heater JEEP CJ 1953 Service Manual

GENERAL
DATA
A-8. GENERAL SPECIFICATIONS

MODEL:
CJ-3B
CJ-5,
CJ-5A
DJ-5
CJ-6,
CJ-6A
DJ-6

Engine:.
Number
of
Cylinders

Bore.
.

Stroke.
Displacement
Compression
Ratio:
Late
Production —
Standard
—
Optional.
—
Optional.

Early
Production —
Standard

—
Optional.

—
Optional.

Compression
Pressure

Horsepower
(max.
Brake)
Horsepower
(SAE)

Torque
(Max. at 2000
rpm.).
. . .

Engine:
Number
of
Cylinders

Bore

Stroke

Displacement

Compression
Ratio

Horsepower
(max.
Brake).
Horsepower
(SAE)

Torque
(Max. at 2400
rpm.).
. . .

Wheelbase

Tread
(front and
rear)
,

Height
(Over
all)
Length
(Over
all).

Width
(Over
all)

Ground
Clearance
F-4

4
3.125 [7,93 cm.]
4.375 [11,11 cm.]
134.2 cu. in. [2,20 ltr.]
7.4:1 7.8:1
6.9:1
120 to 130 psi.
[8,4 a 9,2 kg-cm2] 75 <§ 4000 rpm.
15.63
114 lb-ft. [15,8 kg-m.]

80"
[2,03 m.]
487-'f6/' [1,23 m.|
6634" [1,68 m.j

129%"
[3,30 m.]
68%"
[1,75 m.] 8" [20,32 cm.]
F-4

4
3.125 [7,93 cm.]
4.375 [11,11 cm.]
134.2 cu. in. [2,20 ltr.]
6.7:1 7.1:1
6.3:1 7.4:1
7.8:1
6.9:1
120 to 130 psi.
[8,4 a 9,2 kg-cm2] 75 @ 4000 rpm. 15.63
114 lb-ft. [15,8 kg-m.]

V-6
6
3.750" [9,525 cm.]
3.400" [8,636 cm.]
225 cu.
in.
[3,69 ltr.] 9.0:1
160 @ 4200 rpm. 33.748
235 lb-ft. [32,49 kg-m.]
81"
[2,06 m.]

48K6"
[1,23 m.]

67"
[1,70 m.]

138%"
[3,51 m.]
71%"
[1,82 m.] 8" [20,32 cm.]
F-4

4
3,125 [7.93 cm.]
4.375 [11,11 cm.]
134.2 cu. in. [2,20 ltr.]
6.7:1 7.1:1
6.3:1 7.4:1
7.8:1
6.9:1
120 to 130 psi.
[8,4 a 9,2 kg-cm2] 75 @ 4000 rpm.
15.63
114 lb-ft. [15,8 kg-m.]

V-6
6
3.750" [9,525 cm.]
3.400" [8,636 cm.]
225 cu. in. [3,69 ltr.] 9.0:1
160 @, 4200 rpm. 33 748
235 lb-ft. [32,49 kg-m.]
101"
[2,57 m.]
48^6* ]1,23 m.]

67"
[1,70 m.]
1583/4" [4,02 m.]
71%"
[1,82 m.] 8" [20,32 cm.]

CAPACITIES:
U.S.

Imperial
Metric

Fuel
Tank
(Approximate):
Early
Models

Late
Models

Cooling
System

F4
Models

V-6
Models
Note: If not equipped
with
heater deduct 10.5 gal.
16 gal.
12 qt.
10 qt.
1 qt. 8.8 gal.
13.3 gal.
10 qt. 8 qt.
.8 qt. 39,75 ltr.
60,57 ltr.
11,4 ltr. 9,5 ltr.
0,9 ltr.

CJ-
3B

CJ-5
CJ-6
DJ-5

DJ
-6

lb. kg. lb.
kg. lb.
kg. lb.
kg. lb.
kg.

WEIGHTS
(Approximate):
Gross
Vehicle
Weight
(GVW).
3500
1587 3750 1701 3900 1769 3200 1451 3200 1451

Shipping
— V6
Engine
—
'—
2240 1016 2302 1044 1900 862 2033 922

F4
Engine
2132
967 2163
981 2225
1009 1796 814 1858 842

Curb
— V6
Engine
— —

2351 1066 2413 1094 2011 912 2144 972

F4
Engine
2243
1017 2274 1031
2336 1060 1907 865 1969 893

For
Canvas
Half-Top
Model, add 35
17 38
17 38
17 38
17 38 17

For
Canvas
Full-Top
Model, add 56
25 56 25 60 27 56 25 60 27

For
Hard
Top Model, add
~~
340
154 340 154 6

'Jeep*
UNIVERSAL SERIES
SERVICE
MANUAL

B
LUBRICATION
AND
PERIODIC SERVICES

Contents
PAR. SUBJECT
PAR.
SUBJECT

GENERAL
.B-l
Chassis
Lubrication
B-7
Engine
Lubrication System B-4, B-6

Special
Lubricants B-2

Fresh
Lubricant.
.B-3

LUBRICATION CHARTS
. Pages 8, 9

SERVICE
MAINTENANCE SCHEDULE.
.B-8
Air
Cleaner
B-2
5,
B-2
6
Air
Filter
—
F.E.E.C.
System Canister
B-2
4

Axle
U-Bolts B-49 Body
Lube
Points: B-65 Hood Hinge Pivot Points B-66

Glove
Compartment Door
Latch
B-6
7
Tailgate Hinges .B-68

Brakes,
Adjust .B-41
Brake
Linings .B-42

Brake
Master Cylinder B-40
Charging
Circuit
B-l9
Clutch
. B-43, B-44
Cooling System—Radiator. B-28, B-29 Differentials
........
.B-50, B-51, B-52, B-53

Distributor
B-14, B-l5

Engine
Oil B-9
Engine
Oil
Filter
B-10, B-ll

Engine
Tune-Up B-20
Exhaust
Emission Control System
B-2
2

Exhaust
Manifold Heat Control Valve. . . .B-l2

Exhaust
System
B-2 3
Fan
Belt . .B-21
Front
Axle U-Joint B-54, B-55

Generator
.B-16
Headlights B-61
Heater Controls B-62
Lights
and Controls B-59 Positive Crankcase Ventilation Valve. . . .B-l3
Shock Absorbers B-48
Spark
Plugs. B-17
Speedometer Cable. .B-60

Spring
Bushings.. . .B-46

Spring
Shackles .B-47
Steering
Gear
B-2 7
B-l. GENERAL
All
'Jeep' Universal vehicles require periodic
lubri­

cation and other maintenance services for normal
vehicle
usage
and application to promote satis­ factory operation and prevent
excessive
wear. Un­
der severe operating or atmospheric conditions
these
services should be performed more
often
than
under normal conditions. It should also be remem­
bered that common short trips and
stop-and-go
driving
are more severe on lubrication
points
than
Starting
Circuit
B-l8

Tie
Rod and Drag
Link
Sockets
.
B-45

Tires
B-64

Transmission
and Transfer Case—
Lubricant
Level
Check B-30

General
B-31

Transfer
Case B-32
Transmission
.B-33

Transmission
and Transfer
Case
—

Lubricant
Change .B-34
General
.B-35

Transfer
Case B-36
Transmission
B-3
7, B-38

Transfer
Case Linkage B-39

Universal
Joints and Slip Joints.
.......
.B-58

Wheel
Bearings..
.........
. . .B-56, B-57
Windshield
Wiper and Washer B-63

LUBRICATION
OF

OPTIONAL EQUIPMENT
B-69
Centrifugal
Governor. .B-71
Pintle Hook .B-70

Powr-Lok
or
Trac-Lok
Differential B-72

PARTS REQUIRING
NO LUBRICATION.
. . .B-73

Alternator
Bearings. B-76
Clutch
Release Bearings.
.............
.B-74
Shock Absorbers B-78
Springs
B-7
7
Starter
Motor Bearings B-75

Water
Pump Bearings B-74

LUBRICATION REQUIREMENTS FOR OFF-HIGHWAY OPERATIONS
B-79

Air
Cleaner B-82

Chassis
Lubrication
B-83

Engine
Oil B-80
Engine
Oil
Filter
B-81
Differentials .B-86
Front
Axle U-Joints. B-84
Transfer
Case and Transmission .B-85
constant
speed
driving on highways, and even more
intensified in extreme cold or hot weather; there­ fore, vehicles driven under
these
conditions must
be lubricated and serviced more
often
than nor­ mally operated vehicles. The specifications of
types
and
amounts of lubricant given in the Lubrication

Chart
and
text
of this section should be closely
followed. The off-highway operation lubrication
notes,
given in the last part of the section, should
be followed when applicable. 7

B
LUBRICATION B-3.
SERVICE
MAINTENANCE
SCHEDULE

Perform
the following operations at the mileage shown. Two thousand miles equals
3,200
km.

SERVICE
MAINTENANCE
SCHEDULE

OPERATION
VEHICLE
^ n>
MILEAGE
IN
THOUSANDS

6 8 10 12 24 30
Check Wheel Nut Torque*
Check
Fluid
Level
in Battery X Check
Fluid
Level
in Brake Master Cylinder0. X
Service
Cooling
System X Service Tires X

Lubricate
Distributor
Cam Lubricator (F4-134) X
Lubricate
Steering Linkage X

Lubricate
Propeller Shaft Universal Joints X

Lubricate
Propeller Shaft
Slip
Joints ; X
Lubricate
Tie Rod and Drag
Link
Sockets................................... X Change Engine
Oil
and
Filter,
and Service Air Cleaner (F4 134 Engine)** X
Change Engine Oil and
Filter,
and Service Air Cleaner (V6-225 Engine)**....
Check Brake Operation and Pedal
Free
Play X Check
Clutch
Pedal
Free
Play. .... X
Check all
V-Belt
Tensions X
Check Exhaust Emission System
(If
so equipped)*** \ X
Service Positive
Crankcase
Vent
Valve
and Breather . .' X
Road Test
Including
a Check of all Instrument
Lights
and Controls X Tune-up Engine
Check Operation of
Manifold
Heat
Control
Valve

Clean
Exterior of Radiator

Align
Headlights • Check Brake
Linings
,
Check Exhaust System for Leaks Replace Canister Air
Filter
(F. E. E. C. System)
Check
Axle
U-Bolt
Torque. Check Lubricaunt
Level
of Front
Axle
Universal Joints
Check Shock Absorber Mountings and Bushings Check Front and
Rear
Spring Bushings

Lubricate
Distributor
(V6-225).
Replace Spark, Plugs
Check Charging and Starting Circuits
Lubricate
Tailgate Latch, Supports and Hinges.

Lubricate
Door and
Hood
Hinge Pivots ;
Lubricate
Glove Compartment Door Latch

Lubricate
Heater Controls •

Lubricate
Windshield
Wiper and Washer Controls
Clean,
Repack and
Adjust
Wheel Bearings
Change Transmission and Transfer Lubricant. .
Replace
Dry-Type
Air Cleaner • Check Lubricant
Level
of
Differential

Lubricate
Transfer
Case
Shift
LeArer
Control
C«se.
. , . . . . . . . .
Continuing
each
2,000 miles

Continuing
each
6,000 miles

Continuing
each
24,000 miles

X
Continuing
each
30,000 miles
•Check after the
first
200 miles [320
km.
J
of operation.
If
wheel or wheels are changed for any
reason,
have
wheel nut torque rechecked after an additional two hundred miles of operation
••Service mileage shown or every 60 days, whichever occurs
first.

•••Maintenance check on emission system must be performed per
information
in this manual. "See text for brakes.

"Nj
^Miles
2,000
6,000
12,000
18,000
24,000
30,000
Kilometers

3,200
9,600
19,200
28,800
38,400 48,000

B-9.
Engine Oil

For
maximum
engine
protection under all driving conditions encountered during the recommended

oil
change intervals, it is necessary to use only

"MS"
certified
sequence-tested
oils. The term
"MS"
must appear on the oil container singly or

in
conjunction with other designations. "MS" des­
ignated oils are heavy-duty detergent oils that are
formulated to withstand all service conditions in
modern powerplants. Engine oils designated only
as
"ML"
and/or
"MM"
are not recommended and should not be used except in an emergency when

"MS"
oil is not available. Certified
sequence-tested

engine
oils are described on their containers by

such
phrases as:
meets,
exceeds,
excels, or has
proven superior in the
test
requirements,
test
sequences, MS Service
tests,
standards, and service

requirements,
of automotive manufacturers, auto­
makers,
or car manufacturers for MS service or
Service
MS.
It
may be necessary to change
engine
oil more
frequently than normally recommended, depending upon the type and quality of oil used, the severity
of operation conditions, if the
engine
is used for
short
periods in cold weather, or if the
engine
is allowed to idle for excessive periods.

Always
drain
the crankcase while the
engine
is hot since
dirt
and contaminants are then more
likely
to be held in suspension and therefore
will

drain
out more completely.
Drain
the crankcase as follows:

a.
Position the
drain
receptacle under the
drain

plug.

b.
Remove the
drain
plug using the correct size

wrench.
Be careful of hot oil.
c.
Carefully
clean the
drain
plug. Inspect and

replace
the gasket, if deteriorated.
d.
When the oil has drained, replace and tighten
the crankcase
drain
plug. 12

'Jeep'
UNIVERSAL SERIES SERVICE
MANUAL

B
Reinstall
the axle shafts, and
refill
the housings to
plug level using the universal joint lubricant
specified in
Lubrication
Specifications.

B-56.
Front
Axle Wheel Bearings

To
lubricate the wheel bearings, it is necessary
to remove, clean, repack, and adjust them. When
front wheel hubs and bearings are removed for
lubrication,
they should be thoroughly washed in a
suitable cleaning solvent. The bearings should be
carefully
dried and then given a thorough cleaning

and
inspection. Use a clean brush to remove all

particles
of old lubricant from bearings and hubs.

After
the bearings are cleaned, inspect them for
pitted races and rollers. Also, check the hub oil
seals.

Note:
Wheel bearing lithium base lubricants are
used at the factory for
initial
fill
of
these
bearings.
When
lithium base and sodium base lubricants are

mixed,
the result is a thinned-out mixture that
can
bleed through seals. It is therefore important
that lubricants with the correct base be used when

lubricating
the wheel bearings.
Should
leaks occur at wheel bearing seals, the leaks

may
be caused by a mixture of two
types
of
lubri­

cants.
In such cases, the old lubricant should be
completely removed before new lubricant is added.

Wheel
bearings should be thoroughly cleaned,
lubricated
with lithium base and reinstalled.

Repack
the bearing
cones
and rollers with grease

and
reassemble hub in the reverse order of the
disassembly. Test the bearing adjustment as out­

lined
in Section Q.

B-57.
Rear
Axle Wheel Bearings

The
Rear
wheel bearings an early models equipped

with
lubrication fittings with a vent opening
through the housings above each fitting should be
lubricated
sparingly, each
2,000
miles
[3.200
km.].

Use
a hand compressor and wheel bearing grease,
forcing
the grease through each lubrication fitting

until
it flows from the vent. Vent should be kept
clear
of obstruction or grease
will
back up into the

brakes.
Do not add grease after it flows from the
vent for it may be forced through the wheel key-
way
onto
the outside of the wheel and possibly

onto
the brake linings.
Rear
wheel bearings that do
not have lubrication fittings should be removed
each
12,000
miles
[19.200
km.] and the bearing
cleaned, inspected and repacked. Refer to proce­

dure
in Par. B-56.

Note:
When servicing the Flanged Axle Unit
Bear­

ing Assembly, refer to Section N, Par. N-5 for

proper
lubrication procedures.

B-58.
Propeller Shafts
and
Universal Joints

The
propeller shaft slip joints and universals should
be lubricated with a hand compressor grease gun so as to not damage the bearing seals. The units
should be lubricated with a
good
quality grease.

Refer
to the
Lubrication
Chart
for lubrication fre­
quency and lubricant type and grade. B-59.
Lights
and
Controls

a.
Check
all interior and exterior lights and light
switches for proper operation, including: parking
lights, headlamps (high beam and low beam),

tail
lights, brake lights, directional lights, and in­ strument panel lights.

b.
Check
all instrument panel controls and
instru­

ments for proper operation.

B-60.
Speedometer Cable

Remove the
speedometer
cable from its housing every
12,000
miles
[19.300
km.].
Clean
it thor­
oughly and coat it with a
good
quality light graphite grease.

B-61.
Headlights

Refer
to Section H.

B-62.
Heater Controls

Apply
Lubriplate
130-A to all friction points and
pivot points on the heater controls panel unit as well as the pivot points at the dashpot. Apply

a
few drops of penetrating oil all along the Bowden
cable.
This
oil
will
penetrate into the center wire.

B-63.
Windshield Wiper and
Washer Controls

Lubricate
the friction points and the pivot points
on the windshield wiper transmission and linkage

arms
with a slight amount of
Lubriplate
130-A.

B-64.
Rotate Tires

Refer
to Section Q for the correct method of rotat­ ing the tires.

B-65.
Body Lube Points
•
Refer to Par. B-66 through B-68.

B-66.
Hood Hinge Pivot Points

Lubricate
the frictional points of the hood hinge
pivot points with a few drops of light-weight
engine

oil.
B-67.
Glove Compartment Door Latch
Sparingly
wipe
Lubriplate
130-A on the
glove
com­
partment door latch.

B-68.
Tailgate Hinges

Lubricate
the friction points of the tailgate hinges

with
a few drops of light-weight
engine
oil.

B-69.
LUBRICATION
OF
OPTIONAL EQUIPMENT

B-70.
Pintle Hook

When
lubricating the vehicle, place a few drops of oil on the pintle hook and safety latch pivot pins.

B-7!.
Centrifugal Governor

Check
the oil level in the governor housing at each
vehicle lubrication. Use the same seasonal grade
oil
as is used in the
engine
and change oil at each

engine
oil change. Do not
fill
the housing above
the level indicating plug opening. Keep the vent

in
the filler plug open at all times. 17

'Jeep*
UNIVERSAL SERIES
SERVICE
MANUAL

D
insulator
mountings attached to the frame side

rail
brackets. The
rear
of the engine-transmission
assembly is supported by a rubber insulator
mounting under the
rear
of the transmission on
the frame center cross member.
This
cross member
is bolted to the frame side
rails
so that it can be
dropped when removing the transmission or engine-

transmission
assembly. The rubber insulators allow
free side and vertical oscillation to effectively

neutralize
engine
vibration at the source.

The
rubber
insulator mountings should be inspected
for separation and deterioration by jacking the
power plant away from the frame, near the sup­
ports. Vibration cannot be effectively absorbed by
separated or worn insulators. They should be re­ placed if faulty.

D-4.
Engine
Ground
Strap

To
be sure of an
effective
ground for the electrical

circuits,
a ground strap bridges the right front

engine
support to the chassis. The connections of this strap must be kept clean and tight for proper
operation of the electrical system.

D-5. ENGINE REMOVAL

Should
the
engine
require overhauling, it is neces­

sary
to remove it from the vehicle. The following procedure covers removal of the
engine
only.

The
engine, transmission and transfer case may be
removed as a unit by removing (in addition to the following procedure) the radiator guard and the
access plates in the floor pan.

a.
Drain
the cooling system by opening the
drain
cocks at the
bottom
of the radiator and lower right
side of the cylinder block.

b.
Disconnect the battery at the positive terminal
to avoid the possibility of short
circuit.

c. Remove the air cleaner horn from the carburetor
and
disconnect the breather
hose
at the oil filler
pipe.

d.
Disconnect the carburetor choke and throttle controls by loosening the clamp
bolts
and set
screws.

e. Disconnect the fuel-tank-to-fuel-pump line at the fuel pump by unscrewing the connecting nut.
f- Plug the fuel line to prevent fuel leakage.
g. Remove the radiator and radiator grille support

rods.

h. Remove the upper and lower radiator
hoses
by
loosening the
hose
clamps and slipping the clamps
back
on the
hose.
If so equipped, remove the heater

hoses
(one to the water pump, one to the
rear
of
the cylinder head) in the same manner.

i.
Remove the four
bolts
from the fan hub and re­

move
the fan hub and fan blades.

j.
Remove the four radiator attaching screws. Re­
move
the radiator and shroud as one unit, k. Remove the starting motor cables. Remove the

starting
motor.

I.
Disconnect the wires from the alternator or
generator. Disconnect the ignition
primary
wire
at the ignition coil.
NOTE:
ON
ENGINES EQUIPPED WITH EX­

HAUST
EMISSION CONTROL, REMOVE THE
AIR
PUMP,
AIR
DISTRIBUTION
MANI­
FOLD,
AND
ANTI-BACKFIRE (DIVERTER)

VALVE.
SEE SECTION
Fl
FOR PROCEDURE.
m.
Disconnect the oil pressure and temperature
sending unit wires at the units.

n.
Disconnect the exhaust pipe at the exhaust
manifold by removing the stud nuts.

o.
Disconnect the
spark
plug cables at the plugs

and
remove the cable bracket from the rocker arm cover stud.

p.
Remove the rocker arm cover by removing the
attaching stud nuts.

q.
Attach a lifting bracket to the
engine
using
existing head bolt locations. Be sure the
bolts
selected
will
hold the
engine
with the weight

balanced.
Attach lifting bracket to a boom hoist,

or
other lifting device, and take up all slack,
r.
Remove the two nuts and
bolts
from each front

engine
support. Disconnect the
engine
ground strap.
Remove the
engine
supports.
Lower
the
engine
slightly to permit access to the two top
bolts
on
the flywheel housing.
s. Remove the
bolts
which attach the flywheel
housing to the engine.

t.
Pull
the
engine
forward, or
roll
the vehicle back­

wards,
until the clutch clears the flywheel housing.

Lift
the
engine
from the vehicle.

D-6. ENGINE DISASSEMBLY

Engine
disassembly is presented in the sequence to be followed when the
engine
is to be completely
overhauled after removal from the vehicle. Some
of the operations of the procedure are also ap­
plicable
separately with the
engine
in the vehicle,

provided
that wherever necessary the part of the

engine
to be worked on is first made accessible by
removal
of
engine
accessories or other parts.

When
the disassembly operations are performed

with
the
engine
out of the vehicle, it is assumed,
in
this procedure, that all of the accessories have been removed
prior
to starting the disassembly

and
the oil has been drained.
In
addition to the instructions covering operations
for disassembling the
engine
out of the vehicle,

special
instructions are given to cover different
operations required when disassembly is
done
with the
engine
installed.

During
disassembly operations, the
engine
should
be mounted in a suitable
engine
repair
stand. Where

practicable,
modify or adapt an existing repair

stand
as necessary to accommodate the engine. If

an
engine
repair stand is not used, take care to

perform
disassembly operations in a manner that

will
protect personnel against an accident and the
engine
and its parts against damage.

NOTE:
If the
engine
is being disassembled because
of possible valve failure, check the valve tappet
clearance
before disassembly. Improper valve

clearance
could be the possible cause of valve

failure,
indicating a need for more frequent valve
checks and adjustments. 41

D
HURRICANE
F4
ENGINE d.
Remove the intake valve adjusting screw lock-
nuts from each of the rocker arm valve lash ad­

justing
screws. Remove the screws from the rocker
arms.

D-76.
Inspection and
Repair

Run
a round wire brush through the bore of the

rocker
arm shaft and clean out the drilled oil holes.
Clean
out the oil
holes
in the rocker arm shaft

brackets,
and the oil
holes
and
grooves
in the bores
of the rocker arm.
Inspect
the diameter of the shaft at the rocker arm

bearing
areas. Replace the shaft if there are scores

or
abrasion marks along the length of the shaft.
Check
the shaft for alignment by rolling it across

a
smooth level surface. If the shaft
will
not
roll
freely, or if it rolls with a bumping motion, the
shaft is out of alignment and must be replaced.
Inspect
the threads of the adjusting screw
hole
in
the rocker arms and if necessary clean with a

proper
size tap. Replace the adjusting screw lock-
nut or the adjusting screw if either part is damaged

or
deformed.

Inspect
the threads in the tapped
hole
in the top
of the rocker arm shaft brackets and if necessary

clean
with a proper size tap. Replace the bracket

if
either side is worn or scored.

D-77.
Reassembly

a.
Install
two rocker arm shaft plugs, one in each
end of the shaft. Slide two
rocker
arm
shaft brackets
onto
the center of the shaft. Align the tapped
holes

in
the brackets with the drilled
holes
in the top of
the shaft and install the rocker arm shaft lock
screws,
making sure the points of the screws enter
the drilled
holes
in the shaft.

b.
Screw the intake valve adjusting screws into
the rocker arms and install the locknuts.

c.
The rocker arms are paired; that is, two of the
arms
are angled to the right and two are angled to
the left. One of each type is used on each end of
the rocker arm shaft. Slide a rocker arm with the

adjusting
screw end of the rocker arm angling

away
from the bracket
onto
the shaft so that the
adjusting
screw is on the same side of the shaft
as the mounting
hole
in the bracket.

d.
Temporarily
secure the end bracket in place by
installing
a rocker arm cover stud in the tapped
opening in the top of the support.
e. Assemble the parts on the
opposite
end of the
rocker
arm shaft repeating
steps
c and d above.

D-78. ENGINE REASSEMBLY
The
engine
reassembly procedure in the following

paragraphs
is given in the sequence to be followed
when the
engine
is being completely overhauled.
Individual
inspection,
repair,
and fitting operations
previously covered in detail are made throughout
the reassembly procedure. The reassembly pro­
cedure
does
not cover accessories. If a new cylinder

block
fitted with pistons is used, many of the
operations
will
not be required.
Mount
the cylinder block in an
engine
repair stand.
If
an
engine
stand is not available, perform the fol­
lowing reassembly operation in a manner designed to protect personnel against an accident and the

engine
and its parts against damage.

Note:
During
engine
reassembly, use Perfect Seal

Aerosol
Spray
Sealer
Part
No.
994757
on all
engine
gaskets to ensure against vacuum, oil, gasoline and

water
leaks. Apply to head gaskets, valve covers,
water
pumps, oil pan gaskets, radiator and heater
hose
connections, felt gaskets, gasoline and oil line
connections, stud bolts,
spark
plug threads, and
grease retainer washers. Refer to manufacturer's in­
structions on container for proper application pro­
cedure.

D-79.
Install
Oil
Gallery
Plug

Coat
plug threads with a suitable sealing compound

and
install the plugs in the front and
rear
ends of
the oil gallery in the cylinder block and the
rear

end of the cylinder head. Torque the plugs 20 to 25 lb-ft. [2,8 a 3,4 kg-m.].

There
is also a pipe plug
(}/g,f
[3,2 mm.] slotted, headless) in the opening in the main oil gallery inside the cylinder block at No. 2 cylinder and another pipe plug
(}/g
"
square-head) in the opening

in
the oil passage directly below the oil pump intake
passage. If
these
two pipe plugs were removed,
make
certain they are reinstalled in the locations
described above or the counterweight of the

crankshaft
might strike the projecting head of the
square-head
plug.

D-80.
Install
Tappets

Turn
the block upside down. Beginning at the

rear
end of the cylinder block, install the intake

and
exhaust valve tappets in the tappet bores in the cylinder block in the following order: one
exhaust, two intake, two exhaust, two intake, and
finally
one exhaust valve tappet.

Check
the tappet to bore fit of each tappet as it
is installed in the block. If the stem-to-block

clearance
tolerance of .0005" to .002" [0,0127 a
0,051 mm.] is
exceeded
install a new tappet fitting
within
this tolerance or ream the bore to accomo­ date the next oversize tappet which is available

in
.004" oversize.

D-81.
Install
Camshaft and
Thrust
Plate

Lubricate
all camshaft bearings and cam surfaces generously with clean, light
engine
oil.
Carefully,

so not to damage or score the camshaft front bear­
ing,
install the camshaft, locating it properly in the bearings. Do not allow the
rear
end of the cam­shaft to strike sharply against the expansion plug

installed
in the
rear
end of the bore.
Install
the camshaft thrust plate. Slide the thrust
plate spacer
onto
the end of the camshaft with the
beveled inner
edge
of the spacer facing the cam­
shaft. If the same camshaft is being reinstalled,
install
any shims previously removed. These shims
are
placed
between
the camshaft shoulder and the

spacer.
Torque the thrust plate attaching
bolts
20
to 26 lb-ft. [2,8 a 3,6 kg-m.].

End
play of the camshaft is determined by running
clearance
between
the
rear
face of the camshaft
gear and the thrust plate. The standard clearance 62

D
HURRICANE
F4
ENGINE
D-101.
Install
Manifold

If
manifold studs were removed for replacement,
apply sealer on the stud threads
before
installing
a
new stud.
See Section Fl for exhaust emission controlled

engines.
Make
certain that no foreign objects are inside the manifold and that all
passages
are clear. Place a
new set of manifold
gaskets
in position on the side
of the cylinder block.
Then,
carefully slide the manifold
onto
the studs and against the cylinder block being careful not to damage the gaskets.
Torque
all manifold attaching nuts evenly 29 to
35 lb-ft. [4,0 a 4,8 kg-m.].
D-102.
Install
Oil
Filler
Tube

When
installing the oil filler tube, be sure that the
beveled lower end is away from the crankshaft.
Place a
piece
of
hard
wood
over the top of the
tube

to prevent damage to the cap gasket seat.
D-103.
Install
Water Pump

Make
certain that the mating surfaces of the water pump and the cylinder block are clean and smooth.
Install
the gasket on the
flange
of the pump and

install
the pump in position on the cylinder block.
Torque
the water pump attaching
bolts
alternately

and
evenly 12 to 17 lb-ft. [1,7 a 2,3 kg-m.].
D-104.
Install
Water Outlet Fitting

Install
the thermostat and the water
outlet
fitting.
Torque
the water
outlet
fitting attaching
bolts
20
to 25 lb-ft. [2,8 a 3,4 kg-m.].
FIG.
D-42—INSTALLING HURRICANE F4 ENGINE
IN
VEHICLE

1—
Lifting
Sling
2— Hoist
Cable

3—
Hurricane
F4 Engine
4— Dowel Bolt
5—
Flywheel
Housing
D-105.
ENGINE INSTALLATION
a.
Install
lifting sling to
engine
and using suitable hoist raise the
engine
from its blocking or stand

and
then slowly lower it
into
the
engine
compart­ment of the vehicle.

Note:
When installing the
Hurricane
F4 Engine,
two % x 4 inch
guide
bolts
or
dowels
should be
used to properly
guide
and align the
engine
to the
flywheel housing (See Fig. D-42).
b. Slightly tilt the
engine
downward and at the
same time slide the
engine
rearward
while lining up the transmission main gear shaft with the clutch
throw-out bearing and disc spline.

Note
:The
engine
crankshaft may have to be turned
slightly to align the transmission main gear shaft
with the clutch disc spline.
c. Remove the
guide
bolts
or
dowels
and secure
the
engine
to the housing.

d.
Secure the front
engine
mounts to the frame brackets and
bolt
ground cable to
engine.

e. Remove lifting sling from
engine.

f. Connect exhaust pipe to
engine
manifold flange.
g. Connect throttle and choke cables to carburetor.
h.
Install
fan to water pump pulley.
i.
Connect fuel pump line to main fuel line,

j.
Replace starting motor assembly. k. Connect
engine
wiring harness connectors at
front of cowl.

I.
Connect wires to starting motor assembly, water
temperature and oil pressure sending units and alternator.

NOTE:
ON
ENGINES EQUIPPED WITH EX­

HAUST
EMISSION CONTROL,
REPLACE
THE
AIR
PUMP,
AIR
DISTRIBUTOR
MANI­

FOLD,
AND
ANTI-BACKFIRE (DIVERTER)
VALVE.
SEE
SECTION
Fl.
m. Replace radiator and radiator grille support
rods and connect coolant
hoses
to
engine.

Note:
Replace heater
hoses
if vehicle is equipped
with hot water heater.

n. Fill
radiator with coolant and
engine
with oil
(see
Lubrication
Chart).

o.
Install
air cleaner and connect carburetor air
hose.

p. Connect battery cables and start
engine,

q.
Install
hood
and road
test
vehicle.
D-103.
FINAL
IN-VEHICLE
ADJUSTMENTS
a.
Clean
battery terminals and check battery. b.
Check
ignition terminals and check battery.
c. Service carburetor air cleaner.

d.
Service positive crankcase ventilation valve.
e.
Check
fuel lines. f. Gap and install new
spark
plugs.
g.
Check
distributor
points
and capacitor; replace
if
necessary. 68

Dl

DAUNTLESS
V-6
ENGINE
Note:
During
engine
reassembly, use Perfect Seal

Aerosol
Spray Sealer
Part
No.
994757
on all en­
gine
gaskets to ensure against vacuum, oil, gasoline

and
water leaks. Apply to head gaskets, valve covers, water pumps, oil pan gaskets, radiator and
heater
hose
connections, felt gaskets, gasoline and
oil
line connections, stud bolts, spark plug threads,

and
grease retainer washers. Refer to manufac­
turer's
instructions on container for proper appli­
cation procedure.

Dl-72.
Cylinder
Block
and Crankshaft
Rear
Oil Seals

Braided
fabric seals are pressed into
grooves
of
cylinder
block and
rear
main bearing cap, to
rear

of the oil collecting groove, to seal against oil leak­ age at the crankshaft. Refer to Fig. Dl-32.

FIG.
Dl-32—INSTALLING
CRANKSHAFT REAR
OIL
SEAL

1—Neoprene
Seal
2—Fabric
Seal

A
neoprene composition (stick) seal is installed in
grooves
in the sides of the
rear
main bearing cap
to seal against leakage in the joints
between
the
cap and cylinder block. The neoprene composition
expands in the presence of oil and heat.
This
seal
is undersize when newly installed. Refer to Fig.

Dl-32.

a.
The braided fabric seal can be installed in the

cylinder
block only when the crankshaft is re­ moved; however, the seal in the cap can be replaced
whenever the cap is removed. Remove oil seal and place new seal in groove, with both ends projecting
above parting surface of cap. Force seal into
groove

by rubbing down with hammer handle or smooth
stick
until seal projects above the
groove
not more

than
[1,59 mm.]. Cut ends off flush with
sur­

face of cap, using sharp knife or razor blade.
Lubricate
the seal with heavy
engine
oil just before
installation.

Caution:
The
engine
must be operated at slow
speed when first started after new braided seal
has been installed.
b. The neoprene composition seal is slightly longer

than
the
grooves
in the bearing cap. The seal must
not be cut to length. The seals are installed after the bearing cap is installed in the block and torqued
firmly
in place. Dip the neoprene seals in kerosene
approximately IV2 minutes, then install seals into
bearing cap grooves. The protruding ends of the seals are, again, squirted with kerosene, wiped off,

and
peaned over with a hammer to be sure of a
seal
at the upper parting line
between
the cap and

cylinder
block.

Dl-73.
Main
Bearing and Crankshaft
Installation

Refer
to Fig. Dl-6.

This
procedure assumes that crankshaft main bear­
ings have been inspected and proven satisfactory,

or
that new crankshaft main bearings of appropriate size have been selected. If necessary, check or select
main
bearings as described in Par. Dl-41 and
Pars.

Dl-42 and Dl-43.

a.
Install
four upper main bearing halves in
seats

of cylinder block so that prong of each bearing half
fits into corresponding notch of seat. Flanged thrust
bearing must be installed in the second seat from
front of engine.
Install
a new upper crankshaft
rear
oil seal in the cylinder block as described in

Par.
Dl-72.

Caution:
Upper main bearing halves have an oil groove, while lower halves are plain. They must
not be interchanged.
b. Apply
engine
oil to upper bearing surfaces.

Install
the crankshaft so that its four journals rest

in
the upper bearing halves.
c. Seat all four lower main bearing halves in cor­
responding bearing caps.
Install
a new lower
crank­

shaft
rear
oil seal and cylinder block
rear
oil seal
described in
Par.
Dl-72, a and b.
Lubricate
all lower

main
bearing surfaces with
engine
oil. Position bear­ ing caps to cylinder block and crankcase journals.

Install
two cap bolts,
loosely,
at each cap.

d.
It is necessary to align thrust surfaces of the
second main bearing whenever it has been removed

from
the engine. To do this, pry the crankshaft

back
and forth several times, throughout its entire end travel, with cap
bolts
of second main bearing
only finger tight.
e. Tighten alternate cap
bolts
of each main bearing

cap,
a little at a time, until they have been tight­ ened to 80 to 110 lb-ft. [11,1 a 15,2 kg-m.] torque.
D1-74. Crankshaft End Play Check

To
measure crankshaft end play, mount a dial
indicator
on the cylinder block and index its plung­

er
to either a front or
rear
face of one crankshaft
counterweight. Pry the crankshaft to one limit
of its end travel and adjust the dial indicator to
zero. Pry the crankshaft to its
opposite
end travel

limit
and
note
end play as indicated by the dial

indicator.
Crankshaft end play tolerances are .004"
to .008" [0,102 a
0,204
mm.]. If end play is too great, it can be corrected only by replacement of
the second main (thrust) bearing.

Dl-75.
Piston and Connecting Rod
Installation

This
procedure assumes that connecting rod bear­ ings have been inspected and proven satisfactory,

or
that new connecting rod bearings of appropriate 96

'Jeep*
UNIVERSAL
SERIES
SERVICE
MANUAL

COOLING
SYSTEM

Contents

SUBJECT
PAR.

GENERAL
.G-l Antifreeze Solutions. .G-l6
Cylinder
Block.
..................
.G-8

Draining
Cooling System............... G-3

Engine
Overheating..
.................
.G-19
Fan
Belt.
......... .........
.G-18
Filling
Cooling System.................
G-2

Inhibited
Coolant Solution .G-l7

Temperature
Sending Unit.
...........
.G-l0

Thermostat
.........................
G-9

RADIATOR
.G-5
Radiator
and Heater Hoses.............
G-7
SUBJECT
PAR.

Radiator
Pressure
Cap.................
G-4

Radiator
Removal and Replacement..... G-6

WATER
PUMP.
. . .G-ll
Water
Pump Disassembly. .............G-13

Water
Pump Inspection.
..............
.G-12

Water
Pump Reassembly.
.............
.G-14

Water
Pump Removal and Replacement. .G-l5

SERVICE
DIAGNOSIS.
.G-20

SPECIFICATIONS
. .G-21

ANTIFREEZE
CHART.
..... ... .G-22

G-l. GENERAL
a.
The satisfactory performance of the Hurricane

F4
engine
is controlled to a great
extent
by the proper operation of the cooling system. The
engine

block is full length water jacketed which prevents
distortion of the cylinder walls. Directed cooling
and
large water holes, properly placed in the cylin­
der head gasket cause more water to flow past the
valve
seats
(which are the
hottest
parts of the

block)
and
carry
the heat away from the valves, giving positive cooling of valves and seats.

Minimum
temperature of the coolant is controlled by a thermostat mounted in the
outlet
passage of
the engine. When the coolant temperature is below
thermostat-rated temperature, the thermostat re­ mains closed and the coolant is directed through
the radiator-bypass
hose
to the water pump. When the thermostat opens, coolant flow is directed to
the top of the radiator. The radiator dissipates the
excess
engine
heat before the coolant is recirculated
through the engine.
The
cooling system is pressurized. Operating pres­
sure
is regulated by the rating of the radiator cap

which
contains a relief valve, b. The Dauntless V-6
engine
efficiency and per­formance is controlled to a great
extent
by proper
operation of the cooling system. The cooling system

does
more than cool the engine. It also directs
the flow of coolant to provide the
best
operating
temperature range for each part of the engine.

In
the Dauntless V-6
engine
coolant is forced by
the water pump into two main passages that run the length of the block on each side (Fig. G-l).
FIG.
G-1—COOLANT
FLOW
THROUGH
THE
DAUNTLESS
V-6
ENGINE

161

COOLING
SYSTEM

14263

FIG.
G-2—COOLING SYSTEM
COMPONENTS
V-6
ENGINE

1—
Radiator
Pressure Cap

2—
Hose
Clamp

3—
Radiator
Hose (Inlet-Upper)
4—
Radiator
Hose (Outlet-Lower) 5—
Bolt
6—
Water
Pump Assembly 7—
Cap
8—Thermostat
By-Pass Hose
g—Water Outlet
Elbow

10—
Gasket

11—
Thermostat
12—
Water
Pump Gasket

13—
Dowel
Pin
14—
Radiator
Shroud (Heavy Duty Cooling) 15—
Pulley

16—
Fan
Spacer
17—
Fan
and Alternator Belt

18—Fan

19—
Lockwasher

20—
Radiator

21—
Drain
Cock
From
these
main passages, the coolant flows around
the
full
length of each combustion chamber.

After
cooling the block, the coolant passes through
ports between the block and each cylinder head.
These
ports direct most of the coolant flow around the exhaust valve area to prevent hot exhaust
gases

from
overheating the exhaust ports.

From
the cylinder heads, the water passes into a
water
manifold between each of the heads and the

water
pump. If the thermostat is closed, the coolant
is ported back to the pump where it is recirculated

back
into the pump and into the engine. After the
coolant heats enough to open the thermostat, the coolant is directed from the water manifold through
a
hose
to the top of the radiator and then through
the radiator which acts as a heat exchanger to cool the fluid. The coolant is then ported through a
hose

from
the bottom of the radiator to the pump, which

recirculates
it back to the engine.

The
cooling system is pressurized. Operating pres­
sure
is regulated by a relief valve in the radiator

cap. The
heater inlet
hose
is connected to a port on
the right bank cylinder head. The outlet
hose
is connected to the heater adapter tube on the water

pump.

c.
It is recommended when using water for coolant
that the cooling system be flushed and checked for leaks twice a year, preferably in the
fall
before
antifreeze is added and in the spring when the antifreeze is drained.

Reverse
flushing
will
aid greatly in removing rust 162