charging JEEP CJ 1953 Service Manual
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Page 7 of 376
'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
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 13 of 376
'Jeep'
UNIVERSAL
SERIES SERVICE
MANUAL
B
e.
Check
for the presence of
excess
water in the
oil
that might indicate an internal leak from the
cooling system.
f.
Pour oil into the oil filler tube. Replace the oil
filler
cap.
B-10.
Engine Oil
Filter
Service —
Hurricane
F4 Engine
The
engine
oil filter assembly should be replaced at each
2000
miles
[3.200
km.] of normal
engine
use. To remove the filter, use oil filter wrench
C-4065.
To install a new filter, wipe the gasket —
contact surface with
engine
oil, screw on the unit
until
gasket contacts the sealing surface, and then tighten at least one
half
turn
more. DO NOT USE
TOOLS.
Turn
by hand only. When refilling the
engine
crankcase after filter has been changed be
sure
to add one extra quart [1 ltr.] of oil to
fill
filter
and oil passages. Run
engine
to make sure there is no leak at oil filter.
B-l 1.
Engine Oil
Filter
Service — Dauntless V-6 Engine
To
replace the oil filter, use oil filter wrench, Tool
C-4065,
to remove the filter. After the filter has
been removed from the oil pump housing located
on the right front side of the engine, wipe the
housing surface clean and oil the gasket on the base of the new filter to make a
good
seal. Screw
the new filter in position until its gasket contacts
the pump housing surface, then tighten at least
one-half
turn
until filter fits snug.
Note:
Tighten by hand only, do not use a tool to
tighten.
Replace
oil filter each
6000
miles
[9.600
km.] at
engine
oil change.
B-12.
Exhaust
Manifold
Heat
Control
Valve
— Dauntless V-6 Engine
A
thermally-actuated heat control valve is located at
rear
of the right exhaust manifold of the Daunt
less
V-6 engine.
This
valve has a bimetal thermo
static spring which holds the valve closed when
the
engine
is cold.
Each
time the vehicle is lubricated place a few drops of penetrating oil on the valve shaft bushings
and
then work the valve by hand making sure that
the lubricant is worked into the bushings.
Note:
If the valve shaft
does
not operate freely
penetrating oil should be used to free the shaft.
B-l 3.
Positive
Crankcase
Ventilation
System
Service
the ventilation system of the
engine
each
multiple of
6000
miles
[9.600
km.] on the odometer
after
initial
2000
miles
[3.200
km.] service. Re
place the ventilation valve each
12,000
miles
[19.200
km.].
For
information on servicing the positive crankcase
ventilation system on the
Hurricane
F4
engine
and
the Dauntless V-6 engine, refer to the Tune-up Section.
B-l4.
Distributor
— Hurricane F4 Engine
The
distributor shaft is lubricated through an oiler mounted on the side of the housing. Place three or four drops of light
engine
oil in the oiler each
2,000
miles
[3.200
km.]. Also place one drop of light
engine
oil on the wick located on the top of the
shaft, which is made accessible by removing the
rotor
arm. Sparingly apply cam lubricant to the
breaker
arm cam and place a drop of oil on the
breaker
arm pivot.
B-l
5.
Distributor
— Dauntless V-6 Engine
The
distributor has a lubricant reservoir that
car
ries
sufficient
lubricant
for the life of the distributor.
When
servicing breaker points, place one drop of
light
engine
oil on the wick located on the top of the shaft Also, apply cam lubricant sparingly to
the breaker arm cam, and place a drop of oil on the
breaker
arm pivot.
B-l6.
Generator
On
early production vehicles oilers are provided
at each end of the generator, for lubrication
pur
pose.
On late production vehicles one oiler is pro
vided at the
rear
(bushing end) of the generator for lubrication purpose. Place two to four drops of
light
engine
oil in each oiler every
2,000
miles
[3.200
km.].
B-l
7. Spark Plugs
Replace
spark
plugs. Refer to Section C.
B-18.
Starting
Circuit
Check
the starting
circuit.
Refer to Section H.
B-l
9. Charging
Circuit
Check
the charging
circuit.
Refer to Section H.
B-20.
Engine Tune-Up
Refer
to Section C of this manual.
B-21.
Adjust
Fan
Belt
Refer
to Section C.
B-22.
Exhaust Emission
Control
System or
Controlled
Combustion System
•
Refer to the appropriate section in this manual.
B-23.
Exhaust System
Check
the exhaust system for leaks. Refer to Section F.
B-24.
Fuel Evaporative Emission
Control
Canister Air
Filter
The
only service required for the
F.E.E.C.
system
is cleaning the air cleaner filter mounted at the
bottom
of the canister. The filter requires replace
ment at
12,000
mile intervals. Refer to Section
E,
Par. E-9 for service procedure.
B-25.
Oil Bath Air Cleaner
Some 'Jeep' Universal vehicles are equipped with
an
oil bath type air cleaner.
This
type air cleaner
thoroughly removes all dust from the air before it enters the carburetor, if it is properly serviced.
When
the vehicle is operated under normal condi
tions the air cleaner must be serviced at regular
intervals
as care of the air cleaner is extremely 13
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 168 of 376
G
COOLING SYSTEM
12761
FIG.
G-10—WATER
PUMP—
CROSS-SECTIONAL
VIEW
—
DAUNTLESS
V-6
1—
Hub
2—
—Shaft
and Bearing
3—
Cover
4—
Impeller
5—
Ceramic
Seal
6—
Seal
Assembly front end of the pump body. Position the seal,
washer,
and pump seal on shaft flush against the ground seat in the water pump body. Place the
impeller
on an arbor press and press the long end
of the shaft into the impeller until the end of the shaft is flush with the hub of the impeller. Support
the assembly on the impeller end of the shaft and
press the pulley hub on the shaft until the shaft end is flush with the pulley hub. Move the shaft
in
the pump body to align the retaining wire
grooves
in the bearing and pump body and place
the bearing retaining wire in position.
G-l
5. Water Pump Removal and Replacement — Dauntless V-6 Engine
Drain
the cooling system. Remove the fan belt and remove the cooling fan and pulley from the hub on
the water pump. Disconnect the
hoses
from the
water
pump. Remove the cap screws that secure
the water pump to the timing chain cover; remove
the water pump. Do not disassemble the water
pump;
it is serviceable only as an assembly. When
replacing
the water pump, torque the water pump cap screws 6 to 8 lb-ft. [0,829 a 1,106 kg-m.].
G-16.
Antifreeze Solutions
When
water freezes it expands approximately 9%
in
volume. When water, confined in a cooling sys
tem, freezes it exerts tremendous pressures causing
serious damage. To prevent freezing, antifreeze can
be added to the water to lower its freezing point.
The
two
types
of antifreeze commonly used today have either a methanol or ethylene glycol base,
and
contain corrosion inhibitors. The only anti
freeze recommended for the cooling system of
'Jeep'
vehicles is ethylene glycol (permanent type).
Methanol
base antifreeze evaporates with the water
when the vehicle is operated at warmer tempera
tures and requires more attention to avoid
loss
of
protection. Ethylene glycol base antifreeze seldom
evaporates at normal operating temperatures.
Methanol
solution is injurious to vehicle finishes.
Should
any be spilled on the vehicle, it should be
washed off immediately with a
good
supply of cold water without wiping or rubbing. Under ordi
nary
conditions, ethylene glycol is not injurious to
vehicle finishes.
Warning.*
Drinking
ethylene glycol antifreeze or its
solutions can be harmful or fatal. Do not use anti
freeze containers for
food
or beverages.
A
table in Par.
G-2
2
gives
the protection obtained
by the addition of various amounts cf ethylene glycol.
Before installing antifreeze, inspect the cooling sys
tem to be sure it is clean, leak-proof, and otherwise
in
proper operating condition.
Drain
the cooling system, see Par. G-3. Pour in 3 quarts [3 ltr.] of
clean
water, add the required quantity of anti freeze, then add clean water to within 1" [2,54 cm.] of the top of the overflow pipe to allow for expan
sion when hot. Run the
engine
until it is
warm.
Then
recheck the solution level.
Check
the anti
freeze protection with a hydrometer reading.
G-l7.
Inhibited Coolant Solutions
All
'Jeep5 vehicles equipped with either the
Hur
ricane
F4 or Dauntless V-6
engine
should use only
inhibited
year-round, permanent-type
engine
cool
ant
solutions that are formulated to withstand two
full
calendar years of normal operation without
draining
or adding inhibitors. The
engine
cooling
system should be completely drained and the
rec
ommended coolant installed every two years. Be-
fo
a
installing the permanent-type solution, inspect the cooling system to be sure it is clean, leakproof,
and
in proper operating condition.
Note:
Water alone, methanol, or alcohol-type anti
freeze is definitely not recommended for 'Jeep*
Vehicles.
G-l8.
Fan Belt
The
fan, water pump, generator or alternator are
driven
by a V-belt. The drive of the V-belt is on
the side of the V. A fan belt that is too tight
will
cause
rapid
wear of the alternator or generator and
water
pump bearings. If the belt is too
loose,
it may
slip
preventing the water pump from properly cool
ing the
engine
or the generator or alternator from
properly
charging the electrical
circuit.
Use fan belt
tension
gauge
Tool W-283 to properly adjust belt.
The
fan belt is properly adjusted when it can be
deflected Vi" [13 mm.] with strong thumb pres
sure
applied midway
between
the fan and alter
nator
pulleys.
Check
this adjustment and inspect the condition of the fan belt at each
engine
lubri-
168
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
Page 172 of 376
H
ELECTRICAL
SYSTEM SUBJECT
PAR.
Directional
Signal
Lamps
H-138
Hazard
Warning
Lamps
H-139
Head
Lamp
Replacement H-130
Head
Lamp
Aiming Procedure H-131 Headlight Dimmer Switch H-127
License
Plate
Lamp
H-136
Main
Light
Switch. H-126
Marker
Lights .H-l40
Parking
and
Turn
Signal
Light
H-133
Stop
Light
Switch. H-l28
Tail,
Stop and
Turn
Signal
Lamp
.H-134
H-1. GENERAL
All
'Jeep' Universal vehicles are equipped with 12- volt electrical systems. Use caution around the higher
voltage
of the 12-volt system as accidental
short
circuits are more capable of damaging electri
cal
units. Also, arcs around the 12-volt battery are
more apt to ignite any gas that may be escaping
from
it. In the following paragraphs
will
be found
information about the battery, distributor, coil,
generator, alternator,
voltage
regulator and start ing motor. These units with the connecting wires,
make
up the
engine
electrical system. The wiring
diagram
will
show the different circuits of the en
gine
electrical system and the various units which
make
up
those
circuits.
With
plastic-covered wiring harnesses use only
rubber-insulated
wiring clips.
Caution:
All current production vehicles are 12- volt, negative ground. Whenever servicing a 12-
volt electrical system, use caution, as an accidental
short
circuit is capable of damaging electrical units. Disconnect battery ground cable before changing
electrical
components.
H-2.
Battery
The
battery is a storage reservoir for electrical
energy produced by the alternator or generator.
The
battery should store sufficient energy for
operation of the entire electrical system when the
alternator
or generator is not pr 1,scing output,
such
as when the ignition is first turned on. Of
particular
importance is maintaining the electrolyte
at the correct level, regularly checking with a
hydrometer, and maintaining clean, tight cable connections.
Battery
service information is given in this section.
Caution:
Do not allow flames or sparks to be
brought near the vent
openings
of the battery since
hydrogen gas may be present in the battery and might explode.
Note:
The liquid in the battery (electrolyte) is a
solution of sulphuric acid which, on contact, can
injure
skin or
eyes,
or damage clothes. If it is spilled
on the skin or spattered in the
eyes,
promptly flush
it
away with quantities of clear water only. If the
acid
is spilled on clothes, wet it thoroughly with a
weak
solution of ammonia, or with a solution of sodium bicarbonate or baking soda.
SUBJECT
PAR.
HORN
H-137
ELECTRICAL
COMPONENT
REPLACEMENT
H-150
WINDSHIPLD
WIPER SYSTEM
H-141
thru
149
SERVICE
DIAGNOSIS.
. .H-151
ELECTRICAL
SPECIFICATIONS
H-152
Caution:
When installing the battery, the nega
tive terminal must be grounded. Reverse polarity of the battery can cause severe damage to the charging system.
Battery
Inspection
a.
Check
the specific gravity of the electrolyte 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 in
dicates 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
pressure
could damage the battery case.
d.
Clean
the battery terminals and cable con nectors. 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,
connect cables to battery and coat the terminals
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 connection at the frame to ensure a
good
ground
connection.
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 the battery is satisfactory. If the
voltage
falls
below the figure given, yet the specific gravity is
above
1.225,
the condition of the battery is questionable.
g. Be sure the
engine
ground strap connection, 172
Page 174 of 376
H
ELECTRICAL
SYSTEM
the condenser. Replace the condenser. If there is
no jump to full voltage, overhaul or replace the
distributor.
k.
With the points closed, connect the voltmeter
from
a clean, paint-free
post
on the distributor
body to the negative
post
of the battery. The volt
age drop should be practically zero, a hardly
readable deflection on the voltmeter. If the volt meter registers a
voltage
drop, perform the checks
in
steps
1
and m following.
I.
Check
for
voltage
drop in the battery ground
cable.
Clean
the battery
post,
cable terminals, and contact surface on the bellhousing, or on body if
a
noticeable deflection of the voltmeter occurs,
m.
Check
for any
voltage
drop
between
the dis
tributor
body and a clean, paint-free
spot
on the
cylinder
block. If there is any
voltage
drop, remove
the distributor and clean the mounting surfaces of
distributor
body and cylinder block.
H-5.
SECONDARY
CIRCUIT
If
satisfactory ignition is not obtainable with cor
rect
point gap and tension; satisfactory condenser;
sufficient primary voltage; and correctly cleaned, gapped, and installed spark plugs; the secondary
circiut
should be investigated.
a.
Test the coil.
Bring
the coil up to operating
temperature using the coil heat feature of a coil tester, if available. Refer to the coil tester manu
facturer's
instructions for specific hook-ups for
performing the checks given in
steps
b, c, and d following.
b. Connect the positive lead of the tester to the
battery terminal of the coil primary winding.
Con
nect the tester ground lead to the coil tower. Mea
sure
the resistance of the secondary winding. If the
resistance is more than
20,000
ohms, a fault in the
secondary winding is indicated.
c.
Check
for a grounded secondary by touching the tester ground lead to the coil cover. If resistance
is not over
100,000
ohms, the secondary is grounded
to the cover.
d.
If the secondary winding is satisfactory, mea
sure
the primary current draw in accordance with
the instructions of the
test
equipment manu
facturer.
e.
Check
the secondary circuit for leakage. With the coil primary in the circuit with the breaker unit of the tester, connect a long, high-tension
test
lead
to the coil tower.
Check
the secondary circuit for
leakage by performing the checks given in
steps
f. g, h, and i following.
Note:
In the following
tests,
a slight sparking and
meter deflection
will
usually be
seen
just as contact
is made.
This
is caused by capacitance and
does
not
indicate defective insulation.
f.
Check
distributor cap. Remove the coil lead from the cap and touch the
test
lead to the center contact
inside the cap. If the meter reading drops when the contact is touched or if sparking is seen, a leakage
path is present
between
the center contact and one
of the plug towers.
This
leakage path
will
be in the
form
of a
crack
or carbon track in the cap. Discon nect the spark plug wires from the cap one at a
time and
test
each plug contact with the high-
voltage
lead and with all other plug wires con
nected. Any sparking or meter drop indicates that
a
leakage path exists
between
that particular con
tact and an adjacent one. Testing the adjacent contacts
will
determine which pair is at fault,
g-
Check
distributor rotor. Touch the
test
lead to
the spring contact in the center of the distributor
rotor.
Any leakage in the rotor insulation
between
the contact and the shaft
will
cause a drop in the meter reading and usually sparking
will
be seen.
h.
Check
spark plug wires. Disconnect the spark
plug wires from the plugs and
test
the plug terminal of each. The meter reading should not drop below
the open secondary value (value before making contact). If it
does
or if a large spark occurs when
the
test
lead and the plug wire are separated, there
is a break in the insulation on that wire.
i.
Check
the coil tower insulation. Remove the
high-tension
test
lead from the coil tower and touch
the ground lead of the coil tester to several points
around
the base of the tower. Any sparking or deflection of the meter indicates a leakage path in
the tower insulation.
H-6.
Alternator Charging System
All
Jeep
Universal
Series vehicles have, as standard
equipment a 35-amp., 12-volt, negative ground
alternator and a transistorized
voltage
regulator.
For
repairing the alternator, many of its major components are furnished as complete assemblies
including:
complete brush assembly which requires no soldering or unsoldering of leads; two complete
rectifying
diode
assemblies which eliminate the need for removing and replacing individual diodes;
a
complete isolation
diode
assembly; and a rotor assembly complete with shaft,
pole
pieces, field coil,
and
slip rings.
The
transistorized
voltage
regulator is an electronic
switching device. It
senses
the
voltage
appearing at the auxiliary terminal of the alternator and
supplies the necessary field current for maintaining the system
voltage
at the output
terminal.
The out
put current is determined by the battery electrical
load;
such as headlights, heater, etc.
The
transistorized
voltage
regulator is a sealed unit,
has no adjustments, and must be replaced as a
complete unit.
H-7.
Starting System
The
operation of the starter motor is controlled by
the ignition switch. The starter is made up of a
frame,
field coil, armature, and brushes.
The
starter solenoid electrically
closes
the circuit
between
the battery and the starter motor. When the ignition key is turned to its extreme right, the
solenoid is energized and
closes
the battery-to- starter-motor circuit.
Note:
All Jeep Universal Series vehicles have the
starter
solenoid switch secured to the starter motor
assembly. The Hurricane F4 and Dauntless V-6
engine
Prestolite starter drive is of the inertia type
(rexr
continued on
page
176) 174
Page 175 of 376
'Jeep'
UNIVERSAL
SERIES
SERVICE
MANUAL
H
11514
FIG.
H-2—WIRING
DIAGRAM—MODEL
CJ-3B
(Serial No.
35522
and
after)
1—
Left
Headlamp
2—
Left
Parking and Signal Lamp
3— Right Parking and Signal Lamp
4— Right Headlamp 5— Battery Ground Strap
6— Generator 7— Ignition
Coil
8— Junction Block
9—
Horn
10— Distributor
11— Battery
12—
Voltage
Regulator 13— Starting Motor
14—
Oil
Pressure Signal Switch 15— Temperature Sending Unit
16—
Solenoid
Switch 17— Foot Dimmer Switch
18—
Stop
Light Switch 19— Directional Signal Flasher
20— Fuse
21—
Light
Switch 22— Directional Signal Switch
23—
Horn
Button 24— Ignition and Starter Switch 25—Instrument Cluster
A—Upper Beam Indicator
B—Turn
Signal Indicator C—Instrument Lights
D—Oil
Pressure Indicator
E—Charging
Indicator F—Temperature Gauge
G—Fuel
Gauge
H—Instrument
Voltage
Regulator
25—Fuel Gauge Tank Unit
27—
Left
Tail
and
Stop
Lamp
28— Right
Tail
and
Stop
Lamp 175