23 15 Ft. Lbs. 10 33 8 11 58 33
247 133 292 124 97 309 566 97 97 221 In. Lbs. 97 97 97 133 885+ 75° 283 398 398 97 283 177 In. Lbs. 133 398 97 133 699 398
N·m 33 33 33 45 32 45 32
Ft. Lbs. 24 24 24 33 23 33 23
In. Lbs. 283 283 283 398 283 33 283
Turbocharger Oil Feed Line at the Turbocharger Turbocharger Oil Feed Line at the Engine Block Turbocharger Oil Return Line Turbocharger Brace Turbocharger Adapter (oil feed line to engine block connection) EGR Valve EGR Cooler High Pressure Fuel Pump High Pressure Fuel Pump Sprocket. Oil Cooler Housing Oil Cooler Feed Line
24 32 15 32 54 15 15 24 88 32 11
18 23 11 23 40 11 11 18 65 23 8
212 283 133 283 478 133 133 212 779 283 97
EXHAUST DESCRIPTION Bolts, Crossmember to Sill Nuts, Crossmember to Transmission Mount Nuts/Bolt, Exhaust Manifold to Engine #6&7 #1,2,3,4,5,8,9,10&11 Nuts, Exhaust Pipe to Catalytic Converter Flange Nuts, Catalytic Converter to Turbocharger Bolt, DPF to Catalytic Converter Bolts, DPF to Muffler Clamp, Tailpipe to Rear Tailpipe Hanger Oxygen Sensors Heat Shields
N·m 42 22
Ft. Lbs. 31 16
In. Lbs. -
31 33 27 27 32 32 27 27 45
23 24 19 24 24 20 20 33
19 -
FRAME AND BUMPER DESCRIPTION Front bumper support bolts Fuel tank skid plate to crossmember bolts
N·m 90 99
Ft. Lbs 66.5 73
In. Lbs. — —
Rear bumper support bolts Rear bumper support bracket to frame bolts Trailer hitch/rear tow hook bolts Transfer case skid plate crossmember bolts Transfer case skid plate support bracket bolts Transmission crossmember bolts Transmission skid plate support crossmember bolts Transmission skid plate to crossmember bolt
25 55 81 65 65 122 65 65
18.5 40.5 60 48 48 90 48 48
— — — — — — — —
TORQUE - 3.8L GAS DESCRIPTION Accelerator Pedal Bracket Mounting Crankshaft Position Sensor - 3.8L Camshaft Position Sensor - 3.8L Fuel Filler Hose Clamp at Tank Fuel Filler Housing-toBody Screws Fuel Rail Mounting Bolts - 3.8L Fuel Tank Mounting Straps Throttle Body Mounting Bolts - 3.8L Oxygen Sensors
N·m 12 28 3 2 22 41 7.5 41
Ft. Lbs. 21 17 30 5.5 30
In. Lbs. 105 106 30 17 200 65 -
STEERING COLUMN DESCRIPTION Steering Wheel Nut Steering Column Mounting Nuts Intermediate Shafts Coupler Pinch Bolts Upper & Lower Upper Intermediate Shaft Mounting Nuts
N·m 54 17 49 13
Ft. Lbs. 40 — 36 —
In. Lbs. — 150 — 115
POWER STEERING GEAR DESCRIPTION
SPECIFICATION
Steering Gear Type Steering Gear Overall Ratio DESCRIPTION Pitman Shaft Overcenter Drag Power Steering Gear Adjustment Screw Locknut Power Steering Gear to Frame Bolts Power Steering Gear Pitman Shaft Nut Power Steering Gear Pressure Line Power Steering Gear Return Line N·m 0.45-0.80 + Worm Shaft Preload 65 108 251 36 36
Recirculating Ball 14:1 LWB or 16:1 SWB Ft. Lbs. — 48 870 185 27 27 In. Lbs. 4-7 + Worm Shaft Preload — — — — —
STEERING LINKAGE DESCRIPTION Pitman Arm Shaft Drag Link Ball Stud to Pitman Arm Drag Link Ball Stud to Knuckle Drag Link Clamp Tie Rod Ends Ball Studs Tie Rod Ends Clamp Steering Damper to Frame Steering Damper Tie Rod nut Track Bar Frame Bracket Nut Track Bar Axle Bracket Bolt
N·m 251 105 85 35 85 61 68 68 169 169
Ft. Lbs. 185 77 63 26 63 45 50 50 125 125
In. Lbs. — — — — — — — — — —
STEERING PUMP DESCRIPTION Power Steering Pump to engine Diesel Power Steering Pump Pulley Power Steering Pump Pressure Line
N·m 26 28 31
Ft. Lbs. 19 21 23
In. Lbs. — — —
MANUAL TRANSMISSION - NSG370 DESCRIPTION N·m
Ft. Lbs.
In. Lbs.
Drain Plug Fill Plug Shift Tower Bolts Shift Lever Bolt Housing Bolts Input Shaft Retainer Bolts Bearing Retainer Bolts Shift Rail Support Bolts Idler Gear Shaft Bolt Countershaft Bolt Transmission - Top Four Bolts Transmission - Side Two Bolts Transmission - Bottom Four Bolts Crossmember Bolts Transmission Mount Bolts GEAR FIRST SECOND THIRD FOURTH FIFTH SIXTH REVERSE
30 30 14 4 28 9 10 8 20 100 40 68 54 47 47 GEAR RATIOS RATIO 4.46 2.61 1.72 1.24 1 0.84 4.06
22 22 10 20 15 74 30 50 40 35 35
33 80 88 71 -
42RLE AUTOMATIC TRANSMISSION GENERAL SPECIFICATIONS Transmission Type Lubrication Method Cooling Method GEAR 1st Gear 2nd Gear 3rd Gear (Direct) 4th Gear (Overdrive) Reverse Gear BEARING PRELOAD (Drag Torque) DESCRIPTION Output Shaft CLUTCH PACK
Four-Speed Automatic, Electronically Controlled, Fully Adaptive, Electronically Modulated Torque Converter Pump (internal - external gear-type) Water Heat Exchanger / Air-to-Oil Heat Exchanger GEAR RATIOS RATIO 2.84:1 1.57:1 1.00:1 0.69:1 2.21:1 METRIC 0.22-0.903 N·m STANDARD 1-8 in. lbs.
DESCRIPTION Low/Reverse Clutch (Select Reaction Plate) Two/Four Clutch (No Select) Reverse Clutch (Select Snap Ring) Overdrive Clutch (No Select) Underdrive Clutch (Select Reaction Plate) INPUT SHAFT DESCRIPTION End Play OIL PUMP CLEARANCES DESCRIPTION Outer Gear-to-Crescent Inner Gear-to-Crescent Outer Gear-to-Pocket Outer Gear Side Clearance Inner Gear Side Clearance TORQUE SPECIFICATIONS DESCRIPTION Bolt, Converter-toDriveplate Bolt, Fluid Filter-toValve Body Bolt, L/R Clutch Retainer-to-Case Bolt, Adapter/ Extension Housing Bolt, Manual Valve Lever-to-Manual Valve Bolt, Oil Pan-to-Case Bolt, Oil Pump-to-Case Bolt, Park Sprag Retainer Bolt, Reaction Shaft Support Halves Bolt, Solenoid/Pressure Switch Assy-to-Valve Body Bolt, Torque Converter Housing to Engine Block Bolt, Valve Body-toCase Bolt, Valve Body-toTransfer Plate Fitting, Cooler Line Nut, Output Shaft Plug, Pressure Tap Bolt, Input Speed-toCase Sensor N·m 88 5 5 54 5 20 30 4.5 28 5.5 129 12 5 47.5 271 5 9
METRIC 0.84-1.60 mm 0.76-2.64 mm 0.89-1.37 mm 1.07-3.25 mm 0.94-1.50 mm
STANDARD 0.033-0.063 in. 0.030-0.104 in. 0.035-0.054 in. 0.042-0.128 in. 0.037-0.059 in.
METRIC 0.127-0.635 mm METRIC 0.060-0.298 mm 0.093-0.385 mm 0.089-0.202 mm 0.020-0.046 mm 0.020-0.046 mm Ft. Lbs. 65 40 14.5 95 35 200 -
STANDARD 0.005-0.025 in. STANDARD 0.0023-0.0117 in. 0.0036-0.0151 in. 0.0035-0.0079 in. 0.0008-0.0018 in. 0.0008-0.0018 in. In. Lbs. 45 45 45 265 40 250 50
105 45 45 80
Bolt, Output Speed-toCase Sensor 545RFE Transmission COMPONENT Output Shaft End Play Input Shaft End Play 2C Clutch Pack Clearance 4C Clutch Pack Clearance L/R Clutch Pack Clearance OD Clutch Pack Clearance UD Clutch Pack Clearance Reverse Clutch Pack Clearance Recommended fluid 1ST 2ND 2ND PRIME 3RD 4TH 5TH REVERSE TORQUE SPECIFICATIONS DESCRIPTION Fitting, cooler line at trans Bolt, torque converter housing to engine upper four Bolt, torque converter housing to engine lower four Bolts, transmission collar Bolt, torque converter to driveplate Bolt/nut, crossmember Bolt, driveplate to crankshaft Bolts, clevis bracket / rear support Bolt , converter housing Bolt, oil pan Screw, primary fluid filter Nuts, transfer case Oil Filter, Cooler Return Bolt, oil pump Bolt, oil pump body to cover
9
-
80
METRIC 0.22-0.55 mm 0.46-0.89 mm 0.455-1.335 mm 0.770-1.390 mm 1.00-1.74 mm 1.103-1.856 mm 0.84-1.54 mm 0.81-1.24 mm Mopar® ATF +4 GEAR RATIOS 3.00:1 1.67:1 1.50:1 1.00:1 0.75:1 0.67:1 3.00:1 N·m 17.5 41 54 68 31 68 75 47 68 12 4.5 35 9.5 28 4.5 Ft. Lbs. 30 40 50 23 50 55 35 50 26
STANDARD 0.009-0.021 in. 0.018-0.035 in. 0.018-0.053 in. 0.030-0.055 in. 0.039-0.069 in. 0.043-0.073 in. 0.033-0.061 in. 0.032-0.049 in.
In. Lbs. 155
270 -
105 40 84
-
250 40
Screw, plate to oil pump body Bolt, valve body to case Plug, pressure test port Bolt, reaction shaft support Screw, valve body to transfer plate Screw, solenoid module to transfer plate Screw, accumulator cover Screw, detent spring Bolt, input speed sensor Bolt, output speed sensor Bolt, line pressure sensor Bolt, extension housing Screw, manual valve cam retaining Screw, manual selector shaft retaining Cross-bolt, manual selector shaft
4.5 12 5 12 5.5 6 7 4.5 12 12 12 54 4.5 28 16
40 -
40 105 45 105 50 50 60 40 105 105 105 40 250 140
TRANSFER CASE - NV241 GENII DESCRIPTION N-m Plug, Detent 16-24 Plug, Drain/Fill 20-34 Bolt, Extension 16-24 Housing Bolt, Case Half 20-27 Screw, Oil Pump 39432 Nut, Front Companion 122-176 Flange Nut, Range Lever 27-34 Sector Support 27-42 Nuts, Mounting 30-41 Position Sensor 20-34 TRANSFER CASE - NV241OR DESCRIPTION Plug, Detent Plug, Drain/Fill Bolt, Rear Extension Bolt, Front Input Retainer Bolt, Case Half Nut, Front Yoke
Ft. Lbs. 39434 15-25 39434 15-24 39306 90-130 20-25 20-30 20-30 16-25
In. Lbs. -
N·m 16-25 20-34 16-24 21 20-27 122-176
Ft. Lbs. 39434 15-25 39434 16 15-20 90-130
In. Lbs. -
Nut, Rear Companion Flange Bolt, Shift Lever Nuts, Mounting Bolts, U-Joint Support, Sector Sensor, Transfer Case Position WHEELS DESCRIPTION Lug Nut 1/2 X 20 with 60° Cone Spare Wheel Lug Nut TIRE PRESSURE MONITOR DESCRIPTION Tire Pressure Sensor/ Transmitter Mounting Nut BODY DESCRIPTION A/c expansion valve nut Backlite hinge bolts Body isolator mounting bolts Body isolator to body nuts Brake booster bracket nuts Center OCS strain gauge stud nut Door carrier plate screws Door hinge pin nut Door hinge to body bolts Door hinge to hinge bolts Door latch adjustment screw Door latch mounting screws Door latch striker bolts Four door rear seat 40% inner seat back pivot nut Four door rear seat center belt buckle bolt Four door rear seat cushion pivot bolts
258-312 20-34 30-41 19 27-42 20-34
190-230 15-25 20-30 17 20-30 16-25
-
N·m 115-170 54–108
Ft. Lbs. 85-125 40–80
In. Lbs. — —
N·m 8
Ft. Lbs. —
In. Lbs. 71
N·m 23 10 108 54 18 45 10 8.5 28 26 3 8 26 25 61 25
Ft. Lbs 17 — 80 40 13.5 33 — — 21 19 — — 19 18.5 45 18.5
In. Lbs. — 90 — — — — 90 75 — — 26.5 71 — — — —
Four door rear seat front mounting fasteners Four door rear seat headrest bolts Four door rear seat inner latch floor bolts Four door rear seat latch to back frame bolts Four door rear seat outboard latch floor bolts Four door rear seat rear mounting bolt Four door rear seat rear mounting nuts Four door rear seat seat cushion pivot bolt Four door retractor screw Four door seat cushion pivot bolt Front door exterior handle nut Front door glass run nut Front door interior handle screw Front seat back assembly bolts Front seat belt anchor bolt Front seat belt buckle bolt Front seat belt turning loop screw Front seat mounting bolts Front seat riser nuts Half door latch nut Hard top front bolts Hard top side bolts Hood catch bracket nuts Hood catch nuts Hood hinge to body bolts Hood hinge to hood bolts Hood safety catch bolt Instrument panel center support bracket fasteners Instrument panel fence line nuts Instrument panel side support bolts
61 8 25 45 25 61 85 25 55 25 4.5 10 8.5 47 40 50 40 61 28 4.5 10.5 18 7 15 24 26 11 8 12 11
45 — 18.5 33 18.5 45 62.5 18.5 41 18.5 — — — 34.5 29.5 37 29.5 45 21 — — 13 — 11 18 19 8 6 9 8
— 71 — — — — — — — — 40 90 75 — — — — — — 40 93 — 62 — — — 97 71 — —
Lower fender to sill bolts Manual sifter bolt OCS riser nuts Outside rearview mirror bolts Rear door exterior handle nut Rear door glass run bolt Rear door glass run nut Rear door interior handle screw Rear view mirror set screw Seat side airbag nuts Side step bracket bolts Side step sill nuts Soft top pivot knuckle bolts Speaker pod screws Sport bar cross bar bracket bolts Sport bar front cross bar bracket bolts Sport bar rear bolts Sport bar rear cross bar bracket bolts Sport bar side bar bolts Sport bar side bar to windshield frame bolts Sport bar to b-pillar bolts Steering column opening reinforcement plate bolts Tailgate exterior handle nuts Tailgate hinge to body bolts Tailgate hinge to tailgate bolts Tailgate latch screws Tailgate stabilizer insert and cup bolts Tailgate striker bolts Two door rear seat back frame to cushion bolts Two door rear seat back latch bolts Two door rear seat center belt buckle bolt Two door rear seat cushion to back bolts
12 33 28 13 4.5 12 10 8.5 2 7 24 12 14 10 19 19 19 19 19 23 19 11 4.5 26 20 8 10 28 50 45 55 50
9 24.5 21 10 — 9 — — — — 18 9 10 — 14 14 14 14 14 17 14 8 — 19 15 — — 21 37 33 41 37
— — — — 40 — 90 75 18 62 — — — 90 — — — — — — — — 40 — — 71 90 — — — — —
Two door rear seat front latch cushion frame bolts Two door rear seat rear latch nuts Upper fender fasteners Windshield frame hinge to body bolts Windshield frame reinforcement bracket bolts A/C SYSTEM ITEM A/C Compressor Freeze-up Control
45 10 5 20 20
33 — — 15 15
— 90 44 — —
DESCRIPTION Zexel DKS-17DS Evaporator Temperature Sensor
Low PSI Control
A/C Pressure Transducer
High PSI Control
A/C Pressure Transducer
High Pressure Relief Valve
R-134a Refrigerant Charge Capacity A/C Clutch Coil Draw A/C Clutch Coil Resistance A/C Clutch Air Gap DESCRIPTION All Screws NOT Listed Below A/C Compressor Bolts A/C Compressor Clutch Field Coil Screws
0.51 kg (1.125 lbs). 3.3 amps 4.2 ± 0.2 ohms 0.30 - 0.60 mm (0.012 - 0.024 in.) N·m 1.2 28 5 Ft. Lbs. – 21 –
NOTES ZXL-100 PAG Oil HVAC housing mounted - input to powertrain control module (PCM) or engine control module (ECM), depending on engine application A/C discharge line mounted input to powertrain control module (PCM) or engine control module (ECM), depending on engine application - PCM/ECM disengages compressor clutch below 0.451 volts A/C discharge line mounted input to powertrain control module (PCM) or engine control module (ECM), depending on engine application - PCM/ECM disengages compressor clutch above 4.519 volts A/C Compressor mounted opens at a discharge pressure over 3430 - 3930 kPa (497 - 570 psi) Also see A/C Underhood Specification Label located in the engine compartment @ 12V ± 0.5V @ 25° C (77° F) When measured across coil lead connector @ 25° C (77° F)
In. Lbs. 10 – 44
A/C Compressor Shaft Bolt A/C Compressor Field Coil Connector Bracket Screw A/C Condenser to Radiator Bolts A/C Heater Control Screws Air Inlet Housing to Instrument Panel Support Bolts Blend Door Lever Screw Discharge Line to Condenser Nut Discharge Line to Compressor Nut Expansion Valve Bolts HVAC Housing to Instrument Panel Support Bolts Liquid Line to Condenser Nut Mode Door Cam Screw Receiver/Drier to Condenser Bolt Suction Line to Compressor Nut Suction and Liquid Lines to Expansion Valve Nut LAMPS DESCRIPTION Center High Mounted Stop Lamp (CHMSL) Mounting Screws Front Fog Lamp Mounting Screws Left Multi-Function Switch Mounting Screw License Plate Bracket Mounting Screws Park Brake Switch Mounting Screw Rear Fog Lamp Mounting Screws Rear Lamp Unit Mounting Screws
20 4.3 5 2 4 0.6 23 23 11 4 23 0.6 22 23 8
– – – – – – 17 17 – – 17 – 16 17 –
177 38 45 17 35 5 – – 97 35 – 5 – – 70
N·m 2 2 1 1.5 2.5 3 1.5
Ft. Lbs. -
In. Lbs. 20 18 10 15 24 27 15
N·m 27 76 169 169 102 102 61 102 102 169 169 102 136 42 74 74 136 4-6
Ft. Lbs. 20 56 125 125 75 75 45 75 75 125 125 75 100 31 55 55 100 —
In. Lbs. — — — — — — — — — — — — — — — — — 34-50
REAR SUSPENSION DESCRIPTION Shock Absorber Upper Bolts Shock Absorber Lower Nut Suspension Arm Lower Axle Bracket Nut Suspension Arm Lower Frame Bracket Bolt Suspension Arm Upper Axle Bracket Bolt Suspension Arm Upper Frame Bracket Bolt Stabilizer Bar Retainer Bolts Stabilizer Bar Link Nut/Bolt Stabilizer Bar to Link Nut
N·m 50 76 169 169 169 169 61 102 90
Ft. Lbs. 37 56 125 125 125 125 45 75 66
In. Lbs. — — — — — — — — —
Track Bar Frame Bracket Nut Track Bar Axle Bracket Bolt
169 169
125 125
— —
PROPELLER SHAFT DESCRIPTION Front Shaft - Axle Flange Bolts Front Shaft - Transfer Case Flange Bolts Rear Shaft - Axle Flange Bolts Rear Shaft - Transfer Case Flange Bolts
N·m 110 20 20 20
Ft. Lbs. 81 15 15 15
In. Lbs. -
FRONT AXLE - 186FBI DESCRIPTION Axle Ratio Ring Gear Backlash Pinion Torque To Rotate - Original Bearings Pinion Torque To Rotate - New Bearings Differential Total Torque To Rotate: Pinion Torque To Rotate Plus DESCRIPTION Fill Hole Plug Differential Cover Bolts Bearing Cap Bolts Ring Gear Bolts Pinion Bearing Nut Min - Max Axle Nut Hub Bearing Bolts N·m 34 41 61 108 217 - 542 136 102
SPECIFICATION 3.21, 4.10 0.12 - 0.20 mm (0.005 - 0.008 in.) 1.13 - 2.26 N·m (10 - 20 in. lbs.) 2 - 3.4 N·m (15 - 30 in. lbs.) 0.79 - 1.24 N·m (7 - 11 in. lbs.) Ft. Lbs. 25 30 45 80 160 - 400 100 75 In. Lbs. -
FRONT AXLE - 216FBI DESCRIPTION Axle Ratio Ring Gear Backlash Pinion Torque To Rotate - Original Bearing Pinion Torque To Rotate - New Bearing Total Torque To Rotate: Pinion Torque To Rotate plus DESCRIPTION Fill Plug Differential Cover Bolts Bearing Cap Bolts Pinion Nut Ring Gear Bolts Axle Nut Hub Bearing Bolts N·m 34 41 108 217-271 136 136 102
SPECIFICATION 4.1 0.12 - 0.20 mm (0.005 - 0.008 in.) 1 - 2 N·m (10 - 20 in. lbs.) 2 - 4.5 N·m (20 - 40 in. lbs.) 0.79 - 1.24 N·m (7 - 11 in lbs) Ft. Lbs. 25 30 80 160-200 100 100 75 In. Lbs. -
REAR AXLE - 198RBI DESCRIPTION Axle Ratio Ring Gear Backlash Pinion Torque To Rotate - Original Bearings Pinion Torque To Rotate - New Bearings Total Torque To Rotate: Pinion Torque To Rotate plus DESCRIPTION Differential Cover Bolts Bearing Cap Bolts Ring Gear Bolts Pinion Nut Axle Retainer Nuts N·m 41 77 136 271 - 475 61
SPECIFICATION 4.1 0.12 - 0.20 mm (0.005 - 0.008 in.) 1 - 2 N·m (10 - 20 in. lbs.) 2 - 4 N·m (20 - 35 in. lbs.) 0.79 - 1.24 N·m (7 - 11 in. lbs.) Ft. Lbs. 30 57 100 200 - 350 45 In. Lbs. -
REAR AXLE - 226RBI DESCRIPTION Axle Ratio Ring Gear Backlash Pinion Torque To Rotate - Original Bearings Pinion Torque To Rotate - New Bearings Total Torque To Rotate: Pinion Torque To Rotate plus DESCRIPTION Fill Hole Plug Differential Cover Bolts Bearing Cap Bolts Ring Gear Bolts Pinion Nut Axle Retainer Nuts N·m 34 41 108 136 217 - 271 61
SPECIFICATION 3.21, 4.10 0.12 - 0.20 mm (0.005 - 0.008 in.) 1 - 2 N·m (10 - 20 in. lbs.) 2 - 4.5 N·m (20 - 40 in. lbs.) 0.79 - 1.24 N·m (7 - 11 in. lbs.) Ft. Lbs. 25 30 80 100 160 - 200 45 In. Lbs. -
BRAKE COMPONENTS DESCRIPTION Disc Brake Caliper Type Front Disc Brake Rotor Type Rear Disc Brake Rotor Type Front Disc Brake Rotor Diameter Rear Disc Brake Rotor Diameter Front Ventilated Disc Brake Rotor Rear Solid Disc Brake Rotor Front Ventilated Disc Brake Rotor Rear Solid Disc Brake Rotor Front Ventilated Disc Brake Rotor Rear Solid Disc Brake Rotor Brake Booster Type DESCRIPTION N·m
SPECIFICATION Sliding Ventilated Solid 302 x 28 mm (11.89 x 1.10 in.) 312 x 12 mm (12.28 x 0.472 in.) Max. Runout 0.10 mm (0.0039 in.) Max. Runout 0.102 mm (0.004 in) Max. Thickness Variation 0.009 mm (0.00035 in.) Max Thickness Variation 0.018 mm (0.0007 in) Min. Thickness 22.7 mm (0.8937 in.) Min. Thickness 11.00 mm (0.433 in.) Tandem Diaphragm Ft. Lbs. In. Lbs.
Brake Booster Mounting Nuts Master Cylinder Mounting Nuts Booster Mounting Plate Master Cylinder Brake Lines Front Caliper Adapter Mounting Bolts Rear Caliper Adapter Mounting Bolts Front Caliper Brake Hose Banjo Bolt Rear Caliper Brake Hose Banjo Bolt Front Caliper adapter Rear Caliper adapter Parking Brake Lever Bracket Bolts
25 17 18 19 35 35 31 31 163 75 12
18 13 — 14 26 26 23 23 120 55 9
— 151 159 168 — 220 — — — — —
CLUTCH DESCRIPTION Pressure Plate Bolts 2.8L Pressure Plate Bolts 3.8L Flywheel Bolts - 2.8L Flywheel Bolts - 3.8L Slave Cylinder Nuts Dust Shield Bolts Crossmember Frame Bolts
N·m 31 50 95 81 23 50 41
Ft. Lbs. 23 37 70 60 17 37 30
In. Lbs. -
COOLING SYSTEM DESCRIPTION Bolt, Block Heater Bolts, Condenser to Radiator Electric Fan to Fan Shroud bolts Bolts, Fan Blade Assembly to Viscous Drive - Diesel Viscous Fan Drive Diesel Bolts, Fan Shroud to Radiator Mounting Bolts, Radiator Upper Isolator to Crossmember Bolts, Thermostat Housing-
N·m 2 6 23 50 8 9 28
Ft. Lbs. -
In. Lbs. 17 53
37 -
210 70 80 250
Bolts, Water Pump 3.8L 2.8L
12 23
-
105 200
3.8L ENGINE DESCRIPTION Engine Type Number of Cylinders Displacement 3.8L Bore 3.8L Stroke Compression Ratio 3.8L Firing Order Compression Pressure-Minimum Cylinder Compression (Max. Difference Between Cylinders CYLINDER BLOCK DESCRIPTION Cylinder Bore Diameter (Standard) 3.8L Out of Round (Service Limits) Taper (Service Limits) Lifter Bore Diameter Deck Surface Flatness (Max.) CRANKSHAFT DESCRIPTION Connecting Rod Journal Diameter Main Bearing Journal Diameter Journal Out-of-Round (Max.) Journal Taper (Max.) End Play Wear Limit Main Bearing Diametrical Clearance 1-2-3-4 Wear Limit CONNECTING RODS DESCRIPTION Bearing Clearance Wear Limit Side Clearance Wear Limit PISTONS DESCRIPTION Piston Diameter 3.8L-Measured 33.01 mm (1.30 in) From Piston Top Clearance in Bore @ Size Location (New)
METRIC 60° V-6 Engine 6 3.8 Liters 96.0 mm 87 mm 689.5 kPa -
STANDARD 231 cu. in. 3.779 cu.in. 3.425 in. 9.6:1 1-2-3-4-5-6 100 psi. 0.25
METRIC 95.993-96.007 mm 0.076 mm 0.051 mm 22.980-23.010 mm 0.1 mm METRIC 57.979-58.005 mm 63.993-64.013 mm 0.025 mm 0.025 mm 0.09-0.24 mm 0.381 mm 0.011-0.055 mm 0.076 mm METRIC 0.019-0.065 mm. 0.074 mm 0.13-0.32 mm 0.38 mm METRIC 95.968-95.998 mm. -0.005-0.039 mm
STANDARD 3.7792-3.780 in. 0.003 in. 0.002 in. 0.905-0.906 in. 0.004 in. STANDARD 2.2827-2.2837 in. 2.5194-2.5202 in. 0.001 in. 0.001 in 0.0036-0.0095 in. 0.015 in. 0.0005-0.0022 in. 0.003 in. STANDARD 0.017-0.020 in. 0.003 in. 0.005-0.013 in. 0.015 in. STANDARD 3.778-3.779 in. -0.0002–0.0015 in.
Weight 3.8L PISTON PINS DESCRIPTION Type Clearance in Piston @ 21C (70°F) Clearance in Connecting Rod Diameter Length 3.8L PISTON RINGS DESCRIPTION Ring End Gap Top Compression Ring Second Compression Ring Oil Control (Steel Rails) Wear Limit-Compression Rings Wear Limit-Oil Control Steel Rails Ring Side Clearance Top Compression Ring 3.8L Second Compression Ring 3.8L Oil Ring (Steel Ring) Wear Limit- Top Ring Wear Limit-2nd Ring Wear Limit Oil Ring Pack Ring Width-Top Compression Ring 3.8L Ring Width-2nd Compression Ring 3.8L Ring Width-Oil Ring (Steel Rails) 3.8L CAMSHAFT DESCRIPTION Journal Diameter #1 #2 #3 #4 Bearing Clearance-Diametrical Bearing Clearance (Max.Allowable) End Play Camshaft Bearing Diameter #1 #2 #3 #4
426 ± 5 grams METRIC Press Fit in Rod (Serviced as a Assembly) 0.006-0.019 mm Interference Fit 22.87-22.88 mm 71.25-71.75 mm METRIC 0.18-0.38 mm 0.28-0.57 mm 0.23-0.78 mm 1.0 mm 1.88 mm
15.03 ± 0.1764 oz. STANDARD 0.0002-0.0007 in. 0.9007-0.9009 in. 2.805-2.824 in. STANDARD 0.007-0.015 in. 0.011-0.022 in. 0.009-0.030 in. 0.039 in. 0.074 in.
0.030-0.069 mm 0.041-0.085 mm 0.039-0.200 mm 0.10 mm 0.13 mm 0.266 mm 1.175-1.190 mm 1.46-1.49 mm 0.435-0.510 mm
0.0012-0.0027 in. 0.0016-0.0033 in. 0.0015-0.0078 in. 0.004 in. 0.005 0.009 0.0462-0.0468 0.0575-0.058 in. 0.017-0.020
METRIC 50.724-50.775 mm 50.317-50.368 mm 49.936-49.987 mm 49.530-49.581 mm 0.025-0.101 mm 0.127 mm 0.254-0.508 mm 50.800-50.825 50.393-50.419 mm 50.013-50.038 mm 49.606-49.632 mm
STANDARD 1.997-1.999 in. 1.9809-1.9829 in. 1.9659-1.9679 in. 1.9499-1.9520 in. 0.001-0.004 in. 0.005 in. 0.010-0.020 in. 1.9999-2.0009 in. 1.9839-1.9849 in. 1.9690-1.9699 in. 1.9529-1.954 in.
Exhaust Valve Timing Closes-3.8L (ATDC) Opens-3.8L (BBDC) Duration-3.8L Intake Valve Timing Closes-3.8L (ABDC) Opens-3.8L (ATDC) Duration-3.8L Valve Overlap-3.8L HYDRAULIC LIFTER DESCRIPTION Type Outside Diameter Clearance in Block CYLINDER HEAD DESCRIPTION Gasket Thickness (Compressed) VALVES DESCRIPTION Face Angle-Intake Face Angle-Exhaust Head Diameter-Intake Head Diameter-Exhaust Valve Lift (Zero Lash)-Intake and Exhaust-3.8L Valve Length-Intake Valve Length-Exhaust Valve Stem to Tip Height (valve tip to spring seat washer)-Intake Valve Stem to Tip Height (valve tip to spring seat washer)Exhaust VALVE SEAT DESCRIPTION Angle Run Out (Service Limits) Width-Intake and Exhaust VALVE GUIDE DESCRIPTION Guide Bore Diameter (Std.) VALVE MARGIN DESCRIPTION Intake Exhaust VALVE STEM DIAMETER DESCRIPTION
METRIC Hydraulic Roller 22.949-22.962 mm 0.020-0.061 mm METRIC 0.65-0.75 mm METRIC 47.87-48.13 mm 35.37-35.63 mm 11.0 mm 125.84-126.6 mm 127.20-127.96 48.1-49.7 mm 48.53-50.09 mm
18° 46° 244° 63° 1° 242° 17° STANDARD 0.903-0.904 in. 0.0007-0.0024 in. STANDARD 0.0007-0.0024 in. STANDARD 45-45.5° 45-45.5° 1.88-1.89 in. 1.39-1.40 in. 0.433 in. 4.95-4.98 in. 5.00-5.04 in. 1.89-1.95 in. 1.91-1.97 in.
METRIC 0.0762 mm 1.50-2.00 mm METRIC 6.975-7.00 mm METRIC 0.825-0.973 mm 1.565-1.713 mm METRIC
STANDARD 44.5-45° 0.003 in. 0.057-0.078 in. STANDARD 0.274-0.275 in. STANDARD 0.032-0.038 in. 0.061-0.067 in. STANDARD
Intake (Standard) Exhaust (Standard)
6.935-6.953 mm 6.906-6.924 mm
0.2718-0.2725 in. 0.2718-0.2725 in. STANDARD 0.001-0.0025 in. 0.002-0.0037 in. 0.010 in. 0.016 in.
VALVE STEM TO GUIDE CLEARANCE DESCRIPTION METRIC Intake 0.025-0.065 mm Exhaust 0.059-0.094 mm Max Allowable-Intake (Rocking 0.247 mm Method) Max Allowable-Exhaust 0.414 mm (Rocking Method) PUSH RODS DESCRIPTION Length VALVE SPRING DESCRIPTION Free Length-Type A Free Length-Type B Wire Diameter Type A Wire Diameter Type B Number of Coils Type A Number of Coils Type B Spring Tension (Valve Closed) Type A Spring Tension (Valve Open) Type A Spring Tension (Valve Closed) Type B Spring Tension (Valve Open) Type B Installed Height METRIC 135.438 mm METRIC 51.4 mm 53.4 mm 3.95-4.77 mm 4.19-4.29 mm 7.52 7.25 376.4-424.4 N @ 41.9 mm 863.9-959.9 N @ 41.9 mm 377-423 N @ 41.9 mm 880-962 N @ 30.91 mm 41.1-42.7 mm
STANDARD 5.33 in. STANDARD 2.02 in. 2.10 in. 0.15-0.19 in. 0.16-0.17 in. 84.6-95.6 lbs. @ 1.65 in. 194.2-215.8 lbs. @ 1.65 in. 84.8-95.2 lbs. @ 1.65 in. 197.9-216.3 lbs. @ 122 in. 1.61-1.68 in
LUBRICATION DESCRIPTION METRIC STANDARD At Curb Idle Speed* (Minimum 34.47 kPa 5 psi with engine at operating temperature) At 3000 RPM 205-551 kPa 30-80 psi Oil Filter By-Pass Valve Setting 62-103 kPa 9-15 psi Oil Pressure Switch Actuating 14-28 Kpa 2-4 psi Pressure CAUTION: *If pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm. OIL PUMP DESCRIPTION Clearance Over rotors-Inner and Outer Cover Out-Of-Flat (Max.) Inner Rotor Thickness Outer Rotor Thickness (Min) Outer Rotor Clearance (Max) Outer Rotor Diameter (Min) METRIC 0.10 mm 0.025 mm 7.64 mm 7.64 mm 0.039 mm 79.95 mm STANDARD 0.004 in. 0.001 in. 0.301 in. 0.301 in. 0.015 in. 3.148 in.
Tip Clearance Between Rotors (Max) DESCRIPTION Camshaft Sprocket— Bolt Camshaft Thrust Plate —Bolts Forged Connecting Rod Cap-Nuts Cracked Connecting Rod Cap-Bolts Crankshaft Main Bearing Cap-Bolts Crankshaft Main Bearing Cap Cross Bolts (3.8L) Crankshaft Oil Seal Retainer Rear-Bolts Crankshaft DamperBolt Cylinder Block Drain Plugs Cylinder Head-Bolts Cylinder Head CoverBolts Flex Plate to Crankshaft Engine Mounting Exhaust Manifold-Bolts Intake Manifold Lower-Bolts Intake Manifold Lower Gasket RetainerBolts Intake Manifold UpperBolts Lifter Yoke RetainerBolts Oil Filter Attaching Fitting Oil Cooler Attaching Fitting Oil Filter Oil Filter Adapter-Bolts Oil Gallery Plug Oil Pan—Bolts Oil Pan Drain-Plug Oil Pressure Switch Oil Pump Cover PlateScrews Oil Pump Pick-up Tube-Bolt Oil Dipstick HousingBolts N·m 54 12 54 +¼ turn
0.20 mm Ft. Lbs. 40 — 40 +¼ turn
0.008 in. In. Lbs. — 105 —
41 +¼ turn 61 12 54 20 12 88 23 23 12 12 12 54 27 20 28 27 12 27 23 12 28 48
30 +¼ turn 45 — 40 15 — 65 — — — — — 40 20 15 — 20 — 20 — — — 35
— — 105 — — 105 — 200 200 105 105 105 — — — 250 — 105 — 200 105 250 —
Rocker Arm ShaftBolts Spark Plug Thermostat Housing Timing Chain Case Cover —M8 Bolt —M10 Bolt Water Pump-Bolts Water Pump PulleyBolts
23 16 12 27 54 12 28
— 12 — 20 40 — —
200 — 105 — — 105 250
2.8L Panther Engine Engine Engine Type Displacement Bore Stroke Power (VGT) Torque (ATX) Torque (MTX) Cylinders Injection Order Compression Ratio Maximum compression pressure variation between two cylinders. Vacuum at idle Idle Speed (ATX) Idle Speed (MTX) Maximum RPM in Gear Maximum RPM in neutral Belt tension Thermostat opening Generator Rating Emissions Level Block configuration/Material Cylinder Head Timing System Fuel System Electronic Control Unit Timing System Air Intake Fuel System Emission devices Combustion Cycle Cylinder Compression Difference Between Cylinders Cooling System Turbocharging:
2.8L PANTHER JK 2.8L — 16 Valves 2777 cc 94 100.05 130 kW (177CV)@3800 RPM 400 Nm @ 2000 RPM 410 Nm @ 2000 RPM 4 In line 1–3–4–2 17.0:1 5 bar 680 mm/HG (27.5 In/HG) 760 +/- 50 RPM 875 +/- 50 RPM 4500 RPM ATX 2800 MTX 3500 Automatic Belt Tensioner 80°C +/- 2°C Denso 12V-180A EU4 Open/Cast Iron Dual Overhead Cam Belt CP3.2+ 1,600 bar Fuel Pump, Piezo Injectors EDC 16 Belt Driven DOHC Overhead Camshaft Dry Filter With turbocharger and Charge Air Cooler Direct Fuel Injection Common Rail System Cooled EGR (pneumatic) Electric Intake Throttle Fast Metallic Glow plugs 4 Stroke 5 bar (72.5 psi) Water Cooling Single VGT with REA
Intake Ports Crankshaft Camshafts Intake & Exhaust Valves Intake Manifold Lubrication Engine Rotation 2.8L Panther Engine Specifications Cylinder Head Cylinder head height Cylinder head flatness deformation tolerance Cylinder head gasket thickness 0 Hole 1 Hole 2 Holes Intake Manifold Intake manifold flatness deformation tolerance Exhaust Manifold Exhaust manifold flatness deformation tolerance Tappets Hydraulic tappet outside diameters Valves Intake valve face angle Exhaust valve face angle Intake Valve Head Diameter Exhaust Valve Head Diameter Intake Valve Stem Diameter Exhaust Valve Stem Diameter Intake Valve Guide Stem Clearance Min Max Exhaust Valve Guide Stem Clearance Min Max Valve Springs Free Length Closed Valve Opened Valve Camshafts
Aluminum heads with traditional dual side intake and exhaust ports. One intake port is helical and the other has a directed entry. 8 Counterweights with an incorporated balance shaft gear. 2 overhead camshafts with axial front bearings and identical camshaft caps, finger followers, and hydraulic lifters. Flat with fire deck face. Aluminum, with Cast-in EGR passages, intake mixer, vacuum actuated EGR valve, electric intake throttle and a U-type EGR cooler Pressure Lubricated By Rotary Pump Clockwise Viewed From Front Cover
135.5 mm (5.334 in.) 0.075 mm (0.003 in.) 1.10 mm ( 0.043 in) 1.20 mm (0.047 in) 1.30 mm (0.051 in) 0.075 mm (0.003 in.) 0.075 mm (0.003 in.) 11.994 mm +/- 0.06 mm (0.472 in +/- 0.002) 45°30' 45°30' 32 mm (1.25 in.) 29.4 mm (1.15 in.) 5.97 mm (0.235 in.) 5.96 mm (0.235 in.) 0.030 mm (0.0012 in.) 0.060 mm (0.0024 in.) 0.040 mm (0.0016 in.) 0.070 mm (0.0028 in.) 50.8 mm (2 in.) 38 mm (1.49 in.) 29 mm (1.14 in.)
Camshaft End Play Max Min Outer Journal Diameter (at crankshaft) Inner Journal Diameter (at cylinder head) Crankshaft Journal Clearance. Max Min Connecting Rods Connecting Rod Diameter (Small End) Connecting Rod Diameter (Large End) Piston Pin Diameter Length Crankshaft End Play Bearing Selection Engine Block Cylinder Bore Internal Diameter Cylinder Bore Taper Cylinder Bore Out-Of-Round Fuel System Injection Pressure High Pressure Pump ECU Injectors Glow Plugs Make/Type Voltage Lubrication System Oil Pump Outer Rotor End Play Min Max Oil Pump Inner Rotor End Play Max Min Oil Pump Outer Rotor to Body Diameter Clearance Max Min Oil Pressure Relief Valve Opening Pressure Oil Pressure Valve Spring Free Length
0.350 mm (0.013 in.) 0.150 mm (0.006 in.) 25.95 mm +/– 0.01 mm (1.021 mm +/- .0004 in) 26.00 mm +/– 0.015 mm (1.027 mm +/- .0006 in) 0.075 mm (0.003 in.) 0.030 mm (0.0012 in) 32 mm (1.26 in.) 57.563 mm ( 2.266 in.) 32 mm (1.26 in.) 70.7 mm - 71.00 mm (2.78 in — 2.79 in.) 0.1 mm — 0.33 mm (0.004 in. — 0.013 in.)
94 mm (3.700 in.) TBD 0.007 mm (0.0003 in.) CRS 3.0 — 1600 Bar CP3.2+ EDC16CP31 Piezo CRI 3.0 Bosch / GLP2 4.4V
0.01 (0.0004 in.) 0.09 (0.0036 in.) 0.01 mm (0.0004 in.) 0.09 mm (0.0036 in.)
0.130 mm (0.052 in.) 0.230 mm (0.0091 in) 5 Bar 46.8 mm (1.84 in)
Minimum Oil Pressure (Warm) at Idle at 3800 RPM Cooling System Thermostat Opening Temperature Engine Oil Coolant ENGINE BLOCK DESCRIPTION Lower Oil Pan Upper Oil Pan (m6 bolt) Upper Oil Pan (m8 bolt) Oil Pickup Tube Oil Drain Plug Balance Shaft Main Bearing Caps Connecting Rod Caps Dipstick Tube (sump) Dipstick Tube (block) Oil Cooler Coolant Line Transmission adapter bolts (hex head) Transmission adapter bolts (Allen Head) Oil Jet Engine Mount Bolts Oil Filter Cap Oil Pressure Sensor Air Temp/Pressure sensor CYLINDER HEAD DESCRIPTION Cylinder Head Bolt Cylinder Head Cover Vacuum Tube Fuel Rail Fuel Injector Lines at the injector Fuel injector lines at the fuel rail High Pressure Fuel Feed Line at the Fuel Rail
0.7 Bar 2.5 Bar 80°C (176°F)
N·m 15 15 32 15 54 32 11 33 15 15 78 11 12 25 14 12
Ft. Lbs. 12 12 23 12 40 23 8 24 12 12 57 8 9 18.4 10 9
In. Lbs. 133 133 283 133 478 283 97 292 133 133 690 97 106 221 124 106
N·m 11 11 24 28 20 20
Ft. Lbs. 8 8 18 20 15 15
In. Lbs. 97 97 18 247 177 177
High Pressure Fuel Feed Line at the High Pressure Pump High Pressure Fuel Line Bracket bolt Fuel injector Glow Plugs EGR Throttle Assembly Exhaust Manifold Camshaft Sprocket Camshaft Cap Front Camshaft Journal Intake Manifold FRONT ENGINE DESCRIPTION Outer Front Cover (upper) Outer Front Cover (lower) Inner Front Cover Front Cover Crankshaft Sprocket Crankshaft Pulley Front Engine Lifting Bracket Accessory Drive Idler Pulley CMP sensor Water Pump Timing Belt Tensioner REAR ENGINE DESCRIPTION Rear Cover Rear Lifting Bracket Crankshaft Sensor CKP Cover Plate Trans Adapter Plate (allen bolts) Trans Adapter Plate (hex bolt) ACCESSORY DRIVE DESCRIPTION Power Steering Pump Pulley Power Steering Pump Generator Generator Bracket A/C Compressor A/C Compressor Bracket Turbocharger
28 15 33 14 11 35 64 11 11 25 N·m 11 11 11 15 100 + 75° 32 45 45 11 32 20 N·m 15 45 11 15 79 45
20 11 24 10 8 29 47 8 8 19 Ft. Lbs. 8 8 8 12 74+ 75° 23 33 33 8 23 15 Ft. Lbs. 10 33 8 11 58 33
247 133 292 124 97 309 566 97 97 221 In. Lbs. 97 97 97 133 885+ 75° 283 398 398 97 283 177 In. Lbs. 133 398 97 133 699 398
N·m 33 33 33 45 32 45 32
Ft. Lbs. 24 24 24 33 23 33 23
In. Lbs. 283 283 283 398 283 33 283
Turbocharger Oil Feed Line at the Turbocharger Turbocharger Oil Feed Line at the Engine Block Turbocharger Oil Return Line Turbocharger Brace Turbocharger Adapter (oil feed line to engine block connection) EGR Valve EGR Cooler High Pressure Fuel Pump High Pressure Fuel Pump Sprocket. Oil Cooler Housing Oil Cooler Feed Line
24 32 15 32 54 15 15 24 88 32 11
18 23 11 23 40 11 11 18 65 23 8
212 283 133 283 478 133 133 212 779 283 97
EXHAUST DESCRIPTION Bolts, Crossmember to Sill Nuts, Crossmember to Transmission Mount Nuts/Bolt, Exhaust Manifold to Engine #6&7 #1,2,3,4,5,8,9,10&11 Nuts, Exhaust Pipe to Catalytic Converter Flange Nuts, Catalytic Converter to Turbocharger Bolt, DPF to Catalytic Converter Bolts, DPF to Muffler Clamp, Tailpipe to Rear Tailpipe Hanger Oxygen Sensors Heat Shields
N·m 42 22
Ft. Lbs. 31 16
In. Lbs. -
31 33 27 27 32 32 27 27 45
23 24 19 24 24 20 20 33
19 -
FRAME AND BUMPER DESCRIPTION Front bumper support bolts Fuel tank skid plate to crossmember bolts
N·m 90 99
Ft. Lbs 66.5 73
In. Lbs. — —
Rear bumper support bolts Rear bumper support bracket to frame bolts Trailer hitch/rear tow hook bolts Transfer case skid plate crossmember bolts Transfer case skid plate support bracket bolts Transmission crossmember bolts Transmission skid plate support crossmember bolts Transmission skid plate to crossmember bolt
25 55 81 65 65 122 65 65
18.5 40.5 60 48 48 90 48 48
— — — — — — — —
TORQUE - 3.8L GAS DESCRIPTION Accelerator Pedal Bracket Mounting Crankshaft Position Sensor - 3.8L Camshaft Position Sensor - 3.8L Fuel Filler Hose Clamp at Tank Fuel Filler Housing-toBody Screws Fuel Rail Mounting Bolts - 3.8L Fuel Tank Mounting Straps Throttle Body Mounting Bolts - 3.8L Oxygen Sensors
N·m 12 28 3 2 22 41 7.5 41
Ft. Lbs. 21 17 30 5.5 30
In. Lbs. 105 106 30 17 200 65 -
STEERING COLUMN DESCRIPTION Steering Wheel Nut Steering Column Mounting Nuts Intermediate Shafts Coupler Pinch Bolts Upper & Lower Upper Intermediate Shaft Mounting Nuts
N·m 54 17 49 13
Ft. Lbs. 40 — 36 —
In. Lbs. — 150 — 115
POWER STEERING GEAR DESCRIPTION
SPECIFICATION
Steering Gear Type Steering Gear Overall Ratio DESCRIPTION Pitman Shaft Overcenter Drag Power Steering Gear Adjustment Screw Locknut Power Steering Gear to Frame Bolts Power Steering Gear Pitman Shaft Nut Power Steering Gear Pressure Line Power Steering Gear Return Line N·m 0.45-0.80 + Worm Shaft Preload 65 108 251 36 36
Recirculating Ball 14:1 LWB or 16:1 SWB Ft. Lbs. — 48 870 185 27 27 In. Lbs. 4-7 + Worm Shaft Preload — — — — —
STEERING LINKAGE DESCRIPTION Pitman Arm Shaft Drag Link Ball Stud to Pitman Arm Drag Link Ball Stud to Knuckle Drag Link Clamp Tie Rod Ends Ball Studs Tie Rod Ends Clamp Steering Damper to Frame Steering Damper Tie Rod nut Track Bar Frame Bracket Nut Track Bar Axle Bracket Bolt
N·m 251 105 85 35 85 61 68 68 169 169
Ft. Lbs. 185 77 63 26 63 45 50 50 125 125
In. Lbs. — — — — — — — — — —
STEERING PUMP DESCRIPTION Power Steering Pump to engine Diesel Power Steering Pump Pulley Power Steering Pump Pressure Line
N·m 26 28 31
Ft. Lbs. 19 21 23
In. Lbs. — — —
MANUAL TRANSMISSION - NSG370 DESCRIPTION N·m
Ft. Lbs.
In. Lbs.
Drain Plug Fill Plug Shift Tower Bolts Shift Lever Bolt Housing Bolts Input Shaft Retainer Bolts Bearing Retainer Bolts Shift Rail Support Bolts Idler Gear Shaft Bolt Countershaft Bolt Transmission - Top Four Bolts Transmission - Side Two Bolts Transmission - Bottom Four Bolts Crossmember Bolts Transmission Mount Bolts GEAR FIRST SECOND THIRD FOURTH FIFTH SIXTH REVERSE
30 30 14 4 28 9 10 8 20 100 40 68 54 47 47 GEAR RATIOS RATIO 4.46 2.61 1.72 1.24 1 0.84 4.06
22 22 10 20 15 74 30 50 40 35 35
33 80 88 71 -
42RLE AUTOMATIC TRANSMISSION GENERAL SPECIFICATIONS Transmission Type Lubrication Method Cooling Method GEAR 1st Gear 2nd Gear 3rd Gear (Direct) 4th Gear (Overdrive) Reverse Gear BEARING PRELOAD (Drag Torque) DESCRIPTION Output Shaft CLUTCH PACK
Four-Speed Automatic, Electronically Controlled, Fully Adaptive, Electronically Modulated Torque Converter Pump (internal - external gear-type) Water Heat Exchanger / Air-to-Oil Heat Exchanger GEAR RATIOS RATIO 2.84:1 1.57:1 1.00:1 0.69:1 2.21:1 METRIC 0.22-0.903 N·m STANDARD 1-8 in. lbs.
DESCRIPTION Low/Reverse Clutch (Select Reaction Plate) Two/Four Clutch (No Select) Reverse Clutch (Select Snap Ring) Overdrive Clutch (No Select) Underdrive Clutch (Select Reaction Plate) INPUT SHAFT DESCRIPTION End Play OIL PUMP CLEARANCES DESCRIPTION Outer Gear-to-Crescent Inner Gear-to-Crescent Outer Gear-to-Pocket Outer Gear Side Clearance Inner Gear Side Clearance TORQUE SPECIFICATIONS DESCRIPTION Bolt, Converter-toDriveplate Bolt, Fluid Filter-toValve Body Bolt, L/R Clutch Retainer-to-Case Bolt, Adapter/ Extension Housing Bolt, Manual Valve Lever-to-Manual Valve Bolt, Oil Pan-to-Case Bolt, Oil Pump-to-Case Bolt, Park Sprag Retainer Bolt, Reaction Shaft Support Halves Bolt, Solenoid/Pressure Switch Assy-to-Valve Body Bolt, Torque Converter Housing to Engine Block Bolt, Valve Body-toCase Bolt, Valve Body-toTransfer Plate Fitting, Cooler Line Nut, Output Shaft Plug, Pressure Tap Bolt, Input Speed-toCase Sensor N·m 88 5 5 54 5 20 30 4.5 28 5.5 129 12 5 47.5 271 5 9
METRIC 0.84-1.60 mm 0.76-2.64 mm 0.89-1.37 mm 1.07-3.25 mm 0.94-1.50 mm
STANDARD 0.033-0.063 in. 0.030-0.104 in. 0.035-0.054 in. 0.042-0.128 in. 0.037-0.059 in.
METRIC 0.127-0.635 mm METRIC 0.060-0.298 mm 0.093-0.385 mm 0.089-0.202 mm 0.020-0.046 mm 0.020-0.046 mm Ft. Lbs. 65 40 14.5 95 35 200 -
STANDARD 0.005-0.025 in. STANDARD 0.0023-0.0117 in. 0.0036-0.0151 in. 0.0035-0.0079 in. 0.0008-0.0018 in. 0.0008-0.0018 in. In. Lbs. 45 45 45 265 40 250 50
105 45 45 80
Bolt, Output Speed-toCase Sensor 545RFE Transmission COMPONENT Output Shaft End Play Input Shaft End Play 2C Clutch Pack Clearance 4C Clutch Pack Clearance L/R Clutch Pack Clearance OD Clutch Pack Clearance UD Clutch Pack Clearance Reverse Clutch Pack Clearance Recommended fluid 1ST 2ND 2ND PRIME 3RD 4TH 5TH REVERSE TORQUE SPECIFICATIONS DESCRIPTION Fitting, cooler line at trans Bolt, torque converter housing to engine upper four Bolt, torque converter housing to engine lower four Bolts, transmission collar Bolt, torque converter to driveplate Bolt/nut, crossmember Bolt, driveplate to crankshaft Bolts, clevis bracket / rear support Bolt , converter housing Bolt, oil pan Screw, primary fluid filter Nuts, transfer case Oil Filter, Cooler Return Bolt, oil pump Bolt, oil pump body to cover
9
-
80
METRIC 0.22-0.55 mm 0.46-0.89 mm 0.455-1.335 mm 0.770-1.390 mm 1.00-1.74 mm 1.103-1.856 mm 0.84-1.54 mm 0.81-1.24 mm Mopar® ATF +4 GEAR RATIOS 3.00:1 1.67:1 1.50:1 1.00:1 0.75:1 0.67:1 3.00:1 N·m 17.5 41 54 68 31 68 75 47 68 12 4.5 35 9.5 28 4.5 Ft. Lbs. 30 40 50 23 50 55 35 50 26
STANDARD 0.009-0.021 in. 0.018-0.035 in. 0.018-0.053 in. 0.030-0.055 in. 0.039-0.069 in. 0.043-0.073 in. 0.033-0.061 in. 0.032-0.049 in.
In. Lbs. 155
270 -
105 40 84
-
250 40
Screw, plate to oil pump body Bolt, valve body to case Plug, pressure test port Bolt, reaction shaft support Screw, valve body to transfer plate Screw, solenoid module to transfer plate Screw, accumulator cover Screw, detent spring Bolt, input speed sensor Bolt, output speed sensor Bolt, line pressure sensor Bolt, extension housing Screw, manual valve cam retaining Screw, manual selector shaft retaining Cross-bolt, manual selector shaft
4.5 12 5 12 5.5 6 7 4.5 12 12 12 54 4.5 28 16
40 -
40 105 45 105 50 50 60 40 105 105 105 40 250 140
TRANSFER CASE - NV241 GENII DESCRIPTION N-m Plug, Detent 16-24 Plug, Drain/Fill 20-34 Bolt, Extension 16-24 Housing Bolt, Case Half 20-27 Screw, Oil Pump 39432 Nut, Front Companion 122-176 Flange Nut, Range Lever 27-34 Sector Support 27-42 Nuts, Mounting 30-41 Position Sensor 20-34 TRANSFER CASE - NV241OR DESCRIPTION Plug, Detent Plug, Drain/Fill Bolt, Rear Extension Bolt, Front Input Retainer Bolt, Case Half Nut, Front Yoke
Ft. Lbs. 39434 15-25 39434 15-24 39306 90-130 20-25 20-30 20-30 16-25
In. Lbs. -
N·m 16-25 20-34 16-24 21 20-27 122-176
Ft. Lbs. 39434 15-25 39434 16 15-20 90-130
In. Lbs. -
Nut, Rear Companion Flange Bolt, Shift Lever Nuts, Mounting Bolts, U-Joint Support, Sector Sensor, Transfer Case Position WHEELS DESCRIPTION Lug Nut 1/2 X 20 with 60° Cone Spare Wheel Lug Nut TIRE PRESSURE MONITOR DESCRIPTION Tire Pressure Sensor/ Transmitter Mounting Nut BODY DESCRIPTION A/c expansion valve nut Backlite hinge bolts Body isolator mounting bolts Body isolator to body nuts Brake booster bracket nuts Center OCS strain gauge stud nut Door carrier plate screws Door hinge pin nut Door hinge to body bolts Door hinge to hinge bolts Door latch adjustment screw Door latch mounting screws Door latch striker bolts Four door rear seat 40% inner seat back pivot nut Four door rear seat center belt buckle bolt Four door rear seat cushion pivot bolts
258-312 20-34 30-41 19 27-42 20-34
190-230 15-25 20-30 17 20-30 16-25
-
N·m 115-170 54–108
Ft. Lbs. 85-125 40–80
In. Lbs. — —
N·m 8
Ft. Lbs. —
In. Lbs. 71
N·m 23 10 108 54 18 45 10 8.5 28 26 3 8 26 25 61 25
Ft. Lbs 17 — 80 40 13.5 33 — — 21 19 — — 19 18.5 45 18.5
In. Lbs. — 90 — — — — 90 75 — — 26.5 71 — — — —
Four door rear seat front mounting fasteners Four door rear seat headrest bolts Four door rear seat inner latch floor bolts Four door rear seat latch to back frame bolts Four door rear seat outboard latch floor bolts Four door rear seat rear mounting bolt Four door rear seat rear mounting nuts Four door rear seat seat cushion pivot bolt Four door retractor screw Four door seat cushion pivot bolt Front door exterior handle nut Front door glass run nut Front door interior handle screw Front seat back assembly bolts Front seat belt anchor bolt Front seat belt buckle bolt Front seat belt turning loop screw Front seat mounting bolts Front seat riser nuts Half door latch nut Hard top front bolts Hard top side bolts Hood catch bracket nuts Hood catch nuts Hood hinge to body bolts Hood hinge to hood bolts Hood safety catch bolt Instrument panel center support bracket fasteners Instrument panel fence line nuts Instrument panel side support bolts
61 8 25 45 25 61 85 25 55 25 4.5 10 8.5 47 40 50 40 61 28 4.5 10.5 18 7 15 24 26 11 8 12 11
45 — 18.5 33 18.5 45 62.5 18.5 41 18.5 — — — 34.5 29.5 37 29.5 45 21 — — 13 — 11 18 19 8 6 9 8
— 71 — — — — — — — — 40 90 75 — — — — — — 40 93 — 62 — — — 97 71 — —
Lower fender to sill bolts Manual sifter bolt OCS riser nuts Outside rearview mirror bolts Rear door exterior handle nut Rear door glass run bolt Rear door glass run nut Rear door interior handle screw Rear view mirror set screw Seat side airbag nuts Side step bracket bolts Side step sill nuts Soft top pivot knuckle bolts Speaker pod screws Sport bar cross bar bracket bolts Sport bar front cross bar bracket bolts Sport bar rear bolts Sport bar rear cross bar bracket bolts Sport bar side bar bolts Sport bar side bar to windshield frame bolts Sport bar to b-pillar bolts Steering column opening reinforcement plate bolts Tailgate exterior handle nuts Tailgate hinge to body bolts Tailgate hinge to tailgate bolts Tailgate latch screws Tailgate stabilizer insert and cup bolts Tailgate striker bolts Two door rear seat back frame to cushion bolts Two door rear seat back latch bolts Two door rear seat center belt buckle bolt Two door rear seat cushion to back bolts
12 33 28 13 4.5 12 10 8.5 2 7 24 12 14 10 19 19 19 19 19 23 19 11 4.5 26 20 8 10 28 50 45 55 50
9 24.5 21 10 — 9 — — — — 18 9 10 — 14 14 14 14 14 17 14 8 — 19 15 — — 21 37 33 41 37
— — — — 40 — 90 75 18 62 — — — 90 — — — — — — — — 40 — — 71 90 — — — — —
Two door rear seat front latch cushion frame bolts Two door rear seat rear latch nuts Upper fender fasteners Windshield frame hinge to body bolts Windshield frame reinforcement bracket bolts A/C SYSTEM ITEM A/C Compressor Freeze-up Control
45 10 5 20 20
33 — — 15 15
— 90 44 — —
DESCRIPTION Zexel DKS-17DS Evaporator Temperature Sensor
Low PSI Control
A/C Pressure Transducer
High PSI Control
A/C Pressure Transducer
High Pressure Relief Valve
R-134a Refrigerant Charge Capacity A/C Clutch Coil Draw A/C Clutch Coil Resistance A/C Clutch Air Gap DESCRIPTION All Screws NOT Listed Below A/C Compressor Bolts A/C Compressor Clutch Field Coil Screws
0.51 kg (1.125 lbs). 3.3 amps 4.2 ± 0.2 ohms 0.30 - 0.60 mm (0.012 - 0.024 in.) N·m 1.2 28 5 Ft. Lbs. – 21 –
NOTES ZXL-100 PAG Oil HVAC housing mounted - input to powertrain control module (PCM) or engine control module (ECM), depending on engine application A/C discharge line mounted input to powertrain control module (PCM) or engine control module (ECM), depending on engine application - PCM/ECM disengages compressor clutch below 0.451 volts A/C discharge line mounted input to powertrain control module (PCM) or engine control module (ECM), depending on engine application - PCM/ECM disengages compressor clutch above 4.519 volts A/C Compressor mounted opens at a discharge pressure over 3430 - 3930 kPa (497 - 570 psi) Also see A/C Underhood Specification Label located in the engine compartment @ 12V ± 0.5V @ 25° C (77° F) When measured across coil lead connector @ 25° C (77° F)
In. Lbs. 10 – 44
A/C Compressor Shaft Bolt A/C Compressor Field Coil Connector Bracket Screw A/C Condenser to Radiator Bolts A/C Heater Control Screws Air Inlet Housing to Instrument Panel Support Bolts Blend Door Lever Screw Discharge Line to Condenser Nut Discharge Line to Compressor Nut Expansion Valve Bolts HVAC Housing to Instrument Panel Support Bolts Liquid Line to Condenser Nut Mode Door Cam Screw Receiver/Drier to Condenser Bolt Suction Line to Compressor Nut Suction and Liquid Lines to Expansion Valve Nut LAMPS DESCRIPTION Center High Mounted Stop Lamp (CHMSL) Mounting Screws Front Fog Lamp Mounting Screws Left Multi-Function Switch Mounting Screw License Plate Bracket Mounting Screws Park Brake Switch Mounting Screw Rear Fog Lamp Mounting Screws Rear Lamp Unit Mounting Screws
20 4.3 5 2 4 0.6 23 23 11 4 23 0.6 22 23 8
– – – – – – 17 17 – – 17 – 16 17 –
177 38 45 17 35 5 – – 97 35 – 5 – – 70
N·m 2 2 1 1.5 2.5 3 1.5
Ft. Lbs. -
In. Lbs. 20 18 10 15 24 27 15
