For 2015, cars with the 2.4 liter engine got a Partial Zero Emissions Vehicle package in the 14 states following California standards. The turbocharged Hurricane engines have their own page.
The “World Gas Engine” spawned a more powerful new generation, dubbed “Tigershark,” in 2.0 and 2.4 liter versions, starting in 2013. TigerShark production goals were set at 600,000 per year; the engine is used in Cherokee, 200, Dart, Journey, ProMaster City, and Renegade. In January 2015, Chrysler reported that the 2.0 was made in Dundee, Michigan, while the 2.4 was made in Dundee, Saltillo (Mexico), and Trenton (Michigan).
The VVT system on the 2.0 and 2.4 was reworked for a broader power band, with the intakes swapped and the valvetrain upgraded to roller cam followers, doing away with the buckets on the valve springs.
According to an industry analyst, the 2.4 is a surprisingly “beefy” engine, with cast steel main bearings; the three middle bearings have a bridge connecting them for added stiffness. The forged crank is unusual, and the oil pump is “massive,” partly, it seems, to get the flow and pressure needed for MultiAir actuation (it has a few patent numbers stamped in it as well). The engine appears to have been redesigned either to allow for extra power, or to reduce vibration and noise.
184 hp @ 6,250
Refinement was key in the redesign of the engine from the original “sewing machine” World Engine to TigerShark, from its isolated aluminum head cover with an integrated oil-separation system, to a high-pressure, die-cast aluminum block. Between the block and the steel oil pan is a lightweight, aluminum ladder frame with an integral oil filter and oil cooler adapter for extra rigidity. Acoustic material is also sandwiched between the oil pan’s outer and inner stampings.
The Tigershark’s polymer-coated piston skirts and tighter piston-to-bore tolerances cut noise and vibration. Each bore has squirters that spray oil on the bottom of the pistons and bore walls for cooling. The forged-steel crankshaft connects with new powder-forged steel connecting rods with full floating piston pins with hard carbon coatings to cut friction.
The Tigershark has a two-stage oil-pressure relief system that reduces engine-oil pumping loads at low engine speeds, while maintaining high pressures when needed. It also has:
MultiAir is Fiat’s variable valve timing and lift technology, with separate timing for each cylinder, controlled by electro-hydraulic valve actuators. A solenoid regulates the amount of oil sent to the actuator, which controls the timing and amount of lift, from completely closed to completely open. A single pair of wires leads to each MultiAir actuator (the actuators and most other parts for the system are made in the United States.) The 2.4 uses MultiAir 2, which controls both valve opening and closing.
The “World Engines” (later altered to “World Gas Engines,” or “WGE”) replaced Chrysler’s 1994-debut 2.0 / 2.4 liter four cylinder engine family, starting in 2006.
The WGE had a Mercedes-derived dual variable valve timing (the “Neon engines” had no variable valve timing) and a flow-control valve intake manifold; the blocks were designed jointly by Chrysler, Mitsubishi, and Hyundai, and were used by all three, with different heads, fuel delivery, and other systems. Reviewers generally praised the Hyundai version, and put the Chrysler version last of the three, calling it rough, peaky, and noisy. It was, though, reportedly cheaper to build than the prior engines, and had much higher peak power ratings.
The Chrysler engines were made in three displacements: 1.8, 2.0, and 2.4 liters. The 2.4 was rated at 172 horsepower and 165 lb-ft of torque. Chrysler was the first company to offer dual VVT in the United States on entry-level vehicles.
The engines were designed to be turbocharged and supercharged, with large water jackets and metal areas around each siamesed cylinder.
Noise was reduced somewhat through an isolated valve cover and damped oil pan, select-fit parts, and the flow control valve intake manifold. The bell housing was designed for a tighter than usual connection to the transmission, to reduce oil leaks in high-mileage engines.
The engine was built in a new joint-venture plant in Dundee, Michigan (south of Ann Arbor); blocks were made by J.L. French of Wisconsin. Starting in 2013, production of the new TigerShark version began in the “old” Trenton Engine Plant in Michigan.
The photos with blue backgrounds (or no backgrounds) are courtesy of Chrysler; these are from the first generation.
The plastic intake manifold had equal-length runners with electrical flow control valves that, when closed, increased air tumble by blocking over half the intake port. Over 3,200 rpm, the valves were opened to allow full airflow.
The variable valve timing used by Chrysler was developed by Mercedes and tuned at Auburn Hills. The system, used in the original 2.4 and in all the 2.0s, used oil under pressure to adjust timing using cam phasing, so that timing was continuously variable. There was little overlap at idle and more overlap at speed, to permit built-in exhaust gas reburning without a pump.
The exhaust cam could move through 35 degrees; the intake through 40 degrees. The cams rode on tappets that came in four dozen very similar thicknesses; the tappets were matched to the individual heads during assembly, eliminating the need to adjust valve lash.
The 1.8, 2.0, and 2.4 engines used the same block, with different strokes or piston liner thicknesses; short-skirt pistons had friction-reducing graphite patches. The crankshaft was forged steel, drawing oil from the oil pan, with an integrated pump. Key components such as pistons and bearings were matched to blocks to reduce machining.
GEMA never built engines for anyone but Chrysler, and eventually was absorbed back into the company. The million-square-foot GEMA plant cost over $700 million; each of its two plants had capacity of 420,000 units per year. One was idled, with assembly lines for making the engines placed in Trenton (Michigan) and Saltillo (Mexico) during 2013-14.
144 cu. in. (2360 cu. cm)
Bore x Stroke
3.46 x 3.82 (88 x 97)
Chain-driven DOHC, 16 valves
High-pressure die-cast aluminum block, dry iron liners, cast aluminum heads and ladder frame, forged steel crank
172 bhp (129 kW) @ 6,000 rpm
184 bhp (138 kW) @ 6,250
165 lb.-ft. @ 4,400 rpm
171 lb.-ft. (200 N•m) @ 4,800
5 qt. (4.7L) 5W-20
7.2 qt. (6.8L)
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