wiring JEEP CJ 1953 Service Manual

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

'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

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

'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.

Dl

DAUNTLESS
V-6
ENGINE
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 re­

pair
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.

Dl-6.
Mounting Engine
On
Engine Stand

Refer
to Fig. Dl-4.
a.
With
the
engine
supported by a hoist, remove
the clutch housing and clutch. Match
mark
the flywheel and the clutch cover before disassembly to assure proper reassembly.
b. Position the
engine
on the
engine
stand.
c. Release
some
tension of the hoist cables and secure
engine
to stand.

d.
Make sure the position lock on the
engine
stand
is tight to prevent the
engine
from accidentally
inverting.

e.
Release the hoist cables.
FIG.
D1
-4—ENGINE
MOUNTED
ON
STAND

1—
Spacer
J-8690-6
A—Bolt,
i/2-NC
x 3i/2"

2—
Bolt,
3/a-NC
x 4*/2" 5—Adapter 21316-J 3—
Engine
Mounting Stand
Dl-7.
Remove Intake Manifold
and

Carburetor Assembly

Disconnect crankcase vent
hose,
distributor vacuum

hose,
and fuel line from carburetor. Disconnect two distributor leads from ignition coil. Disconnect

wiring
harness from coolant temperature sending

unit.
Remove ten cap
bolts
which attach intake
manifold to cylinder heads. Remove intake mani­
fold assembly and gaskets from
engine.

Dl-8. Remove Exhaust Manifold
The
engine
has two exhaust manifolds. Remove five attaching screws, one nut, and exhaust mani­
fold from each cylinder head.

Dl-9.
Remove Distributor

Disconnect vacuum
hose
and wiring harness from

distributor.
Disconnect spark plug cables from
spark
plugs. Remove sparks plugs from
engine.
Pull

spark
plug cable retainers from brackets on rocker

arm
covers. Remove mounting screw, retainer

bracket,
and distributor from timing chain cover.
If
timing chain and sprockets are not to be re­
moved from
engine,
note
position of distributor
rotor so that it can be installed in identical position.

Dl-10. Remove
Fuel Pump
Disconnect output fuel line from fuel pump. Re­
move
two mounting bolts, fuel pump, and gasket

from
timing chain cover.

Dl-11.
Remove Alternator
and Fan
Belt

Disconnect wiring harness from alternator. Remove nut and flat washer which fasten alternator to
adjustment bracket. Pivot alternator
inward,
to­

ward
engine
cylinder block, to relieve fan belt
tension. Remove fan belt from pulleys. Remove
two attaching screws, mounting bracket, and alter­ nator from right cylinder head of
engine.

Dl-12.
Remove Cooling
Fan and
Water Pump

Refer
to Fig. Dl-5.
Remove four cap screws, lock washers, cooling fan,

fan
hub, and fan drive pulley from flange of water
pump shaft. Remove nine attaching screws, water
pump, alternator adjustment bracket, and water pump from timing chain cover.

Dl-13.
Remove
Oil
Filter

Unscrew
oil filter from
engine
oil pump.

Dl-14.
Remove Starter Motor

Disconnect wiring harness from starter motor and
solenoid. Remove two attaching screws, starter motor, solenoid, and motor attaching bracket from

engine
flywheel housing and cylinder block.

Dl-15.
Remove
Oil
Pressure Sending Unit

Disconnect wiring harness from oil pressure send­
ing unit. Remove oil pressure sending unit from

engine
cylinder block.

Dl-16.
Remove
Oil
Dipstick

Withdraw
and remove oil level dipstick and dip­

stick
tube
from
engine
cylinder block.

Dl-17.
Remove Crankshaft Pulley

Remove six attaching screws and crankshaft pulley

from
crankshaft vibration damper. 80

Dl
DAUNTLESS
V-6
ENGINE

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

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

kg-m.].

Dl-88.
Install
Crankshaft
Vibration
Damper

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

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

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

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

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

Dl-90.
Install
Oil
Level
Dipstick

Insert
oil level dipstick
into
the dipstick tube.

Dl-91.
Install
Oil
Pressure Sending Unit

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

Dl-92.
Install Starting Motor

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

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

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

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

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

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

Dl-96.
Install
Alternator
and Fan
Belt

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

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

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

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

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

Dl-97.
Install
Fuel Pump

Install
two mounting
bolts
and new
gasket
on

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

Dl-98.
Install Exhaust Manifold

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

Dl-99.
Install Distributor

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

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

102

Dl

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

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

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

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

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

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

into
the
engine
compartment of the vehicle.

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

d.
Install
and tighten front
engine
mounting bolts.

e.
Remove sling from the
engine.

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

buretor.

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

I.
Connect fuel lines.

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

starter
motor.

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

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

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

s.
Replace the hood.

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

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

Dl-103.
FINAL IN-VEHICLE ADJUSTMENTS

a.
Clean
battery terminals and check battery.
b.
Check
ignition wires and connections.
c. Service carburetor air cleaner.

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

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

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

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

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

'Jeep'
UNIVERSAL SERIES SERVICE
MANUAL

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

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

'Jeep'
UNIVERSAL
SERIES
SERVICE
MANUAL

H

FIG.
H-l—ENGINE
GROUND
STRAP—F4
ENGINE
Fig.
H-l, is tight at both connections. If
these

connections are
loose
-
or
dirty,
hard
starting or
failure
to start may result.

H-3.
Ignition System

The
ignition system consists of the battery, ignition

switch,
ignition coil ballast resistor (V-6 engine
only),
ignition coil, ignition distributor,
spark
plugs,

and
the low and high tension wiring.
Electrical

energy is obtained from the battery while cranking
and
from the alternator after the engine is running.

These
supply circuits must be considered part of
the ignition system.

The
ignition system furnishes the
spark
-for the

spark
plugs. The
spark
must occur in each cylinder
at exactly the proper time. To accomplish this, the following units are required.

a.
The battery, supplying the electrical energy.
Note: 'Jeep* vehicles equipped with Dauntless

V-6
engines have a ballast resistor connected be­ tween the ignition switch and the positive (+)

terminal
of the coil. The ballast resistor limits to
a
safe maximum the
primary
current flow through
the coil and the distributor contact points.

b.
The ignition coil, transforming the battery low
tension current to high tension current that jumps
the
spark
plug gap in the cylinders under com­
pression.

c.
The distributor, delivering the
spark
to the

proper
cylinders and incorporates the mechanical

breaker,
that
opens
and closes the
primary
circuit at the exact time.

d.
The
spark
plugs, providing the gap in the engine
cylinders.

e. The wiring, connecting the various ignition
units.

f. The ignition switch controling the battery
current
when it is desired to start or
stop
the engine.
g. The firing order for the
Hurricane
F4 engine is
1-3-4-2.
Cylinder
No. 1 is the cylinder closest to the

radiator.

h.
The firing order for the Dauntless V-6 engine
is
1-6-5-4-3-2.
Cylinders
1-3-5 are on the left bank

and
cylinders 2-4-6 are on the right bank. H-4.
PRIMARY
CIRCUIT

Before testing the
primary
circuit,
make certain
that the battery is satisfactory or install a fully

charged
battery for the
primary
circuit
tests. Also,

check
the starter motor for excessive voltage drop

and
check the starter motor itself for excessive
draw.

a.
Measure the voltage at the coil
primary
termi­

nals
while cranking the engine with the starter
motor. If the voltage is less than 9 volts the trouble

will
be found in the
primary
circuit.
If there is no voltage at all, check for a break in the
primary

circuit,
possibly in the coil
primary
winding.

b.
To check the
primary
circuit,
turn
the ignition
on,
turn
the engine until the points are closed, and
then measure the voltage drop across each portion
of the circuit with a voltmeter.
Note: Most voltage drops
will
be found at the con­
nections of wires to terminals as
dirt,
oxidation etc. can cause excessive resistance at
these
points.

Measure
voltage drops in wires to take this into
account.

c.
Connect the voltmeter from the battery cable

terminal
on the starter solenoid to the battery

terminal
of the coil
primary.
If the voltmeter reads more than 0.2 volt, perform the checks given in
steps, d, e, and f following.

d.
Connect the voltmeter from the solenoid termi­

nal
to the battery terminal of the ignition switch.
If
the voltmeter reads more than .05 volt, check

and
clean the connections at solenoid, light switch,
and
ignition switch.
e. If the voltmeter reading in
step
d is less than .05 volt, connect the voltmeter from the battery

terminal
to the ignition terminal on the ignition
switch.
If the voltage drop is more than 0.1 volt,

repair
or replace the ignition switch.
f. If the voltage drop in
step
e is not more than 0.1 volt, connect the voltmeter from the ignition

terminal
of the ignition switch to the battery termi­

nal
of the coil
primary.
If the voltmeter reads more

than
.05 volt, clean and tighten the connections

and
check again. If the voltmeter again reads more

than
.05 volt, replace the wire.
g. Connect the voltmeter from the distributor
primary
terminal on the coil to the coil terminal on
the distributor. Voltage drop should not exceed .05 volt.
Clean
and tighten connections if necessary.

h.
Connect the voltmeter from the coil terminal
on the distributor to a clean,
paint-
free spot on the

distributor
body. The reading should not exceed .05
volt. If more, it indicates excessive resistance
through the points or in the distributor internal connections.
Clean
and align the points and make

sure
the breaker arm connection to the
primary

terminal
as well as the stationary contact point mounting in the body is clean and tight.

i.
Open the points and check the voltmeter. It
should read close to peak voltage. Low voltage in­ dicates that a circuit through the distributor (a

short)
exists while the points are open.

j.
Disconnect the condenser lead and open the points. A jump to
full
voltage indicates a short in 173