battery JEEP CJ 1953 Service Manual
[x] Cancel search | Manufacturer: JEEP, Model Year: 1953, Model line: CJ, Model: JEEP CJ 1953Pages: 376, PDF Size: 19.96 MB
Page 12 of 376
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
Page 19 of 376
Jeep*
UNIVERSAL SERIES SERVICE
MANUAL
c
TUNE-UP
Contents
SUBJECT
PAR.
GENERAL
C-l
TUNE-UP
.C-2
Air
Cleaner
C-21
Battery
. C-3
Carburetor
Adjustments
C-2 5
Coil
C-20
Crankcase
Ventilation C-6
Cylinder
Compression C-9
Cylinder
Head(s) .C-5
Dash
Pot Adjustments .C-26
Distributor
Service C-10
thru
C-13
Distributor
Resistance Test C-l6
Fan
Belt
C-2 7
Fuel
Lines
and Screens
C-2
2
C-l.
GENERAL
An
engine tune-up should be performed for all
Jeep Vehicles each 6000 miles [9.600 km.] or at the end of each 250 hours off-the-road operation,
to ensure best possible performance at all times.
The
tune-up should follow the sequence given in
this section.
Because of federal laws limiting exhaust emissions,
it
is even more important that the engine tune-up is
done
accurately, using the specifications listed
on the tune-up sticker found in each engine com
partment.
Note;
To ensure proper operation and effectiveness
of the exhaust emission control system, and to
comply with
Federal
and State requirements, a
recheck
of ignition timing, idle speed and idle mix
ture
and necessary adjustments must be performed
after the first
2,000
miles [3.200 km.] of vehicle
operation.
A
minor engine tune-up should be performed every
6,000
miles [9.600 km.] or at the end of 250 hours
of off-the-road use.
Major
engine tune-up should
be performed every 12,000 miles [19.300 km.].
The
parts of units which affect power and perform
ance may be divided into three groups:
(1) Units affecting compression
(2) Units affecting ignition
(3) Units affecting carburetion
The
tune-up procedure should cover
these
groups
in
the order given. While the items affecting com
pression and ignition may be handled according
to personal preference, correction of items in the
carburetion
group should not be attempted until
all
items affecting compression and ignition have
been satisfactorily corrected.
Note:
To make sure hydro-carbon and carbon
monoxide emissions
will
be within limits, it is very
impotrant
that the adjustments be followed exactly
as listed on the sticker found in each engine compartment.
SUBJECT
PAR.
Fuel
Pump . . C-23
Heat
Control
Valve C-7
Ignition
Cables C-19
Ignition
Timing
. C-14
Ignition
Wires C-l8
Manifold
C-5
Manifold
Vacuum C-24
Point
Dwell C-17
Primary
Circuit
Tests
.................
C-15
Spark
Plugs C-4
Tappets
C-8
ROAD TEST C-2
8
SERVICE
DIAGNOSIS
. : C-29
TUNE-UP SPECIFICATIONS..
C-30
Minor
engine tune-up consists of the following.
Inspect
and correct as required:
Battery
cables and connections.
Alternator
and regulator wiring.
Primary
— Secondary wiring, distributor cap.
Cylinder
head torque.
Contact
point dwell.
Vacuum
and centrifugal advance.
Ignition
timing.
Spark
plugs for correct air gap.
Adjust
idle speed and idle air mixture.
Adjust
all drive belt tensions.
Clean
carburetor air cleaner.
Lubricate
exhaust manifold damper.
Major
engine tune-up includes the following.
Inspect
and correct as required:
Battery
condition and charging
circuit.
Clean,
lubricate
and tighten battery cable connec
tions.
Ingition
system.
Spark
plugs; replace if necessary or clean and gap.
Compression
check.
Primary—Secondary
wiring, distributor cap.
Replace
contact points and condenser.
Lubricate
distributor cam with cam grease.
Adjust
contact points.
Check
vacuum and centrifugal advance. Set ignition timing.
Torque
cylinder head.
Adjust
idle speed and idle air mixture.
Replace
fuel filter element (every 12,000 miles [19.300
km.]).
Adjust
all drive belt tensions.
IMPORTANT: SPECIFICATIONS
FOR EN-
GINE
RPM.
DISTRIBUTOR POINT DWELL,
AND IGNITION TIMING GIVEN
IN
TUNE- UP SECTION
C
REFER
TO
VEHICLES
WITH
AND WITHOUT EXHAUST EMISSION CON
TROL
SYSTEMS.
FOR
VEHICLES
EQUIPPED WITH EXHAUST
EMISSION CONTROL SYSTEMS ALSO
REFER
TO
SECTION
Fl (F4-134
ENGINE)
AND
F2 (V6-225
ENGINE).
19
Page 20 of 376
c
TUNE-UP
C-2.
TUNE-UP SEQUENCE
The
following
Pars.
C-3 through
C-2
7
give the
sequence and describe the services to be performed
when tuning the engine.
C-3.
Clean
and
Check
Battery
Inspect
battery and cables. If the battery is not
satisfactory, install a fully-charged battery to allow
completion of the tune-up.
Note: If the battery fails any of the following tests,
remember that the cause may be other electrical
trouble, and not necessarily only a defective battery.
Refer
to Section H for electrical troubleshooting
and
tests.
a.
Check
the specific gravity of the eletrolyte in
each cell of the battery. A hydrometer reading of 1.260 indicates that the battery is fully charged.
If
the reading is 1.225 or below, the battery
needs
recharging.
If one or more cells is 25 "points" (.025)
or
more lower than the other cells, this indicates
that the cell is shorted, the cell is about to
fail,
or
there is a
crack
in the battery partition in the case.
Unless the battery is repaired or replaced, battery trouble
will
soon be experienced.
b.
Check
the electrolyte level in each cell, add
distilled
water to maintain the solution %" [9.5
mm.] above the plates. Avoid overfilling. Replace
the filler caps and tighten securely. It is important
to keep the electrolyte level above the plates at
all
times because plates that are exposed for any
length of time
will
be seriously damaged.
c.
Check
the wing nuts on the hold-down frame
for tightness. Tighten them only with finger pres
sure,
never with pliers or a wrench. Excessive pres
sure
could damage the battery case.
d.
Clean
the battery terminals and cable connec-
FIG.
C-l—FRAME
GROUND
STRAP
—
HURRICANE
F4
1—
Right
Front
Engine Mount
2—
Frame
Ground
Strap
DAUNTLESS
V-6
tors.
Prepare a strong solution of baking soda and
water
and brush it around the terminals to remove
any
corrosion that is present. The cell caps must
be tight and their vents sealed to prevent cleaning
solution entering the cells. After cleaning install
cable connectors on terminals and coat the ter
minals
and connectors with heavy grease.
e. Inspect the battery cables and replace if badly
corroded
or frayed.
Check
tightness of terminal
screws to ensure
good
electrical connections.
Check
the tightness of the negative ground cable connec tion at the engine to ensure a
good
ground con nection.
f.
Load
test
the battery. Connect a voltmeter across the battery. Run the starting motor for 15 seconds.
If
the voltage
does
not drop below 10 volts on a 12 volt battery the battery is satisfactory. If the
voltage falls below
these
values, yet the specific
gravity
is above
1.225,
the condition of the battery
is questionable.
g.
Make sure the engine to frame ground strap or
cable connections are tight. If
these
connections
are
loose,
corroded or dirty,
hard
starting or failure
of the vehicle electrical system may result. Refer
to
Fig.
C-l
for location of the
Hurricane
F4 engine
to frame ground strap and its connections. Refer to Fig. C-2 for location of the Dauntless V-6 en gine to frame ground cable.
C-4.
Clean and
Adjust
Spark Plugs
Clean,
inspect, and gap
spark
plugs. Do not install
spark
plugs until completion of compression tests.
a.
Use a
Spark
Cable
and Installing
Plier
Tool,
W-2
74,
to remove the leads from the
spark
plugs.
Caution:
Pulling on the cables to remove them
from
the
spark
plugs can cause internal breaks in
the leads that
will
cause ignition failure.
b.
Using a
spark
plug wrench, loosen each
spark
plug one or two turns to break
loose
any carbon
deposits on the plug base. 20
Page 29 of 376
'Jeep'
UNIVERSAL
SERIES
SERVICE
MANUAL
C
FIG.
C-18—DAUNTLESS
V-6
ENGINE
TIMING
MARKS
C-15.
Primary
Circuit
Tests
Excessive
voltage
drop in the primary circuit
will
reduce the secondary output of the ignition coil,
resulting in hard starting and poor performance. Inspect all primary wiring for
loose
or corroded
terminals, worn insulation, and broken strands,
a.
Connect voltmeter positive (-J-) lead to the
positive battery terminal, as shown in Fig. C-20.
The
negative
lead (—) is connected to the ignition
side of the resistor on Dauntless V-6
engine.
The
negative
lead (—) is connected to the ignition
pri
mary
of the coil on Hurricane F4
engine.
Con
nect a jumper wire from the distributor primary
terminal
of the coil to the ground. Be sure all lights and accessories are off. b. With the ignition switch on, the
voltage
should
not
exceed
.4 volts. More than .4
volts
indicates
excessive
resistance
exists
in the battery cable, ignition switch wiring, or the ignition switch. The
excessive
resistance may be located with voltmeter checks across each section of the circuit.
c. Remove the jumper wire from the coil. Connect
the voltmeter positive (-f) lead to the distributor
terminal
of the ignition coil. Ground the
negative
(—) lead of the voltmeter.
12156
FIG.
C-20—IGNITION
PRIMARY
CIRCUIT
RESISTANCE
CHECK
1—
Distributor
2—
Distributor
Primary
Terminal
3—
Coil
4— Ignition Resistor 5— Ignition Switch 6— Ignition Switch Side of Resistor 7— Positive Battery
Terminal
8—
Battery
9—
Jumper
Wire
d.
Note
the
voltage
with the ignition switch on.
If
battery
voltage
is indicated, the distributor
breaker
points
are open. Rock the
engine
to
close
the points. Voltage
less
than .2 volt indicates the
points
are satisfactory. Voltage more than .2 volt indicates burned or high resistance in the ignition
points
or a poor distributor ground.
C-l
6. Distributor
Resistance
Test
A
dwell tester is used for the following
tests.
Ex
cessive resistance in the ignition primary circuit,
from the distributor side of the coil through the
points
and to the distributor ground,
will
prevent
the coil from producing sufficient output for
good
overall
ignition. Any resistance in this portion of
the ignition system
will
be indicated on the dwell
FIG.
C-21—DISTRIBUTOR
RESISTANCE
CHECK
14242
FIG.
C-19—DISTRIBUTOR
ROTATION
AND
FIRING
ORDER,
V-6
ENGINE
29
Page 35 of 376
C-30.
TUNE-UP
SPECIFICATIONS
ITEM
BATTERY:
Voltage
Terminal
Ground Specific Gravity:
Fully
Charged Recharge at
Load
Test, minimum:
12-Volt Battery. .
SPARK PLUGS:
Make and Model
Gap
Tightening Torque
COMPRESSION
PRESSURE CRANKING:
VALVES:
Tappet Clearance Cold:
Intake
Exhaust:
Timing (Intake Opens)
DISTRIBUTOR
Model
Dwell
Angle
Point Gap
Arm
Spring Tension
Firing
Order and Direction ....
IGNITION TIMING.
Mark
Location
ENGINE
IDLE
SPEED: W/O
Exhaust Emission Control With Exhaust Emission Control
F4
W/Dist. IAY-4401A
F4
W/Dist. IAY-4401B
FIRING
ORDER HURRICANE
F4
DAUNTLESS
V-6
12 Volts
Negative
1.260 1.225
10 Volts
AC
45 or Champion J-8 .030"
[0,762
mm.]
25 to 33
lb-ft.
[3,5 a 4,6
kg-m.]
120 to 130 psi. [8,4 a 9,2
kg-cm2]
.018"
[0,460
mm.] .016"
[0,406
mm.]
9°
BTC
PRESTOLITE
IAY-4012
IAY-4401A
IAY-4401
IAY-4401B
42°
.020"
[0,508
mm.]
17 to 20 oz.
[0,482
@
0,567
gr.]
1-3-4-2
Counterclockwise
5° BTC
0° TDC
Vibration Damper or Timing Cover
600 rpm.
1-3-4-2
650/700
rpm.
700/750
rpm. 12 Volts
Negative
1.260 1.225
10 Volts
AC
44S or Champion UJ12Y .035"
[0,889
mm.]
25 to 35
lb-ft.
[3,5 a 4,8
kg-m.]
Zero (Hydraulic Lifters)
Zero (Hydraulic Lifters)
DELCO-REMY
1110376
PRESTOLITE
IAT-4501 IAT-4502A
IAT-4502
30°
19 to 23 oz.
[0,538
@
0,652
gr.'
5°
BTC
29°
± 3°
.016"
[0,401
mm.] 17 to 22 oz.
[0,482
1-6-5-4-3-2-
Clockwise
5°
BTC
Timing Cover
650/700
rpm.
650/700
rpm.
1-6-5-4-3-2
%
0,624
gr.]
0°
TDC
NOTE:
FOR
VEHICLES
EQUIPPED WITH EXHAUST
EMISSION
CONTROL, ALSO
REFER
TO
SECTION
Fl (F4-134
ENGINE)
AND
SECTION
F2
(V6-225
ENGINE).
Co O
Page 41 of 376
'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
Page 68 of 376
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
Page 79 of 376
'Jeep*
UNIVERSAL SERIES SERVICE
MANUAL
Dl
12710
FIG.
D1
-3—HYDRAULIC VALVE
LIFTER
ASSEMBLY, CROSS-SECTIONAL VIEW
1—
Snap
Ring
6—Ball Retainer
2— Rod
Seat
7—Plunger Spring
3—
Oil
Inlets
8—Lifter
Body
4—
Plunger
9—Bronzed
Cap
5— Feed
Hole
sages
in the block and cylinder head.
The
water cooled system is pressurized to provide efficient
engine
cooling. It consists of a centrifugal-
type water pump, mounted on the timing chain cover, and is driven by the
engine
fan pulley. The
pump provides coolant flow equally to both
cylin
der banks under control of a thermostat. Coolant
flow is around the cylinders and through the
cylinder
head to dispel the heat of combustion in
the engine.
Dl-3.
Engine Mounts
The
engine-transmission unit is mounted to the chassis at three points by rubber pads. The two
front mounts are bolted to the
engine
cylinder
block and the frame members. These mounts sup port most of the
engine
weight, and absorb
vibra
tion which would otherwise be caused by changes
in
engine
output torque. The single
rear
mount is
placed
between
the transmission and the trans mission support. It supports part of the engine'
and
transmission weight, and locates the
rear
of
the
engine
with respect to the centerline of the
vehicle.
Dl-4. ENGINE REMOVAL
To
remove the
engine
from the vehicle follow the
procedurers listed below:
a.
Remove hood. b. Disconnect battery cables from battery and
engine. c. Remove air cleaner.
d.
Drain
coolant from radiator and engine.
e.
Drain
engine
oil.
f. Disconnect alternator wiring harness from con nector at regulator.
cj.
Disconnect the fuel evaporative purge line con nected to the
P.C.V.
valve.
h.
Disconnect upper and lower radiator
hoses
from
the engine.
i.
Remove right and left radiator support
bars,
j.
Remove radiator from the vehicle.
k.
Disconnect
engine
wiring harnesses from con
nectors located on
engine
firewall.
I.
On
engines
equipped with exhaust emission con
trol,
remove the air pump, air distribution manifold,
and
anti-backfire (gulp) valve. See Section F2 for
procedure.
m.
Disconnect battery cable and wiring from en
gine
starter assembly.
n.
Remove
engine
starter assembly from engine,
o.
Disconnect
engine
fuel
hoses
from fuel lines at
right
frame
rail,
p. Plug fuel lines.
q.
Disconnect choke cable from carburetor and cable support bracket mounted on engine,
r.
Disconnect exhaust pipes from right and left
engine
manifolds.
s. Place
jack
under transmission and support trans
mission weight.
f. Remove
bolts
securing
engine
to front motor mounts.
u.
Attach suitable sling to
engine
lifting
eyes
and,
using hoist, support
engine
weight.
v. Remove
bolts
securing
engine
to flywheel housing.
w. Raise
engine
slightly and slide
engine
forward
to remove transmission main shaft from clutch plate spline.
Note:
Engine and transmission must be raised
slightly to release the main shaft from the clutch
plate while sliding the
engine
forward.
x. When
engine
is free of transmission shaft raise
engine
and remove from vehicle,
y. Place
engine
on suitable blocking or
engine
stand and remove sling from engine.
Dl-5.
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 applicable 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.
Page 104 of 376
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
Page 171 of 376
'Jeep'
UNIVERSAL SERIES SERVICE
MANUAL
H
ELECTRICAL
SYSTEM
Contents
SUBJECT
PAR.
GENERAL
. -H-l Alternator Charging System H-6, 63 Battery. . . .H-2
Electrical
Instruments. H-l 11 Ignition System H-3
Lighting
System H-8, 125
Primary
Circuit.
.. H-4 Secondary
Circuit
H-5
SparkPlugs H-33
Starting System H-7, 88
DISTRIBUTOR
—
HURRICANE
F4
ENGINE
H-9
Coil
H-19 Condenser
.H-l
2
Disassembly.
.........................
.H-16
Distributor Cap H-10 Distributor
Points
H-13
Governor Mechanism H-l4
Inspection H-l
7
Installation and Timing H-18
Removal H-15
Rotor H-ll
DISTRIBUTOR
—
DAUNTLESS
V-6
ENGINE
H-20
Ballast
Resistor. H-32
Centrifugal
Advance H-25
Cleaning and Inspection H-28
Coil
H-31
Condenser H-23
Disassembly. H-27
Distributor Cap H-21 Distributor
Points
H-24
Installation and Timing. . .H-30
Reassembly. H-29
Removal H-2 6
Rotor H-2
2
GENERATOR CHARGING SYSTEM SERVICE
H-34 Generator Armature H-3
7
Generator Assembly. H-40
Generator
Brush
Holders H-39
Generator Disassembly H-36
Generator
Field
Coils.
H-38
Generator Maintenance H-35 Generator -
Current
-
Voltage
Regulator. . .H-41
Generator Regulator Quick Checks...... .H-48
Generator Regulator Test Procedure H-47
ALTERNATOR PRECAUTIONS.
H-64
ALTERNATOR CHARGING SYSTEM.
. .H-63 Alternator On-Vehicle Tests. .H-67
Alternator Output Test. .H-70 Isolation
Diode
Test H-69
Regulator Test .H-71 Removal and Installation of
Voltage
Regulator. H-72
SUBJECT
PAR.
Service
Diagnosis
H-66 Test Equipment H-68
Alternator
Field
Circuit
Test H-73
Brush
Insulation and Continuity Test H-75
Brush
Removal and Inspection H-74
Rotor In-Vehicle Tests H-76
ALTERNATOR BENCH TESTS.
.H-77
ALTERNATOR REMOVAL
H-78 Alternator Disassembly H-80 Alternator Installation. H-87
Assembling Alternator H-86
General
Inspection H-81
Diode
Test H-85
Out-Of-Circuit
Rotor Test. .H-82
Out-Of-Circuit
Stator Leakage Test.. . H-83 Rotor Tests H-79
Stator
Coil
Leakage and Continuity Test. .H-84
STARTING
MOTOR
—
PRESTOLITE.
. .H-92
Armature
.H-l
00 Bench Test H-l04
Bendix
Folo-Thru
Drive H-105
Brush
Holder Inspection. .H-102
Brushes H-98
Commutator H-95, 99
Disassembly H-9 7
Field
Coils H-101
Lubrication
of
Folo-Thru
Drive H-l06
Maintenance Procedure H-93
Overhaul
Procedure H-96
Reassembly of Starting Motor. .
H-l
03
Starter
Solenoid
Switch H-10 7 Starter Ignition Switch. .H-89
Wiring.
. . . H-94
STARTING
MOTOR
—DELCO
H-108
Armature
H-101
Brush
Holder Inspection H-l 15 Brushes
H:lll
Commutator H-112
Field
Coils........
H-114
Locked
Armature Test. . . H-l20
Solenoid
Coils H-l 16
Starting Motor Reassembly H-l 17
Starting Motor Cleaning and Inspection.
.H-l
10
Starting Motor Disassembly .H-109 Starting Motor No-Load Test H-119
Starting Motor Test — General H-l 18 Starter Switch —
Solenoid
Type. H-l21
Starter Ignition Switch. .H-89
ELECTRICAL
INSTRUMENTS
H-122 Testing Instrument Gauges H-l24
LIGHTING
SYSTEM
H-l25 Aiming Head Lamps H-132
Backup
Lamps H-135
(continued
on
next
page)
171