I6 4.0 Part 8 - Induction and Exhaust
I6 4.0 Part 8 - Induction and Exhaust
I6 4.0 Part 8 - Induction and Exhaust
Induction System
INTAKE MANIFOLD
The 4.0L engine standard production intake manifold is
made of cast aluminum and uses eleven bolts to mount to
the cylinder head (Figure 4-48). This mounting style
improves sealing and reduces the chance of leaks.
Knock Sensor
Fuel Injectors
B+ Latch Relay
PCM Inputs
The PCM is powered by the vehicles battery. When the
ignition is turned to the ON or START position, the
following inputs are supplied to the PCM:
Battery Voltage
Ignition Switch ON
Engine Warm-up
Idle
Cruise
Deceleration
Knock Sensor
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Start Signal
PCM Outputs
Throttle Body
Filtered air from the air cleaner enters the intake manifold
through the throttle body. Fuel does not enter the intake
manifold through the throttle body. Fuel is sprayed into the
manifold by the fuel injectors. This throttle body, mounted
on the intake manifold, contains an air bypass passage that
is used to supply air for idle conditions, and a throttle valve
for above idle conditions.
The throttle position sensor and idle speed stepper motor
are attached to the throttle body. The accelerator cable is
connected to the throttle valve through a bellcrank and
linkage mounted to the intake manifold.
There are different throttle bodies for automatic and manual
transmission equipped vehicles. The throttle valve is not
controlled by the PCM:
Fuel Rail
The fuel rail supplies fuel to the injectors and is mounted to
the intake manifold (Figure 4-47). The fuel pressure
regulator is attached to the rail and the fuel pressure test
port is integral with the rail. The fuel rail is not repairable.
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MOU~TING
BOLTS (4)
FUEL RAIL
INJECTOR
PRESSURE TEST
PORT CAP
M
8
e
3
Figure 4 - 47
Fuel Pressure Regulator
The fuel pressure regulator used with the MPI fuel system
is a vacuum assisted, non-adjustable type. The regulator is
mounted on the output end of the fuel rail and is connected
to intake manifold vacuum. The regulator is calibrated to
maintain fuel system pressure at approximately 214 kPa (3 1
psi) with vacuum applied while the engine is at idle. Fuel
pressure will be 55-69 kPa (8-10 psi) higher if vacuum is
not applied to the regulator.
P5249792
P52499 18
P4876273
P4876272
P4529393
TURBOCHARGING
Turbocharging is not for the amateur. People who want
turbochargers on their race vehicles are those looking for
an added amount of horsepower to their already wellrunning engines.
Turbocharging is not a new engineering feature. It has been
used for many years in many applications. Even some
production models of the mid-1960s had a turbocharging
option. However, after a year or two in production, these
options were dropped.
Over the past several years, interest in turbocharging has
increased rapidly. Much of this interest is centered around
the Street Machine, Street Rod, and recreational vehicle
segments of the automotive high performance scene. We
have been evaluating the turbocharging of Jeep engines for
several years. We have been primarily interested in gaining
experience and knowledge in the area and have left the
marketing of kits, etc., to the aftermarket manufacturers.
Turbocharging is best suited to small engines with low
compression ratios because of the quality of gasoline
currently available. Turbochargers can add a lot of power to
an engine without having to change engine displacement,
swap engines, or disassemble the engine. Most aftermarket
systems just bolt right on. Jeep engines are particularly
well-suited to turbocharging because of their heavy duty
construction and reliability.
Choosing a turbocharger can be a complicated task which is
beyond the scope of this discussion. For details, we suggest
that you contact the various turbo manufacturers. In
general, small engines should use small turbochargers.
Also, small turbochargers are best suited for general
purpose use. The larger turbochargers are designed for high
engine speeds and high outputs, which make them best
suited for actual racing applications. The boost pressure
from the turbocharger for a general purpose application
would be in the 5 to 10 psi range. For boost pressures over
10 psi and/or higher compression ratios (over 8.0: l), water
and/or alcohol injection is needed. For general purpose use,
a conservative camshaft is an advantage because it
improves low speed response. Also, for general purpose
use, water injection is not recommended because if the
water is allowed to run out, excessive detonation and
engine failure would quickly result.
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226
Once you have the special intake manifold, the blower can
be bolted on to your engine. After the carburetor or fuel
injection is added to the top of the blower, a hole is cut in
the hood, fuel lines and throttle linkage added, and
everything is done except for the blower drive, which is
added to the front of the engine. The adaptation of the
blower to the intake for your specific engine and the blower
drive itself are best left to the dual purpose blower
specialists that make the kits.
Sources
The various engine builders and suppliers in the
supercharging area are very important people to keep in
touch with to be able to keep up-to-date. Their addresses
are listzed below.
B&M
9142 Independence Avenue
Chatsworth, California 9 1311
www.bmracing.com
Crane Cams
530 Fentress Boulevard
Daytona Beach, Florida 32114
www.cranecams.com
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Exhaust System
INTRODUCTION
The basic exhaust system consists of an exhaust manifold,
exhaust pipe with oxygen sensor, catalytic converter, heat
shield(s), muffler and tailpipe.
The 4.0L engine uses a seal between the exhaust manifold
and exhaust pipe to assure a tight seal and strain-free
connection, a single muffler, and a single, monolithic-type
catalytic converter.
The exhaust system must be properly aligned to prevent
stress, leakage, and body contact. If the system contacts any
body panel, it may amplify objectionable noises originating
from the engine or body.
When inspecting an exhaust system, critical items to look
for are cracked or loose joints, stripped screw or bolt
threads, corrosion damage, and worn, cracked or broken
hangers. Replace all components that are badly corroded or
damaged. DO NOT attempt to repair. When replacement is
required, use original equipment parts (or their equivalent).
This will assure proper alignment and provide acceptable
exhaust noise levels.
All exhaust systems should be checked for leaks. A leak in
the exhaust system is unsafe and will cost you power. DO
NOT, under any circumstances, use flexible tubing
anywhere in the exhaust system as the efficiency of the
flow will be reduced.
Caution: Avoid application of rust prevention compounds
or undercoating materials to exhaust system floor pan heat
shields. Application of coating will result in excessive floor
pan temperatures and objectionable fumes. Light overspray
near the edges is permitted.
Intake/Exhaust Manifold Gasket
The 4.0L engine uses a common intake and exhaust
manifold gasket. This gasket is designed for original
replacement. For 4.0L engine only.
P4529243
Catalytic Converter
There is no regularly scheduled maintenance on any
DaimlerChrysler catalytic converter. If damaged, the
converter must be replaced.
The stainless steel catalytic converter body is designed to
last the life of the vehicle. Excessive heat can result in
bulging or other distortion, but excessive heat will not be
the fault of the converter. A fuel system, air injection
system or ignition system malfunction that permits
unburned fuel to enter the converter will usually cause
overheating: If a converter is heat-damaged, correct the
cause of the damage at the same time the converter is
replaced. Also, inspect all other components of the exhaust
system for heat damage.
Caution: Due to exterior physical similarities of some
catalytic converters with pipe assemblies, extreme care
should be taken when selecting replacement parts. For
availability and pricing, contact your local ChryslerPlymouth-Dodge-Jeep dealer.
The combustion reaction caused by the catalyst releases
additional heat in the exhaust system, causing temperature
increases in the area of the reactor under severe operating
conditions. Such conditions can exist when the engine
misfires or otherwise does not operate at peak efficiency.
DO NOT remove spark plug wires from plugs or by any
other means short out cylinders if exhaust system is
equipped with a catalytic converter. Failure of the catalytic
converter can occur due to temperature increases caused by
unburned fuel passing through the converter.
Unleaded gasoline MUST be used to avoid poisoning the
catalyst core. DO NOT allow engine to operate above 1,200
rpm in neutral for extended periods over 5 minutes. This
condition may result in excessive exhaust systemlfloor pan
temperatures because of no air movement under the vehicle.
POSSIBLE CAUSE
CONDITION
XCESSIVE EXHAUST NOISE
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axhaust system.
3. Replace exhaust pipe.
4. Tighten connection attaching
nuts.
5. Replace exhaust manifold.
6. Tighten exhaust manifold to
cylinder head stud nuts or bolts.
7. Remove restriction, if possible.
Replace muffler or tailpipe, as
necessary.
8. Re-align exhaust system to clear
surrounding components.
~~
gaskets.
Heat Shields
Heat shields are needed to protect both the vehicle and the
environment from the high temperatures developed in the
vicinity of the catalytic converter. The combustion reaction
facilitated by the catalyst releases additional heat in the
exhaust system. Under severe operating conditions, the
temperature increases in the area of the reactor. Such
conditions can exist when the engine misfires or otherwise
does not operate at peak efficiency. DO NOT remove spark
plug wires from plugs or by any other means short out
cylinders. Failure of the catalytic converter can occur due to
a temperature increase caused by unburned fuel passing
through the converter.
The two exhaust manifolds are log style and are made of
high silicon molybdenum cast iron. The exhaust manifolds
share a common gasket with the intake manifold. The
exhaust manifolds also incorporate ball flange outlets for
improved sealing and strain free connections.
2.
3.
4.
Removal
Note: The engine intake and exhaust manifold must be
removed and installed together. The manifolds use a
common gasket at the cylinder head.
1
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7.
8.
Install the fuel system supply line to the fuel rail assembly.
Before connecting the fuel supply line to the fuel rail
inspect the O-rings and replace if necessary. (Refer to the
proper service manual for correct procedure.)
9.
-t
Installation
rn
2.
REAR
FRONT
EXHAUST MANIFOLD
(Figure 4-48).
6. Tighten the fasteners in sequence and to the specified
torque (Figure 4-48):
Fastener Numbers 1 through 5 - Tighten to 33 N*m
(24 ft-lbs) torque.
Fastener Numbers 6 and 7 - Tighten to 31 Nmm
(23 ft-lbs) torque.
0
Figure 4 - 48
"
MAN'FoLD
8ob8988a
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Wrangler, 1995.
p4876260
Wrangler, 1997-98.
p4529530
p48769 18
Cherokee, 1986-91.
p524997 1
P487635 1
P4876352
P4876353
Mufflers
Cat-Back Performance Exhaust
Our Mopar Performance Parts cat-back exhaust systems
are specifically engineered to fit your vehicle - no
modifications are required. These kits simply bolt into the
OE hangers and brackets. Features include heavy wall, 16
gauge aluminized tubing with true mandrel bends
allowing for m i m u m flow and minimum back pressure.
A low restriction, aluminized case, flow-through muffler
with a 3" core produces a deep mellow exhaust tone. No
fiberglass packing to bum out. Kits include all necessary
installation hardware. For 4.0L engines only.
P5249739
P4876277
P4876359
P4876089
P4876627