manual transmission JEEP CJ 1953 Service Manual
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Page 1 of 376
1953-71
SERVICE MANUAL
JeeP
UNIVERSAL
4-WHEEL DRIVE
CJ-3B CJ-5A
CJ-5
CJ-6
CJ-6A
2-WHEEL DRIVE DJ-5
DJ-6
Copyright®
1977
FI Jeep Corporation Corporate Publications
Printed
in USA
Reprinted
6-77
SM-1046
SECTION
INDEX
NAME
Section
General
Data
A
Lubrication
B
Tune-Up
C
Hurricane
F4 Engine
D
Dauntless V-6 Engine
Dl
Fuel
System
E
Exhaust
System
F
Exhaust
Emission Control System F4 Engine
Fl
Exhaust
Emission Control System V6-225 Engine
F2
Cooling System
G
Electrical
H
Clutch
I
3-Speed
Transmission
J
4-Speed
Transmission
Jl
Transfer
Case
K
Propeller Shafts
L
Front
Axle
M
Rear
Axle
N
Steering 0
Brakes
P
Wheels 0
Frame
R
Springs
Shock Absorbers
S
Body
T
Miscellaneous
U
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 9 of 376
*Jeep?
UNIVERSAL
SERIES
SERVICE
MANUAL
FIG.
B-2—LUBRICATION
CHART
—
2-WHEEL
DRIVE
VEHICLES
CHART
NO
ITEM
TO BE
LUBRICATED
FREQUENCY
1000 miles = 1.600 km.
QUANTITY
U.S.
Imperial Metric
LUBRICANT
TYPE
Summer I Winter
Chassis
Bearings.....
Universal
Joints...... Steering
Gear
Housing
Rear
Wheel Bearings fx
Front
Wheel
Bearings®
Transmission
Differential
Hand
Brake Control Handle Cable
Hand
Brake Control
Cable
Rear
Generator — F4
Speedometer
Cable....
Distributor — F4
Oiler
Wick
Pivot
Cam
Distributor Cam — V6.
Air
Cleaner — F4
—
V6.
....
Engine
— F4
Engine
— V6
Each
2,000
miles
Each
2,000
miles
Check
each
2,000
miles
With
Lube Fittings;
Sparingly each
2.000
miles
Without Lube Fittings: Disassemble to Lubricate
each
12,000
miles
Disassemble to lubricate each
12,000
miles
Check
each
2,000
miles
Change each
20,000
miles
Check
each
2,000
miles Change each
12,000
miles
Each
12,000
miles
Each
12,000
miles
Each
2,000
miles Disassemble to lubricate each
12,000
miles
Each
2,000
miles
Each
2,000
miles
Each
2,000
miles
Each
2,000
miles
At
each breaker point replacement
Each
2,000
miles
Each
6,000
miles
Change each
2,000
miles or 60 days Change each
6.000
miles or 60 days
As
required
As
required
As
required
As
required
As
required
1 XA pts. 114 pts. 0,7 ltrs. 2 pts. 1 % pts. 0,9 ltrs.
As
required
As
required
2 to 4 Drops
As
required
Several
Drops One Drop
One Drop
2 c.c.
As
required
1
M
pts. 1 pt. 0,6 ltrs.
4 qt.** 3 H qts. 3,8 ltrs. 4 qt.** 3
}A
qts. 3,8 ltrs.
Chassis
Lubricant
Chassis
Lubricant
MIL-L-2105-B
Wheel Bearing Lubricant
Wheel Bearing Lubricant
GL4
MIL-L-2105-B*
Graphite
Grease
Graphite
Grease
Engine
Oil
Graphite
Grease
Engine
Oil
Engine
Oil
Engine
Oil
Cam
Lubricant
Cam
Lubricant
Engine
Oil
Engine
Oil
Engine
Oil No. 1 No. 1
No. 1 No. 1
SAE-80 SAE-80
No. 2 No. 2
No. 2 No. 2
SAE-90 SAE-80
SAE-80 SAE-80
Medium Medium
Medium Medium Same as
engine
Light
Same as
engine
Same as
engine
Same as
engine
SAE-40
or 50
®
Above
90°F.
Between -f
10°F.
and
90°F.
Between
-10°F.
and
-fl0°F.
Below
-10°F.
use SAE 30 or 10W-30 use SAE 20W or 10W-30 use SAE 10W or 10W-20 use SAE 5W or 5W-20
BE
St
Not lower than
32°F.
[08C] Between
32°F.
10°C] and 0°F.
l-17°CI
Below 0°F. [-17°C] use SAE 20W or SAE 10W-30 use SAE 10W or SAE 10W-30 use SAE 5W or SAE 5W-20
•For
Powr-Lok and
Trac-Lok
differential use only 'Jeep' Differential Oil, Part No.
94557.
**When oil filter is changed at the same time, add one quart {one
ltr.].
(x)Do not mix lithium and sodium
base
lubricants. Use lithium
base
lubricants as specified. 9
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 15 of 376
'Jeep*
UNIVERSAL SERIES SERVICE
MANUAL
B
solvent.
Wrap
the polyurethane element in a clean
dry
cloth and
squeeze
to remove all possible sol
vent. Do not wring the element or it may
become
torn.
After cleaning, oil the polyurethane element
liberally
with
engine
oil
(SAE
10W30) and
squeeze
to evenly distribute the oil through the element and to remove
excess
oil. The element should be damp
with
oil, not dripping.
Install
the polyurethane element on the paper element, taking care to have
edges
of the polyurethane element over the plastic end plates of the paper element.
Replace
the complete air cleaner element assembly every
24,000
miles
[38.400
km.]. Replace more
frequently if there is any apparent damage or evidence of plugging.
The
crankcase ventilation filter should be replaced, not cleaned, every
6,000
miles
[9.600
km.]. The
filter
is located inside the air cleaner housing.
12992
FIG.
B-7—DRY-TYPE
AIR
CLEANER DAUNTLESS
V-6
ENGINE
1—
Crankcase
Ventilation
Filter
2—
Polyurethane
Element
3—
Paper
Element
B-27.
Steering
Gear
Check
that the steering gear lubricant is at the
level of the fill-hole. If not, add lubricant to the
level of the fill-hole with the lubricant recom mended in the
Lubrication
Specifications. If abnor
mally
low, check the steering gear for possibility
of leaks.
B-28.
Cooling System
Check
the coolant level in the
radiator.
It should be
half
an inch below the neck. If not,
fill
the radiator
to
half
inch below the neck with the proper coolant.
Refer
to Section G.
If
the level of the coolant is abnormally low, check
the radiator,
hoses
and water pump for possible
leaks.
If a leak is suspected, refer to Section G.
B-29.
Clean
Exterior
of Radiator
For
proper cooling efficiency the radiator should be cleaned of foreign objects. Refer to Section G.
B-30.
Transmission
and
Transfer Case
Lubricant
Level
Cheek
•
Refer to Par. B-31 through B-33 as applicable.
B-31.
General
All
transfer cases and transmissions should be
serviced
separately even though drilled passages
are
provided for oil circulation
between
some
trans
mission and the transfer case housings. Procedure
from
the appropriate Par. below should be fol lowed to check the lubricant level of the various
types
of transfer cases and transmissions.
If
the transfer case or transmission fluid levels
are
found to be abnormally low, check both units
for any possible leaks.
B-32.
Transfer
Case
:
The
transfer case fill-hole is located on the right side of the transfer case housing. To check the
lubricant
level, remove the
fill
plug.
Lubricant
should be level with this fill-hole. If not, bring up to level by adding make-up lubricant as specified
in
the
Lubrication
Specifications.
B-33.
Transmission
The
transmission fill-hole is located on the right side of the transmission housing. To check the
lubricant
level, remove the
fill
plug.
Lubricant
should be level with this fill-hole. If not, bring
up to level by adding make-up
lubricant
as specified
in
the
Lubrication
Specifications.
B-34.
Transmission and Transfer
Case
Lubricant
Change
•
Refer to Par. B-35 through B-37 as applicable.
B-35.
General
Transfer
case and transmission lubricants should
be changed at the same time.
B-36.
Transfer
Case
To
drain
the transfer case, first remove the transfer
case fill-hole plug and then the transfer case
drain-
hole
plug. Let all fluid
drain
from case.
Then
install
the transfer case drainhole plug, and
refill
the
transfer
case through the fill-hole using the correct
lubricant
as specified in the
Lubrication
Specifica
tions.
At
30,000
mile
[48,000
km.] intervals lube the
transfer
case shift levers with
Lubriplate
No.
130AA.
Late
models have a lube fitting. To lube
older models, (without lube fitting) remove the
bottom
cover of the case, clean thoroughly and
pack
case
full
of lubricant.
B-37.
Transmission (3-Speed)
To
change the lubricant on all vehicles equipped
with
a three speed synchromesh transmission,
drain
the old fluid by first removing the fill-hole plug
and
then removing the drainhole plug. Since on
some
transmissions there are drilled passages be tween the transmission and transfer case that allow
oil
to circulate
between
the two units, the transfer
case should be drained before refilling the trans
mission.
When
all the fluid is completely drained, replace
the drainhole plugs only. For the correct specifi
cations and quantity, refer to the
Lubrication
Specifications. 15
Page 17 of 376
'Jeep'
UNIVERSAL SERIES SERVICE
MANUAL
B
Reinstall
the axle shafts, and
refill
the housings to
plug level using the universal joint lubricant
specified in
Lubrication
Specifications.
B-56.
Front
Axle Wheel Bearings
To
lubricate the wheel bearings, it is necessary
to remove, clean, repack, and adjust them. When
front wheel hubs and bearings are removed for
lubrication,
they should be thoroughly washed in a
suitable cleaning solvent. The bearings should be
carefully
dried and then given a thorough cleaning
and
inspection. Use a clean brush to remove all
particles
of old lubricant from bearings and hubs.
After
the bearings are cleaned, inspect them for
pitted races and rollers. Also, check the hub oil
seals.
Note:
Wheel bearing lithium base lubricants are
used at the factory for
initial
fill
of
these
bearings.
When
lithium base and sodium base lubricants are
mixed,
the result is a thinned-out mixture that
can
bleed through seals. It is therefore important
that lubricants with the correct base be used when
lubricating
the wheel bearings.
Should
leaks occur at wheel bearing seals, the leaks
may
be caused by a mixture of two
types
of
lubri
cants.
In such cases, the old lubricant should be
completely removed before new lubricant is added.
Wheel
bearings should be thoroughly cleaned,
lubricated
with lithium base and reinstalled.
Repack
the bearing
cones
and rollers with grease
and
reassemble hub in the reverse order of the
disassembly. Test the bearing adjustment as out
lined
in Section Q.
B-57.
Rear
Axle Wheel Bearings
The
Rear
wheel bearings an early models equipped
with
lubrication fittings with a vent opening
through the housings above each fitting should be
lubricated
sparingly, each
2,000
miles
[3.200
km.].
Use
a hand compressor and wheel bearing grease,
forcing
the grease through each lubrication fitting
until
it flows from the vent. Vent should be kept
clear
of obstruction or grease
will
back up into the
brakes.
Do not add grease after it flows from the
vent for it may be forced through the wheel key-
way
onto
the outside of the wheel and possibly
onto
the brake linings.
Rear
wheel bearings that do
not have lubrication fittings should be removed
each
12,000
miles
[19.200
km.] and the bearing
cleaned, inspected and repacked. Refer to proce
dure
in Par. B-56.
Note:
When servicing the Flanged Axle Unit
Bear
ing Assembly, refer to Section N, Par. N-5 for
proper
lubrication procedures.
B-58.
Propeller Shafts
and
Universal Joints
The
propeller shaft slip joints and universals should
be lubricated with a hand compressor grease gun so as to not damage the bearing seals. The units
should be lubricated with a
good
quality grease.
Refer
to the
Lubrication
Chart
for lubrication fre
quency and lubricant type and grade. B-59.
Lights
and
Controls
a.
Check
all interior and exterior lights and light
switches for proper operation, including: parking
lights, headlamps (high beam and low beam),
tail
lights, brake lights, directional lights, and in strument panel lights.
b.
Check
all instrument panel controls and
instru
ments for proper operation.
B-60.
Speedometer Cable
Remove the
speedometer
cable from its housing every
12,000
miles
[19.300
km.].
Clean
it thor
oughly and coat it with a
good
quality light graphite grease.
B-61.
Headlights
Refer
to Section H.
B-62.
Heater Controls
Apply
Lubriplate
130-A to all friction points and
pivot points on the heater controls panel unit as well as the pivot points at the dashpot. Apply
a
few drops of penetrating oil all along the Bowden
cable.
This
oil
will
penetrate into the center wire.
B-63.
Windshield Wiper and
Washer Controls
Lubricate
the friction points and the pivot points
on the windshield wiper transmission and linkage
arms
with a slight amount of
Lubriplate
130-A.
B-64.
Rotate Tires
Refer
to Section Q for the correct method of rotat ing the tires.
B-65.
Body Lube Points
•
Refer to Par. B-66 through B-68.
B-66.
Hood Hinge Pivot Points
Lubricate
the frictional points of the hood hinge
pivot points with a few drops of light-weight
engine
oil.
B-67.
Glove Compartment Door Latch
Sparingly
wipe
Lubriplate
130-A on the
glove
com
partment door latch.
B-68.
Tailgate Hinges
Lubricate
the friction points of the tailgate hinges
with
a few drops of light-weight
engine
oil.
B-69.
LUBRICATION
OF
OPTIONAL EQUIPMENT
B-70.
Pintle Hook
When
lubricating the vehicle, place a few drops of oil on the pintle hook and safety latch pivot pins.
B-7!.
Centrifugal Governor
Check
the oil level in the governor housing at each
vehicle lubrication. Use the same seasonal grade
oil
as is used in the
engine
and change oil at each
engine
oil change. Do not
fill
the housing above
the level indicating plug opening. Keep the vent
in
the filler plug open at all times. 17
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 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 148 of 376
Fl
EXHAUST
EMISSION
CONTROL
SYSTEMS
IMPORTANT
NOTICE
The
Exhaust
Emission Systems covered
in
this publication
meet
State and
Federal
requirements for hydrocarbon and carbon
monoxide
emissions.
To
assure continued proper operation,
these
systems
must
be
inspected
regularly,
parts must be replaced
at
factory-recommended intervals and
engine
tune-up services performed at intervals specified in the
Exhaust
Emission
Con
trol
System Maintenance charts.
For
the
above
reasons,
these
systems
must not, under any circumstances,
be
altered
to anything other than
required
specifications provided in this publication.
Further,
the
Exhaust
Emission
Control
System, or any
of
its components, must
not be physically altered or modified in any respect.
DHTfl
TAG
For
the serviceman's guidance, each vehicle equipped with exhaust emission
control
will
have data
tag
permanently affixed
to the
radiator shroud—-in
example:
VEHICLE
EMISSION
CONTROL
INFORMATION
MODEL
F4-134
C.I.D.
•
ENGINE
AT
NORMAL
OPERATING
TEMPERATURE
•
LIGHTS
AND
ALL
ACCESSORIES OFF
•
IDLE
MIXTURE
. . .
LEAN
BEST
IDLE
•
IGNITION
TIMING
0*
(TDC)
•
SPARK
PLUG
GAP
. . . .030
•
DWELL
...
42* (.020
POINT
GAP)
•
IDLE
SPEED
. . .
700-750 RPM
TRANSMISSION
IN
NEUTRAL
DURING
TUNE
UP
SEE SERVICE MANUAL
FOR
ADDITIONAL INFORMATION
THIS VEHICLE CONFORMS
TO U.S.
DEPT.
OF
H.E.W.
REGULATIONS APPLICABLE
TO
1971 MODEL YEAR NEW MOTOR VEHICLES
Jeep
CORPORATION
14401
Important:
Always refer
to
the data tag when checking or re-adjusting ignition
timing,
idle speed, and idle mixture. 148
Page 159 of 376
'Jeep'
UNIVERSAL SERIES SERVICE
MANUAL
F2
F2-35.
EXHAUST EMISSION CONTOL SYSTEM
DISTRIBUTOR SPECIFICATIONS
Distributor:
Make
Delco-Remy Prestolite Prestolite
Model...
1110376
IAT-4501 or IAT-4502 IAT-4502A
Breaker
Point Gap .016"
[0,406
mm.] .016"
[0,406
mm.] .016"
[0,406
mm.]
Breaker
Arm Tension 19 to 23 oz. [538 a 652 gr.] 17 to 22 oz. [482 a 623 gr.] 17 to 22 oz. [482 a 623 gr.]
Cam
Angle. 29° to 31° 29° + 3° 29° ± 3°
Max.
Auto Advance
(Crankshaft
Degrees). 13° to 15° at 1,950 rpm. 16° (& 1800 rpm. 21° @ 1800 rpm.
26°
@
4200
rpm. (Max.) 32° @
4200
rpm. (Max.)
Max.
Vac. Advance
(Distributor
Degrees) 8° 8° 8°
Condenser Capacity. .18 to .23 mfd. .25 to .28 mfd. .25 to .28 mfd.
Timing:
Crankshaft
5°
(BTC)
@ Idle 5°
(BTC)
© Idle 0°
(TDC)
© Idle
Mark
Location Crankshaft Pulley Crankshaft Pulley Crankshaft Pulley
Firing
Order
1-6-5-4-3-2 1-6-5-4-3-2 1-6-5-4-3-2
F2-36.
SPARK PLUG
GAP
Spark
Plug Gap. .035"
[0,889
mm.]
IMPORTANT
NOTICE
The
Exhaust Emission Systems covered in this publication
meet
State and Federal
requirements for hydrocarbon and carbon
monoxide
emissions.
To
assure continued proper operation,
these
systems
must be inspected regularly,
parts must be replaced at factory-recommended intervals and
engine
tune-up services
performed at intervals specified in the Exhaust Emission Control System Maintenance
charts.
For
the
above
reasons,
these
systems
must not, under any circumstances, be altered
to anything other than required specifications provided in this publication.
Further,
the Exhaust Emission Control System, or any of its components, must not be physi
cally
altered or modified in any respect.
DATA
TAG
For
the serviceman's guidance, each vehicle equipped with exhaust emission control
will
have data tag permanently affixed to the radiator shroud — in example:
VEHICLE EMISSION CONTROL INFORMATION MODEL V6-225 C.I.D.
•
ENGINE
AT
NORMAL OPERATING TEMPERATURE
•
LIGHTS
AND ALL
ACCESSORIES
OFF
•
IDLE MIXTURE
.. .
LEAN BEST IDLE
•
IGNITION TIMING
0*
(TDC)
*
SPARK PLUG
GAP 035
•
DWELL
. . . 30* (.016
POINT
GAP) •
IDLE SPEED
. . .
650- 700
RPM
TRANSMISSION
IN
NEUTRAL DURING TUNE
UP
SEE
SERVICE MANUAL FOR ADDITIONAL INFORMATION
THIS VEHICLE CONFORMS
TO U.S. DEPT. OF H.E.W.
REGULATIONS APPLICABLE
TO
1971
MODEL YEAR
NEW
MOTOR VEHICLES
Jeep
CORPORATION
14400
NOTE:
The
above
tag applies to vehicles equipped with Distributor Model
IAT-4502A.
On
vehicles equipped with Distributor Models
1110376,
IAT-4501 and IAT-4502 the tag is the same
except
that Ignition Timing is 5°
T.D.C.
Always
refer to the data tag when checking or re-adjusting ignition timing, idle speed, and idle mixture.
159