wheel JEEP DJ 1953 Owner's Guide

Dl

DAUNTLESS
V-6
ENGINE
This
will
prevent damage to piston rings or
crack­

ing piston lands during removal.
b. Use a silver pencil or quick-drying paint to mark
the cylinder number on all pistons, connecting rods,
and
caps. Starting at the front end of the crankcase,
the cylinders in the right bank are numbered 2-4-6
and
in the
left
bank are numbered
1-3-5.

c. Remove cap and lower connecting rod bearing

half
from No. 1 connecting rod.

d.
Push the piston and rod assembly away from
the crankshaft and remove it from top of cylinder bore. Then install cap and lower bearing half on
connecting rod.
e. Remove each connecting rod and piston as­ sembly as described in c and d, above.
FIG.
D1-9—CRANKSHAFT
MAIN
BEARING
CAPS

1—Thrust
Bearing
D1-32.
Remove
Main
Bearing and Crankshaft
a.
This
engine
has four crankshaft main bearings.

Front
to
rear,
they are numbered 1 to 4. Refer to

Fig.
Dl-9. With a silver pencil or quick-drying
paint, mark the bearing number on each main bearing cap.
b. Remove two
bolts
which secure first (front)

main
bearing cap to
engine
cylinder block. With

a
lifting bar, carefully pry the cap from the crank­ shaft and block. Be careful not to damage the cap,
block or crankshaft. Remove the bearing cap, with
lower main bearing half, from the cylinder block.

Keep
bearing half and cap
together.
Similarly, remove the next two main bearing caps with lower

main
bearing halves. To remove
rear
main bearing
cap,
use
rear
main bearing remover bolt W-323.
c. Remove the fabric seal from inside diameter of
fourth (rear) main bearing cap, and remove neo-
prene composition seal from outer surface of this
bearing cap. Discard both seals.

d.
Lift
and remove the crankshaft from
engine
cylinder
block. Do not remove upper main bearing
halves from block or lower main bearing halves

from
caps at this time. Mount main bearing caps

in
their original positions.
Dl-33.
ENGINE
CLEANING,
INSPECTION,

AND
REPAIR

The
cleaning, inspection, and repair procedures
detailed herein are recommended to be followed
when a
complete
engine
overhaul is to be made
with the
engine
out of the vehicle. These instruc­
tions
can generally be applied individually with the

engine
in the vehicle. Wherever the procedure dif­
fers due to the
engine
being in the vehicle, the necessary special instructions are provided. Inspec­
tion and repair instructions are included to cover
the cylinder block, cylinder head, crankshaft and bearings, connecting rods and bearings, oil pump,
valves and tappets, pistons and rings, flywheel,
timing gears, and the camshaft and bearings. In
addition, fitting operations for
these
engine
com­

ponents
are included.

D1-34.
Cylinder Block

The
cylinder block must be cleaned thoroughly, inspected, and repaired as necessary, as described
below.

Dl-35.
Cylinder Block Cleaning
Steam-clean the cylinder block, or clean it with

a
suitable cleaning solvent A scraper can be used
to remove
hard
deposits, but do not score machined
surfaces. Be certain that oil passages, valve cham­

bers,
crankcase, and cylinder walls are free from sludge, dirt, and carbon deposits. After cleaning,

dry
the cylinder block carefully with compressed
air.

Dl-36.
Cylinder Block Inspection

a.
Inspect cylinder walls visually for scoring,
roughness, or ridges which indicate excessive wear.
Check
cylinder bores for taper and out-of-round
with an accurate cylinder
gauge.
Measure eact bore at top, middle and bottom, both parallel tc
and
at right
angles
to the centerline of the
engine

The
diameter of the cylinder bores at any poin
FIG.
Dl-10—MEASURING
CYLINDER
BORE

1—Telescope Gauge [90*
From
Piston Pin]
84

DAUNTLESS
V-6
ENGINE

Note:
The rib on
edge
of cap and the conical
boss

on web of connecting rod must be toward
rear
of
engine
in all connecting rod assemblies of left
cyl­

inder
bank and toward front of
engine
in all con­necting rod assemblies of right cylinder bank.

Dl-50.
Oil
Pump Intake
and
Screen Cleaning

a.
Pry screen from housing and examine for clog­
ging due to deposit of sludge or other foreign

material.

b.
Clean
the screen and housing thoroughly in sol­
vent; dry with compressed air.

c.
Install
screen in housing.

Dl-51.
Oil Pan Cleaning and Inspection

Inspect
the oil pan for corrosion, dents, leaks, and
other damage. Inspect its mounting flange carefully
for damage or distortion to be certain that it
will
give
a
good
seal.

Dl-52.
Flywheel Cleaning
and
Inspection

Clean
the flywheel with suitable cleaning solvent;

dry
with compressed air. Inspect clutch face for

burned
or scuffed condition and for rivet grooves.
Inspection
for run out or improper mounting is de­

scribed
in installation procedure.
Inspect
teeth
of the flywheel
ring
gear for
burrs,

nicks,
and minor distortion. If necessary and pos­
sible, use a small emery wheel to remove
burrs
and
reshape teeth. If gear
teeth
are broken,
cracked,

seriously
burred
or deformed, the
ring
gear must be replaced.

Dl-53.
Ring Gear Replacement

a.
Drill
a
hole
between
two
ring
gear teeth; then

split
the gear with a cold chisel. Be careful not to
damage
ring
gear shoulder or seat surfaces of fly­
wheel.

b.
Polish several
spots
on the new
ring
gear to be

installed.
With
a hot plate or slowly moving torch,
heat the new
ring
gear until polished
spots
become

blue, about
600°F.
[312°C.].

Caution:
Do not heat the
ring
gear to a temperature
greater than
800°F.
[424°C.].
Excessive heat
will

destroy heat treatment given to
ring
gear during
manufacture.

c.
Quickly
install
ring
gear on flywheel. Chamfered

edge
of
ring
gear must be toward
ring
gear shoulder
of flywheel. Be certain that
ring
gear is seated prop­

erly.
Allow
ring
gear to cool slowly, so that it
will

be held tightly in place.

Dl-54.
Flywheel Housing Cleaning and Inspection

Both
flywheel and clutch are enclosed by a fly­
wheel housing. Its front surface is bolted to the
engine
cylinder block, and its
rear
surface acts as

front
support to the transmission.
Clean
the fly­ wheel housing with a suitable cleaning solvent; dry
with
compressed air. Inspect front and
rear
surfaces
for distortion and improper alignment with each
other;
these
planes must be
parallel
to assure
proper
alignment
between
engine
and transmission.
Dl-55.
Camshaft Cleaning
and
Inspection

Clean
both camshaft and camshaft bearing surfaces

with
a suitable cleaning solvent; dry with com­
pressed air.

Note:
The steel-backed babbitt-lined camshaft
bearings are pressed into the crankcase.
From
front
to
rear,
each bearing is .030" [0,76 mm.] smaller
in
diameter than the preceding bearing.
From
front
to
rear,
each camshaft
journal
is correspondingly
smaller
in diameter.

The
camshaft bearings must be line reamed to

proper
diameter after being pressed into crankcase.
Since
this operation requires special reaming equip­
ment, the original bearings should be retained un­
less
they are severly damaged. Slightly scored cam­
shaft bearings are satisfactory if the surfaces of camshaft journals are polished, bearings are
polished to remove
burrs,
and
radial
clearance

between
camshaft and bearings is within .0015"
to .004" [0,038 a 0,102 mm.].

Dl-56.
Valve Lifter
and
Push
Rod
Cleaning and Inspection
a.
Examine the cam contact surface at lower end of each valve lifter body. If surface is excessively

worn,
galled, or otherwise damaged, discard the
valve lifter. Also examine the mating camshaft
lobe
for excessive wear or damage.

b.
Disassemble one or two valve lifters, as de­

scribed
below, and inspect them for
dirt
or
varnish.
If
they are dirty or have a varnish deposit, clean

and
inspect all twelve valve lifters. Otherwise,
service
only
those
valve lifters which do not operate

properly.

c.
To disassemble each valve lifter, depress the
push
rod seat with a push rod, and remove the
plunger retainer from the valve lifter body with

a
retainer remover. Remove push rod seat and
plunger from valve lifter body. If plunger sticks
in
valve lifter body, place body in large end of

a
plunger remover tool, with plunger downward.
While
holding lifter with thumb, rap the open end
of remover against a block of wood with just enough force to jar the plunger from body. Refer to
Figs.
Dl-20, Dl-22 and Dl-23.

d.
Drain
oil from valve lifter and remove the check
valve retainer,
ball,
valve spring, and plunger
spring.

e. Keep all parts of each valve lifter separated

during
part cleaning and inspection. The valve

lifter
body and plunger are selectively fitted to each other and must not be interchanged with parts
of other valve lifters.
f. Rinse all valve lifter parts in kerosene to remove as much oil as possible.
This
will
reduce contamina­
tion of the cleaning solvent. Immerse all parts in cleaning solvent for approximately one hour. The
time required
will
depend on varnish
deposits
and
effectiveness
of the solvent. After the varnish has
dissolved or has
softened
sufficiently to permit re­

moval
by wiping, allow parts to
drain.
Varnish
can
then be cleaned from the valve lifter body
with
a
brush.
Rinse the parts in kerosene to dissolve 90

'Jeep'
UNIVERSAL
SERIES SERVICE
MANUAL

Dl
size have
been
selected. If necessary, check or
select

connecting rod bearings as described in Par. Dl-49.

Note:
When a piston and connecting rod assembly
is properly installed, the oil spurt
hole
in the con­ necting rod
will
face the camshaft. The rib on the

edge
of the bearing cap
will
be on the same side
as the conical
boss
on the connecting rod web;
these
marks (rib and boss)
will
be toward the other
connecting rod on the same crankpin. The notch
on the piston
will
face the front of the
engine.

a.
Be certain that cylinder bores, pistons, connect­
ing rod bearings and crankshaft journals are absolutely clean. Coat all bearing surfaces with

engine
oil.
b. Before installing a piston and connecting rod as­
sembly into its bore, rotate the crankshaft so that
the corresponding crankpin is moved downward, away from the cylinder bore.
c. Remove bearing cap from connecting rod. With
upper bearing half seated in connecting rod, install connecting rod guides. These
guides
hold the upper
bearing half in place and prevent damage to the

crankshaft
crankpin during installation of the con­
necting rod and piston assembly.

d.
Be certain that the gap in the oil ring rails faces

upward,
toward center of
engine.
Gaps of the com­
pression rings shall not be aligned with each other

or
with the oil ring
rails.

e. Lubricate the piston and rings. Compress the
rings with a suitable piston ring compressor; install
the piston and connecting rod assembly from top of cylinder bore. Refer to Fig. Dl-33.

f.
Install
bearing cap, with lower bearing half, on connecting rod. Torque bolt nuts to 30 to 40 lb-ft. [4,1 a 5,5 kg-m.].
g.
Install
all other piston and connecting rod as­
semblies in same manner.

h.
Check
end clearance
between
connecting rods
on each crankpin with a feeler
gauge.
Clearance should be .005,/ to .012" [0,127 a
0,305
mm.].

Dl-76.
Install
Oil
Pump
Intake
Pipe
and
Screen Assembly

Check
mating surfaces of oil pump intake pipe

and
engine
cylinder block to be certain that they

are
clean. Secure the pipe and screen assembly,
with a new gasket, to
engine
cylinder block with two attaching screws. See Fig. Dl-34. Torque screws 6 to 9 lb-ft. [0,83 a 1,24 kg-m.].

Dl-77.
Install
Oil Pan

Refer
to Fig. Dl-35.

Be
certain the flange surface of oil pan and cor­
responding surface of
engine
cylinder block are
clean.
Install
a new oil pan gasket on the cylinder
block.
Secure
oil pan to cylinder block with mount­ ing bolts. Torque
bolts
10 to 15 lb-ft [1,4 a 2,1

kg-m.].

Dl-78.
Install
Flywheel

Refer
to Fig. Dl-7.

a.
Check
flywheel flange of
engine
crankshaft and corresponding surface of flywheel to
be
certain that
FIG.
Dl-33—INSTALLING
PISTON
AND

CONNECTING
ROD
ASSEMBLY
1—Ring
Compressor

FIG.
Dl-34-^-OIL
PUMP
INTAKE PIPE
AND

SCREEN
INSTALLATION
1—Pipe and Screen
97

'Jeep'
UNIVERSAL SERIES SERVICE
MANUAL

Dl
both are clean. Any foreign material on either of

these
surfaces
will
cause flywheel run out and en­
gine
vibration. Position flywheel to crankshaft and
secure with six mounting bolts. Torque mounting
bolts
50 to 65 lb-ft. [6,91 a 8,98 kg-m.].

Note:
Flywheel mounting
bolts
are unevenly
spaced so that flywheel can be installed in only
one position.
This
assures correct balance of fly­
wheel and crankshaft.

b.
Mount a
dial
indicator on flywheel housing
flange of cylinder block and index its plunger to
the flywheel surface. Measure flywheel run out.

Maximum
allowable run out is .015"
[0,381
mm.].
Dl-82.
Install
Cylinder
Head Assembly

Refer
to Fig. Dl-9.

a.
Wipe cylinder head face of
engine
cylinder
block, and be certain no foreign material has fallen
into the cylinder bores, bolt holes, or in the valve

lifter
area.
It is
good
practice to clean out bolt

holes
with compressed air.

b.
Install
a new cylinder head gasket on the
cylin­

der
block. Dowels in the block
will
hold the gasket

in
position. Always handle gaskets carefully to

avoid
kinking or damage to the surface treatment
of the gasket. Apply Perfect Seal Aerosol
Spray
Sealer
Part
No.
994757
on cylinder head gaskets.

Dl-79.
Install
Clutch
and Flywheel Housing

a.
Note
marks made on clutch assembly and fly­
wheel during
engine
disassembly. Position clutch
assembly to flywheel, according to
marks,
and
fasten
loosely
with six attaching bolts. Torque

bolts
in rotation, one
turn
at a time, to 30 to 40 lb-ft. [4,1 a 5,5 kg-m.].

b.
Engage fork of clutch linkage to clutch and
position flywheel housing to
engine
cylinder block.
Secure
housing to block with six mounting bolts.

Torque
bolts
30 to 40 lb-ft. [4,1 a 5,5 kg-m.].

D1-80.
Install
Camshaft

Insert
camshaft into camshaft bearings of
engine

cylinder
block carefully to avoid damage to bear­
ing surfaces. Make certain camshaft journals are

properly
seated in bearings.
12695

FIG.
D1-36—CAMSHAFT
AND
VALVE LINKAGE
1—
Rocker
Arm

2—
Push
Rod 3—
Valve
Lifter

4—
Camshaft
14203

FIG.
Dl-37—CYLINDER
HEAD
BOLT TIGHTENING SEQUENCE c.
Clean
gasket surface of cylinder head and care­

fully
place on the
engine
block dowel pins.

d.
Clean
and lubricate the cylinder head
bolts
with

a
sealing compound
(Part
No. 994757, or equiv­

alent).

e.
Install,
and alternately tighten the head bolts,
a
little at a time, in the sequence shown in Fig.

Dl-37.
Torque
bolts
65 to 85 lb-ft. [9,0 a 11,8

kg-m.].

f.
Tilt
the rocker arms toward the push rods and locate the top of each push rod in its rocker arm
seat.

g.
Mount the rocker arm and shaft assembly, tightening the bracket
bolts
a little at a time.
Torque
the bracket
bolts
25 to 35 lb-ft. [3,5 a 4,8

kg-m.].
Do not overtighten.

h.
See Section Fl and F2 for
engines
equipped

with
exhaust emission control.

D1-81.
Install
Valve Lifter
and Push Rod

Make
certain valve lifter guide
holes
and adjacent
area
of cylinder block are clean.
Liberally
lubricate
the camshaft and valve lifter bores with
engine

oil,
and install valve lifters.
Each
valve lifter must slide freely in its guide hole. See Fig. Dl-36.
Dl-83.
Install
Rocker Arm Cover

Install
a new gasket on each rocker arm cover.
Secure
each rocker arm cover to corresponding

cylinder
head with four attaching screws.
Install

the positive crankcase ventilation valve on right

rocker
arm cover. 99

Dl
DAUNTLESS
V-6
ENGINE

FIG.
Dl-41—WATER
PUMP
AND
TIMING CHAIN COVER BOLT LOCATION
Cover
Bolts

alternately and evenly 8 to 12 lb-ft. [1,10 a 1,66

kg-m.].

Dl-88.
Install
Crankshaft
Vibration
Damper

a.
Lubricate
the vibration damper hub
before
in­
stallation to prevent
damage
to the crankshaft
front oil seal during installation and when the

engine
is first started.
b.
Install
the vibration damper on the crankshaft.
Secure it with its attaching flat washer and screw.

Torque
the screw to a minimum of 140 lb-ft.
[19,35
kg-m.].

Dl-89.
Install
Crankshaft Pulley
Secure the crankshaft pulley to the crankshaft

vibration
damper with six screws. Torque screws 18 to 25 lb-ft. [2,5 a 3,4 kg-m.].

Dl-90.
Install
Oil
Level
Dipstick

Insert
oil level dipstick
into
the dipstick tube.

Dl-91.
Install
Oil
Pressure Sending Unit

Install
oil pressure sending unit in cylinder block.
Connect electrical wiring harness to unit.

Dl-92.
Install Starting Motor

Secure starting motor and
solenoid
assembly to
the flywheel housing and cylinder block with two attaching screws. Torque screw, which attaches this
assembly to the flywheel housing, 30 to 40 lb-ft. [4,1 a 5,5 kg-m.]. Torque screw, which attaches

bracket
to cylinder block, 10 to 12 lb-ft. [1,4 a 1,7 kg-m.].
Dl-93.
Install
Oil
Filter

Install
a new oil filter
element
at oil filter nipple,
at
left
side
of timing chain cover. Torque 10 to 15 lb-ft. [1,38 a 2,07 kg-m.].

D1-94. Install Water Pump
Be
certain that mating surfaces of the water pump

and
timing chain cover are clean.
Install
a new
gasket
on the pump flange. Secure the pump and
alternator adjustment bracket to the cover with
nine attaching bolts. Torque
bolts
6 to 8 lb-ft. [0,83 a 1,10 kg-m.]. Refer to Fig. Dl-41.

D1-9S.
Install
Cooling Fan
Secure the cooling fan, fan hub, and fan drive
pulley to the water pump shaft
flange
with four
attaching screws. Torque screws 17 to 23 lb-ft. [2,35 a 3,18 kg-m.].

Dl-96.
Install
Alternator
and Fan
Belt

Mount the alternator and bracket assembly on
right
cylinder head with two attaching screws.

Torque
screws 30 to 40 lb-ft. [4,1 a 5,5 kg-m.].

Fasten
the alternator
loosely
to its adjustment
bracket
with attaching flat washer and nut.
Install

the fan
belt
on its pulleys. Pivot the alternator
outward,
away from cylinder block, to apply fan

belt
tension. Adjust fan
belt
tension to 80 lb. [36,2 kg.];
tighten
alternator-to-adjustment bracket
nut to secure adjustment
setting.
Connect wiring
harness to alternator.

Dl-97.
Install
Fuel Pump

Install
two mounting
bolts
and new
gasket
on

flange
of fuel pump. Secure pump to timing chain cover with screws; torque screws 17 to 23 lb-ft. [2,35 a 3,8 kg-m.]. Connect
output
fuel line to
pump.

Dl-98.
Install Exhaust Manifold

Secure each of two exhaust manifolds to corre­
sponding cylinder head with five attaching screws,
and
one nut. Torque screws and nut 15 to 20 lb-ft. [2,07 a 2,8 kg-m.]. See Fig. Dl-42.

Dl-99.
Install Distributor

Insert
distributor drive gear
into
distributor mount-
FIG.
Dl-42—EXHAUST
MANIFOLD INSTALLATION

1—Torque
Bolts—15
to 20
lb-ft.
[2,07 a 2,8
kg-m.]

102

Dl

DAUNTLESS
V-6
ENGINE
e.
Connect electrical wiring harness to coolant
temperature sending unit. Connect two distributor leads to ignition coil. Connect fuel line
between

fuel pump and carburetor, vacuum
hose
between
distributor and carburetor, and crankcase vent
hose

to intake manifold
below
rear
of carburetor.
FIG.
D1-46—-INTAKE
MANIFOLD
INSTALLATION

1—Long Bolt 2—Open Bolt Hole
Dl-102.
ENGINE INSTALLATION

Install
the
engine
in the vehicle in the following
procedure listed
below:

a.
Attach suitable sling to
engine
lifting
eyes
and,
using a hoist, lift the
engine
from blocks or
engine
stand.
b. When
engine
is free of the stand lower it slowly

into
the
engine
compartment of the vehicle.

Note:
The
engine
and transmission must be lined
up to
engage
the main shaft and clutch plate spline
while sliding the
engine
rearward
into
the mounting
position.
c.
Install
and tighten up
bolts
securing
engine
to
flywheel housing.

d.
Install
and tighten front
engine
mounting bolts.

e.
Remove sling from the
engine.

I.
Connect exhaust pipes to right and
left
engine
manifolds.
g. Connect choke cable support bracket to
car­

buretor.

h.
Connect
engine
fuel
hoses
and fuel lines at right
frame
rail.

I.
Connect fuel lines.

j.
Mount
engine
starter motor assembly to
engine.
k.
Connect battery cable and wiring to
engine

starter
motor.

I.
Connect
engine
wiring harnesses to connectors
located on
engine
firewall.

Note:
On
engines
equipped with exhaust emission
control, replace the air pump, air distributor mani­
fold, and anti-backfire (gulp) valve. See Section F2.
m. Replace radiator, and secure with bolts,
n.
Replace and tighten right and
left
radiator sup­
port rods.
0. Connect upper and lower radiator
hoses
to the

engine.
p. Connect alternator wiring harness from connec­
tor at regulator,
q.
Replace air cleaner.
r.
Connect battery ground cable from the battery
to the
engine
and the
engine
ground strap,

s.
Replace the hood.

After
the
engine
is installed in the vehicle,
fill
radiator
with coolant and
engine
with oil (Refer to
Lubrication
Section B), then perform an
engine

Tune-up
and road
test
(Refer to Tune-up Sec­
tion C).

Dl-103.
FINAL IN-VEHICLE ADJUSTMENTS

a.
Clean
battery terminals and check battery.
b.
Check
ignition wires and connections.
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.

h.
Check
ignition (distributor) timing; reset if
necessary. 1.
Check
carburetor adjustments; reset if necessary,

j.
With
engine
fully warmed up, tighten cylinder
head and manifold
bolts
and nuts to specified
torque.
Check
cylinder head
gaskets
and
bolts
for
air
or coolant leaks.

Note:
Tightness of cylinder head
bolts
should be
checked and corrected after 500 miles [800 km.]
of normal operation and again at 1000 miles [1600

km.].
k.
Check
fan belt tension; adjust if necessary.
I.
Check
for and correct any oil leak, fuel leak or
coolant leak. 104

'Jeep'
UNIVERSAL
SERIES SERVICE
MANUAL

Dl
Dl-104.
SERVICE
DIAGNOSIS

Poor Fuel Economy
Ignition Timing Late or Spark Advance Inoperative

Carburetor
Float Setting Too High
Accelerator Pump Improperly Adjusted
Fuel
Pump Pressure High

Fuel
Line
Leakage

Fuel
Pump Diaphragm Leakage
Cylinder
Compression Low
Valves Do Not Seat Properly
Spark
Plugs
Defective

Spark
Plug Cables
Defective

Ignition
Coil
or Capacitor
Defective

Carburetor
Air Cleaner Dirty

Brakes
Drag
Wheel Alignment Incorrect

Tire
Pressure Incorrect Odometer Inaccurate

Fuel
Tank
Cap Clogged or
Defective

Muffler or Exhaust Pipe Clogged or Bent

Lack
of
Power
Cylinder
Compression Low
Ingitdon Timing Late

Carburetor
or
Fuel
Pump Clogged or
Defective

Fuel
Lines Clogged
Air
Cleaner Restricted
Engine Temperature High Valves Do Not Seat Property

Valve
Timing Late Intake Manifold or Cylinder Head
Gasket Leaks
Muffler or Exhaust Pipe Clogged or Bent
Spark
Plugs Dirty or
Defective

Breaker
Point Gap Incorrect
Breaker
Points
Defective
Ignition
Coil
or Capacitor
Defective

Electrical
Connection Loose
Broken
Valve Spring

Broken
Piston Ring or Piston
Cylinder
Head Gasket
Defective

Distributor Cap Cracked

Low
Compression
Valves Not Seating Properly Piston Rings Seal Poorly
Valve
Spring Weak or Broken
Cylinder
Scored or Worn
Piston Clearance Too Great

Cylinder
Head Gasket Leaks

Burned
Valves and
Seats
Valves Stick or Are Too Loose in Guides
Valve
Timing Incorrect

Valve
Head and Seat Have Excessive Carbon
Engine Overheats

Valve
Spring Weak or Broken

Valve
Lifter Seized or Collapsed
Exhaust
System Clogged
Valves Sticking

Valve
Stem Warped

Valve
Stem Carbonized or Scored

Valve
Stem Clearance Insufficient in Guide

Valve
Spring Weak or Broken

Valve
Spring Distorted
Oil
Contaminated

Overheating
Cooling System Inoperative
Thermostat Inoperative Ignition Timing Incorrect

Valve
Timing Incorrect
Carbon
Accumulation Excessive

Fan
Belt Loose
Muffler or Exhaust Pipe Clogged or Bent

Oil
System Failure
Piston Rings Worn or Scored
Popping,
Spitting,
Detonation
Ignition Timing Incorrect

Carburetion
Improper

Carbon
Deposit
in Combustion
Chambers Excessive
Valves Not Seating Properly
Valve
Spring Broken
Spark
Plug Electrodes Burned
Water or Dirt in
Fuel
Fuel
Line
Clogged
Valve
Timing Incorrect

Excessive
Oil
Consumption
Piston Rings Stuck in Grooves, Weak,
Worn,
Broken, or Incorrectly Fitted

Crankshaft
Main Bearings or
Connecting Rod Bearings Have
Excessive Clearance
Gaskets or Oil Seals
Leak

Cylinder
Bores Worn, Scored,
Out-of-Round or Tapered
Pistons Have Too Great Clearance to Cylinder Bores
Connecting Rods Misaligned High Road Speed
High Temperature

Crankcase
Ventilation System Inoperative
Bearing Failure
Crankshaft
Bearing Journal Rough or Out-of-Round

Oil
Level Low
Oil
Leakage

Oil
Dirty
Oil
Pressure Low or Lacking
(Oil
Pump Failure)

Drilled
Passages
in Crankshaft or
Crankcase
Clogged

Oil
Screen Dirty
Connecting Rod Bent 105

'Jeep*
UNIVERSAL
SERIES
SERVICE
MANUAL

Dl
Dl-105.
DAUNTLESS
V-6
ENGINE
SPECIFICATIONS—Continued

CONNECTING
RODS:
Material
Installation
Bearings: Type........
Material.
Length Clearance

End
Play
(total
for two
connecting
rods)

CRANKSHAFT:
Material ,

End
Thrust
End
Play

Main
Bearings: Number Type
Material:
Length, Over-All: No. 1, No. 3, and No. 4
No. 2
Clearance

Main
Journal Diameter.
Crankpin
Journal Diameter
Flywheel Run Out, max

CAMSHAFT:
Material
Bearings: Number Material Clearance

Journal
Diameter: No. 1 No. 2
No. 3.
No. 4
Location Camshaft Drive

Chain
Links
Camshaft Sprocket Material
Crankshaft Sprocket Material

VALVE
SYSTEM:
Valve Lifters Diameter Clearance in Cylinder Block
Leak-down Time
(seconds)

Rocker Arms: Ratio Clearance on Shaft
Valves: Intake: Material
Head Diameter

Seat
Angle
Stem
Diameter

Stem
Clearance in Guide
Exhaust:
Material Head Diameter

Seat
Angle
Stem
Diameter

Stem
Clearance in Guide
Valve Springs — Pressure at Length: Valve Closed English
Pearlitic Malleable Iron

From
Top of Cylinder Bore
Removable, Steel-Backed Aluminum .737"

.0020"
to
.0023"
.006" to .014" Metric
18,72 mm.

0,0508
a
0,0584
mm. 0,153 a
0,356
mm.
Pearlitic Malleable Iron
Second
Main Bearing .004" to .008"

Removable

Moraine 100
.864"

1.057"

.0005"
to
.0021"
2.4995"

2.0000"

.015" 0,102 a
0,203
mm.
21,95 mm.

2,685
cm.

0,0127
a
0,0533
mm.
6,349
cm.
5,080
cm.
0,381 cm.

Cast
Iron Alloy
Steel-Backed Babbitt
.0015"
to
.0040"

1.755"
to
1.756"

1.725"
to
1.726"

1.695"
to
1.696"

1.665"
to
1.666"

In
Cylinder Block, at Center of V
Chain
and Sprocket 54
Aluminum,
Nylon
Coated Sintered Iron
0,0381
a
0,1016
mm.

4,458
a
4,460
cm.
4,382
a
4,384
cm.
4,305
a
4,307
cm.

4,229
a 4,231 cm.
Hydraulic

.8422"
to
.8427"

.0015"
to
.0030"
12 to 60
1.6:1

.0017"
to
.0032"

Steel,
SAE 1041
1.625"
45°

.3415"
to
.3427"
.0012"
to
.0032"

GM-N82152
(21-4N)
1.3750"
45°

.3402"
to
.3412"
.3397"
to
.3407"

.0015"
to
.0035"
(top)
.002" to .004"
(bottom)

1.640"
at 59 - 64 lb.
1.260"
at 168 lb. 21,39 a 21,40 mm.

0,0381
a
0,0762
mm.

0,0432
a
0,0812
mm. 4,128 cm.

8,674
a
8,704
mm.

3,4925
cm.
8,641 a
8,666
mm.

8,628
a
8,653
mm.

0,0381
a
0,0889
mm. 0,051 a 0,102 mm.
4,16 cm. at
26,76
-
29,03
kg. 3,20 cm. at
76,20
kg.
107

'Jeep*
UNIVERSAL
SERIES SERVICE
MANUAL

H
13406

FIG.
H-39—STARTING
CIRCUIT

1—
Ground
Cable
2—
Battery

3—
Positive Cable
4—
Alternator
Wire
5—
Alternator

6— Ignition Switch
Wire

H-93.
Maintenance Procedure

A
periodic inspection should be made of the start­ ing circuit. Since the interval
between
these
checks

will
vary according to the type of service, it should, under normal conditions, be made every 500 hours
of operation. Inspect all starting circuit wiring for damage.
Check
for
loose
or corroded terminals and
for dependable operation of the starting motor.

H-94.
Wiring

Refer
to Fig. H-39. Inspect the starting circuit to make sure that all
connections are clean and tight.
Check
for worn or damaged insulation on the wires. Perform a volt­

age-loss
test
to make sure there is no
loss
of start­ ing motor efficiency resulting from high resistance
connections. Voltage
loss
from the battery ter­
minal
to the starting motor terminal should not
exceed .30 volts for each 100 amperes. Voltage
loss
between
the battery ground
post
and the start­ing motor frame should not exceed .10 volts for
each 100 amperes. If the
voltage
loss
is greater
than
these
limits, measure the
voltage
loss
over
each part of the circuit until the resistance causing the
voltage
loss
is located and corrected.

H-95.
Commutator
Sluggish starting motor operation may be caused by a dirty commutator or worn brushes. The com­mutator cannot be cleaned while the. starting motor is mounted on the
engine
and it
will
be necessary
to remove it and proceed as for an overhaul. Should 7— Ignition Switch
8— Solenoid
Wire

9—
Starter

10— Solenoid
11—
Connector
Strap
the commuator be rough or worn, it should be
removed for cleaning and reconditioning.
H-96.
Overhaul Procedure

At
periodic intervals the starting motor circuit
should be thoroughly checked and the motor re­ moved from the
engine
for cleaning and checking.

H-97.
Removal and Disassembly

Refer
to Fig. H-40 and H-41.
To
remove the starting motor from the engine, dis­
connect the leads and cover the battery lead ter­

minal
with a piece of
hose
or tape to prevent short

circuiting.
Remove the flange
bolts
holding the starting motor to the flywheel housing. Remove
the starting motor from the vehicle.

Each
part of the starting motor should be removed, cleaned, and inspected for evidence of wear or
damage. The Bendix
Folo-Thru
Drive should be
cleaned and inspected for evidence of wear or a distorted spring. Bearings should be checked for
proper clearance and fit. All insulation should be
free of oil and in
good
condition. The armature,
field coils, and brushes should be checked for
good
ground and lack of open circuits.

H-98.
Brushes

a.
The brushes should slide freely in their holders
and
make full contact on the commutator. Worn
brushes should be replaced.
b.
Check
brush spring tension with a spring scale.
Hook the scale under the brush spring near the 203

H

ELECTRICAL
SYSTEM

FIG.
H-42—GROWLER
d.
Install
the armature in starter motor frame,
using care to align the four brushes and brush
springs on the commutator so that they are free to
move
and are square on the commutator.

e.
Install
the thrust washer on the shaft.
Lubricate

the plug and bearing in the end plate.
Install
the
end plate.
Install
the two through
bolts
and tighten securely.

f.
On Prestolite V6 starting motors, check pinion position by measuring from the centerline of the
pinion housing mounting bolt
holes
to the outside

edge
of the pinion.
Correct
measurement with the
Bendix
drive retracted is [19,05 mm.] to
%"
[22,23 mm.]; with drive extended, 1%"

[34,93
mm.] to 1^" [38,10]. Adjust by installing

thrust
washers just inside the commutator end
head or intermediate bearing as required. The
Bendix
drive retaining pin must not project
beyond the outside diameter of the pinion
sleeve.

H-104.
Bench Test

The
motor should first be checked to see that the
free running
voltage
and current are within specifi­ cations. To
test,
connect the motor to a battery,
ammeter and voltmeter. If the current is too high
check
the bearing alignment and end play to make

sure
there is no binding or interference. Using a

spring
scale and torque arm check the stall torque to see that the motor is producing its rated
crank­

ing power. The stall torque
will
be product of the

spring
scale reading and the length of the arm

in
feet.
If the torque is not up to specifications

check
the seating of the brushes on the commutator
and
the internal connection of the motor for high
resistance. The Bendix
Folo-Thru-Drive
should be checked for correct operation. The Bendix pinion
should be checked to see that it shifts when the motor is operated under no load.

H-105.
Bendix Folo-Thru Drive (Prestolite)
The
Bendix
Folo-Thru
Drive is designed to over­

come
premature demeshing of the drive pinion
from
the flywheel ring gear until a predetermined

engine
speed is reached. See Fig. H-43. No repairs or adjustments are possible on this

drive
and a
complete
new unit must be installed

if
trouble develops.

H-106.
Lubrication
of
Folo-Thru Drive
A
periodic cleaning and relubrication of the drive is advisable, the frequency of which
will
depend on
the type of service to which the vehicle is sub­
jected and the locale of operation.

a.
Remove the starting motor from the
engine
and take off the outboard housing. The pinion and

barrel
assembly
will
be in the demeshed position
on the screwshaft. Do not
move
it forward
until
after
that portion of the armature shaft ahead
of the pinion has been cleaned. If accidentally ro­
tated to the outer end of the screwshaft it
will

lock
in that position and cannot be forced back.

b.
Do not disassemble the drive for any reason.

c.
Do not dip or wash the drive in any cleaning solution.

d.
Do not remove the drive from the armature
shaft. Remove
excess
oil, grease or foreign matter
from
the armature shaft by wiping it with a clean cloth.
3
10859
FIG.
H-43—BENDIX
FOLO-THRU DRIVE

Dampen
the cloth with kerosene if necessary. A
light film of
SAE
10 oil may then be applied to the shaft.

e.
Now rotate the pinion and
barrel
assembly to the
fully
extended position, thereby exposing the screw­ shaft triple threads. Use a cloth dampened with
kerosene to wipe them clean. Do not use
gaso­
line
or any
commercial cleaner.
If the dirt is

thick
and gummy, apply the kerosene with a small

brush.
Tilt
the starting motor so that a small
amount
will
run under the control nut. Relubricate

with
a thin film of
SAE
10 oil. Use SAE 5 at ex­ tremely low temperatures.

f.
Reassemble the starting motor to the
engine
with the drive in the extended position.
Carefully
mesh the pinion with the flywheel ring gear before
tightening the starter motor mounting bolts. It may 206