clutch JEEP DJ 1953 User Guide

HURRICANE
F4
ENGINE

FIG.
D-28-
CHECKING
OIL
PUMP
ROTORS

FIG.
D-29—CHECKING OUTER ROTOR
TO
OIL
PUMP
BODY If,
however, the
teeth
are broken, cracked, or
seriously
burred,
the ring gear should be replaced.

D-69.
Ring
Gear
Replacement

The
ring
gear
is secured on the flywheel by a
shrink

fit. Before starting the operation of replacing the
ring
gear, place the new ring gear against the old
gear to make certain both have the same number of
teeth.

To
remove the ring gear from the flywheel,
drill
a [9,5 mm.]
hole
through the ring gear and cut
through any remaining metal with a cold chisel. Remove the ring gear from the flywheel. Thorough-
FIG.
D-30—CHECKING
OIL
PUMP
COVER
ly
clean the ring gear surface of the flywheel. Heat
the new ring gear evenly to a range of
650°F.
to
700°F.
[343°C.
a
371°C.]
and place it on the cold
flywheel,
making
certain that the chamfer on the
teeth
is on the crankshaft side of the flywheel. Be

sure
that the ring gear is firmly seated on the fly­
wheel. Allow the ring gear to cool slowly to
shrink
it
onto
the flywheel. Do not quench the ring gear;
allow it to slowly air cool.

D-7Q.
Flywheel Pilot Bushing

Inspect
the flywheel pilot bushing in the flywheel.

For
procedure on replacing the bushing, refer to

Par.
1-8.

D-71.
Flywheel Housing

The
flywheel housing, which
encloses
the flywheel

and
clutch is bolted to the
engine
rear
plate and
cylinder
block. The
rear
of the housing provides
the front support for the transmission. Examine the housing for cracks and distortion of the

machined
surfaces. The front face must seat evenly
against the
engine
rear
end plate without evidence
of warpage. The
rear
face must be parallel to the front face. Improper alignment may cause trans­mission gear disengagement. In addition, the open­
ing in the
rear
of the housing, which serves as a
pilot for the transmission, must be concentric with the crankshaft. The flywheel housing should be
checked for alignment after it is installed on the
engine. Refer to Par. D-88.

D-72.
Core Hole Expansion Plug

Any
evidence of coolant leakage around any of
the core
hole
expansion plugs
will
require replace­ ment of the plug. The expansion plug at the
rear

end of the cylinder block can be driven out with a 24" [60 cm.] length of half-inch bar stock carefully
inserted through the camshaft bore in the cylinder
block. The other core
hole
expansion plugs in the
cylinder
block and cylinder head can be removed
by piercing the center with a sharp tool and prying them out. Before attempting to install a new plug,
clean
the
hole
thoroughly. Apply a thin coat of
sealer on the new plug and install the plug with a
driver.
60

'Jeep'
UNIVERSAL
SERIES
SERVICE
MANUAL

D

FIG.
D-38—CHECKING
FLYWHEEL
RUN-OUT
place the flywheel on the mounting
bolts
in the

crankshaft.
When installing a new crankshaft or
flywheel, replace the tapered dowel
bolts
with
straight snug-fitting special
bolts
provided using

Flywheel
Dowel Bolt Installing Tool Kit W-231 as shown in Fig. D-35 and D-36. Assemble the

crankshaft
and flywheel in proper relation; then in­

stall
the straight
bolts
previously used and tighten
securely. Next, use the [13,9 mm.]
drill
to
enlarge the tapered holes. Ream the
holes
with the 5fo" [14,3 mm.] straight reamer and install the
two special flywheel
bolts
with nuts and lock­
washers in place of the two tapered dowel
bolts
formerly
used.
This
procedure overcomes the
necessity of reaming special tapered holes.

Tighten
the nuts alternately and evenly until each
is tightened 35 to 41 lb-ft. [4,8 a 5,7 kg-m.].

After
installation check the run-out of the flywheel

with
a
dial
indicator attached to the
engine
plate
as illustrated in
Fig.
D-38. Mount the
dial
indicator

with
the contact button of the indicator resting against the clutch face of the flywheel. Set the

indicator
at zero and rotate the flywheel. Maximum
allowable run-out is .008"
[0,203
mm.] near the
outer
edge
of the
rear
face of the flywheel.
With
the flywheel housing installed temporarily,
the alignment can be checked with a
dial
indicator. Without the clutch installed on the flywheel, a

dial
indicator can be mounted on one of the flywheel bolts. Set the
dial
indicator with the button resting
against the
rear
face of the flywheel housing. Ro­
tate
the flywheel, noting the run-out on the
indi­

cator.
Maximum allowable run-out is .005" [0,127
mm.].
Relocate the
dial
indicator so that the
button is against the side of the
rear
opening to
check the
radial
run-out. Rotate the flywheel and
note
the run-out which should not exceed .006" [0,152 mm.].

D-88.
Install
Flywheel Housing

Be
certain that the mating surfaces of the flywheel housing and cylinder block are clean and smooth.

Place
the flywheel housing in position and attach to the cylinder block and
engine
rear
plate. The
long
bolts
through the lugs on the
engine
crankcase
and
those
below are installed with the nuts on the
flywheel housing side.
Install
the other
bolts
from
the
rear
except the screw used to attach the top
side of the starting motor. Tighten securely.

D-89.
Install
Clutch

To
install the clutch assembly with the
engine
out
of the vehicle use a clutch plate aligning arbor.

Place
the clutch driven plate in position against
the flywheel. Insert the arbor into the clutch driven plate and clutch shaft bushing and expand the arbor

in
the bushing to hold it in place. Hold the clutch
pressure plate assembly in position against the
clutch
driven plate and install the attaching
bolts

and
washers, tightening the
bolts
alternately and
evenly. Remove the arbor.

D-90.
Install
Valves and Springs

Oil
the valve stems. Insert all intake and exhaust valves in the valve
guides
from which they were
removed.

Install
one exhaust valve spring and exhaust valve

spring
retainer (Roto Cap) for each exhaust valve.

Slip
the top end of the spring
onto
the
bottom
end
of the valve guide and, with a large screwdriver,
snap the spring and retainer over the tappet ad­

justing
screw. Make certain that the two closely wound coils of each spring are at the top (placed up to seat against the block.) See Fig. D-39.

Turn
the crankshaft as necessary to bring each
exhaust valve tappet to its lowest position. Using a
valve spring lifter, compress each exhaust valve

spring,
while holding the valve down, so that the
stem
extends
through the valve spring retainer
far
enough to permit installation of the valve

spring
locks. Heavy lubricating oil or grease
placed on the inside surface of the valve locks
will

help to hold the locks on the valve stem until the valve spring lifter can be removed. When installa­
tion of exhaust valves is complete, remove any
cloths used to block the valve compartment floor
openings.
Install
the intake valves and springs in the cylinder head placing the ends of the springs
having the closed coils down against the cylinder
head.
FIG.
D-39—VALVE
TAPPETS
AND
SPRINGS

65

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

DAUNTLESS
V-6
ENGINE
Contents

SUBJECT
PAR.
SUBJEC

GENERAL
.... . . Dl-1 Oil Pump Cl(
ENGINE DESCRIPTION
D1-2

Engine
Mounts Dl-3

ENGINE REMOVAL
Dl-4
ENGINE DISASSEMBLY
Dl-5
Alternator
and Fan Belt Dl-11
Camshaft
.... Dl-26
Cooling Fan and Water Pump.
......
.Dl-12
Crankshaft
Front Oil Seal .Dl-21

Crankshaft
Pulley D1-17
Crankshaft
Vibration Damper Dl-18

Cylinder
Head Assembly Dl-24

Distributor
Dl-9
Exhaust
Manifold .Dl-8

Flywheel
Dl-28

Flywheel
Housing and
Clutch
Dl-27
Fuel
Pump. ... . .Dl-10
Intake
Manifold and
Carburetor
Assembly.
.............
.Dl-7

Main
Bearing and Crankshaft. Dl-32 Mounting Engine on Engine Stand. . . . .Dl-6

Oil
Dipstick. Dl-16
Oil
Filter
Dl-13
Oil
Pan.. ...
.......
.Dl-29
Oil
Pressure Sending Unit Dl-15

Oil
Pump Dl-19
Oil
Pump Intake Pipe and Screen Dl-30
Piston and Rod Assembly. Dl-31
Push
Rod and Valve
Lifter.
.Dl-25
Rocker
Arm Cover Dl-23
Starter
Motor Dl-14

Timing
Chain
and Sprocket Dl-22
Timing
Chain
Cover Dl-20

ENGINE CLEANING, INSPECTION AND REPAIR
. . ... .Dl-33
Camshaft
Cleaning and Inspection Dl-55
Connecting Rod Bearing Inspection
and
Fitting .Dl-49

Crankshaft
Cleaning Dl-38
Crankshaft
Inspection and Repair Dl-39
Crankshaft
Main Bearing Cleaning
and
Inspection Dl-41

Crankshaft
Main Bearings. Dl-40

Crankshaft
Pulley Inspection. Dl-70
Crankshaft
Vibration Damper Inspection. D1-69

Cylinder
Block .Dl-34
Cylinder
Block Cleaning Dl-35
Cylinder
Block Inspection Dl-36

Cylinder
Block Repair. .Dl-37
Cylinder
Head and Valve Repair .Dl-63

Cylinder
Head and Valve Cleaning
and
Inspection.. . .Dl-62

Flywheel
Cleaning and Inspection Dl-52

Flywheel
Housing Cleaning
and
Inspection Dl-54

Hydraulic
Valve
Lifter
Leakdown Test. .Dl-57
Main
Bearing Fitting or

Shim
Stock Dl-42, Dl-43

Oil
Pan Cleaning and Inspection .Dl-51
PAR.
and
Inspection. .... .Dl-68

Oil
Pump Intake and Screen Cleaning. . .Dl-50
Piston and Rod Assembly.
...........
.Dl-48
Piston and Rod Cleaning and Inspection.D1-45
Piston and Rod Disassembly Dl-44
Piston Fitting Dl-46
Piston Ring Fitting. .Dl-47

Ring
Gear
Replacement. .Dl-53
Rocker
Arm Assembly. Dl-60
Rocker
Arm Cleaning and Inspection. . .Dl-59

Rocker
Arm Cover Cleaning

and
Inspection D1-65

Rocker
Arm Disassembly .Dl-58
Timing
Chain
and Sprocket Inspection. . .Dl-66

Timing
Chain
Cover Cleaning

and
Inspection.. . Dl-67

Valve
Installation D1-64
Valve
Lifter
and Push Rod

Cleaning
and Inspection. . Dl-56

Valve
Removal Dl-61

ENGINE REASSEMBLY
Dl-71
Alternator
and Fan Belt Dl-96

Camshaft
Dl-80
Clutch
and Flywheel Housing Dl-79
Cooling Fan.. . .Dl-95
Crankshaft
End Play Check. . Dl-74

Crankshaft
Front Oil Seal Dl-85
Crankshaft
Pulley Dl-89
Crankshaft
Vibration Damper Dl-88
Cylinder
Block and Crankshaft
Rear
Oil Seals Dl-72

Cylinder
Head Assembly .Dl-82

Distributor
Dl-99

Exhaust
Manifold Dl-98
Flywheel
.Dl-78
Fuel
Pump.. .. . Dl-97
Intake
Manifold and Carburetor Assembly Dl-101

Main
Bearing and
Crankshaft
Installation
.
Dl-73

Oil
Filter
Dl-93
Oil
Level
Dipstick Dl-90

Oil
Pan Dl-77
Oil
Pressure Sending Unit Dl-91

Oil
Pump.. .Dl-87
Oil
Pump Intake and Screen Assembly. .Dl-76
Piston and Rod Installation Dl-75

Rocker
Arm Cover. Dl-83

Spark
Plugs.. Dl-100
Starter
Motor Dl-92
Timing
Chain
and Sprocket.
..........
.Dl-84

Timing
Chain
Cover Dl-86
Valve
Lifter
and Push Rod Dl-81

Water
Pump. Dl-94

ENGINE INSTALLATION
Dl-102

FINAL
IN-VEHICLE
ADJUSTMENTS.
D1-103

SERVICE
DIAGNOSIS
Dl-104
ENGINE SPECIFICATIONS
. .Dl-105 75

'Jeep'
UNIVERSAL SERIES SERVICE
MANUAL

Dl

©©©©©©©©©

12697

FIG.
Dl-1—DAUNTLESS
V-6
ENGINE, SIDE SECTIONAL VIEW

1—
Fan
Blade
2—
Fan
Spacer

3—Fan
Pulley
4—
Water
Pump 5—
Timing
Chain
Cover
6—
Camshaft
Sprocket
7—
Thermostat
Bypass Hose
8—
Thermostat
Housing
9—
Thermostat

10—
Carburetor

11—
Intake
Manifold
12—
Rocker
Arm Cover 13—
Cylinder
Block 14—
Push
Rod
15—
Camshaft

16—
Flywheel
17—
Clutch
Pressure Plate
18—
Clutch
Driven Plate
19—
Clutch
Pilot Bearing
20—
Oil
Seal Packing
21—
Rear
Main
Bearing Shell
22— Connecting Rods
23—
Rear
Center
Main
Bearing Shell
24—
Oil
Screen
25—
Oil
Screen Pipe and Housing
26—
Oil
Pan 27—
Front
Center
Main
Bearing Shell
28—
Crankshaft

29—
Front
Main
Bearing Shell
30—
Timing
Chain

31—
Crankshaft
Sprocket
32—
Oil
Slinger
33—
Oil
Shedder 34 Oil Shedder Packing
35—
-Woodruff
Key
36—
"Vibration
Damper
37—
Crankshaft
Pulley
38—
Fan
Belt matic adjuster, to prevent lash in the valve operat­
ing linkage. Hydraulic valve lifters also provide

a
cushion of oil to absorb operating shocks. As shown in Fig. Dl-3, all parts of a hydraulic lifter

are
housed in the body, which is the cam follower.

At
the beginning of valve operation, the valve lifter body rests on the camshaft base circle.

Plunger
spring tension prevents lash clearances in the valve linkage.

As
the camshaft forces the valve lifter body up­

ward,
both oil in the lower chamber and check

ball
spring
tension firmly seat the check ball against the plunger to prevent appreciable
loss
of oil from
the lower chamber. Oil pressure forces the plunger
upward,
with the body, to operate the valve linkage.

As
the camshaft rotates to closed-valve position, the valve spring forces the linkage and lifter down­

ward.
When the
engine
valve seats, the linkage

parts
and plunger stop, but the plunger spring forces
the body downward .002" to .003"
[0,050
a
0,076
mm.] until it again rests on the camshaft base

circle.
Oil pressure then forces the check ball away

from
its seat and allows passage of oil past the check ball into the lower chamber.
This
replaces
the slight amount of oil lost by leakage. During
the valve opening and closing operation, a very
slight amount of oil escapes
between
plunger and body, and returns to the crankcase.
This
slight
loss
of oil (leak-down) is beneficial. It provides a
gradual
change of oil in the valve lifter; fresh oil
enters the lower chamber at the end of each cycle
of operation. 77

'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

'Jeep'
UNIVERSAL
SERIES SERVICE
MANUAL

Dl

14028
j

FIG.
D1-7—TIMING
CHAIN
AND
SPROCKET ALIGNMENT 1—
Camshaft Sprocket

2—
Crankshaft
3—Timing
Chain

Timing
Marks
Dl-24.
Remove
Cylinder
Head Assembly

a.
Unscrew, but do not remove, three
bolts
(Fig.

Dl-8)
which attach rocker
arm
assembly to cylinder
head.
Remove rocker arm assembly, with bolts,

from
cylinder head. See Section F2 for
engines

equipped with exhaust emission control.
b. Remove
eight
cylinder head bolts, cylinder head,

and
gasket from cylinder block.

Dl-25.
Remove Push Rod and Valve
Lifter

Refer
to Fig. Dl-8. Remove push rods and valve lifters from the
cylin­

der
block.
Mark,
or otherwise identify, each valve

lifter
according to its cylinder and valve position.

Note:
If valve lifters are not to be serviced, cover
valve lifters and camshaft with a clean cloth to
protect them from dirt

Dl-26.
Remove Camshaft

Refer
to Fig. Dl-6.

Carefully
withdraw camshaft forward from bear­
ing bores; avoid marring the bearing surfaces. Re­

move
camshaft from cylinder block.

Dl-27.
Remove Flywheel Housing and
Clutch

a.
If flywheel housing and clutch was not pre­
viously removed, remove six mounting
bolts
and
flywheel housing from cylinder block.
b.
Mark
clutch cover and flywheel to assure that
clutch
will
be installed in identical position when

engine
is assembled.
c. Remove six attaching screws and clutch assem­
bly from flywheel.
D1-28. Remove Flywheel

Refer
to Fig. Dl-6.
Remove six attaching
bolts
and flywheel from

engine
crankshaft.

Dl-29.
Remove Oil Pan

Refer
to Fig. Dl-5.

To
gain access to oil pan mounting bolts, invert
the
engine.
Remove mounting bolts, oil pan, and gasket from
engine
cylinder block.

Dl-30.
Remove Oil Pump Intake Pipe and Screen

Refer
to Fig. Dl-5.
Remove two attaching screws, and oil pump intake
pipe and screen assembly from
engine
cylinder block.

Dl-31.
Remove Piston and
Connecting
Rod Assembly

a.
Examine the cylinder bores. If bores are worn
so that shoulder or ridges exist at the top of piston

ring
travel, remove the ridges with a ridge reamer.
FIG.
Dl-8-

-CYLINDER HEAD,
AND COVER
ROCKER
ARM
1—
—Right
Rocker
Arm
Cover

2—
Rocker
Arm
Cover
Bolt

3—
Gasket

4—
Bolt
5—
Baffle
6—
Left
Rocker
Arm
Cover
7—
Rocker
Arm Shaft
8—Plug
9—
Rocker
Arm Spring
10—
Cylinder
Head
11—
Head
Gasket

12—
Push
Rod

13—
Valve
Lifter
14—
Intake
Valve

15—
Exhaust
Valve

16—
Dowel
Pin
17—
Valve
Spring 18—
Valve
Spring Cap
19—
Valve
Spring Cap Key

20—
Cotter
Pin
21—
Rocker
Arm Shaft End Washer

22—
Rocker
Arm Shaft Spring

23—
Rocker
Arm
24—
Rocker
Arm Shaft
Bracket

25—
Bolt
83

DAUNTLESS
V-6
ENGINE

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

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

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

Dl-50.
Oil
Pump Intake
and
Screen Cleaning

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

material.

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

c.
Install
screen in housing.

Dl-51.
Oil Pan Cleaning and Inspection

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

Dl-52.
Flywheel Cleaning
and
Inspection

Clean
the flywheel with suitable cleaning solvent;

dry
with compressed air. Inspect clutch face for

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

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

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

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

Dl-53.
Ring Gear Replacement

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

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

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

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

blue, about
600°F.
[312°C.].

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

destroy heat treatment given to
ring
gear during
manufacture.

c.
Quickly
install
ring
gear on flywheel. Chamfered

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

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

be held tightly in place.

Dl-54.
Flywheel Housing Cleaning and Inspection

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

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

Clean
both camshaft and camshaft bearing surfaces

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

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

The
camshaft bearings must be line reamed to

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

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

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

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

b.
Disassemble one or two valve lifters, as de­

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

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

properly.

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

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

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

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

e. Keep all parts of each valve lifter separated

during
part cleaning and inspection. The valve

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

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

'Jeep'
UNIVERSAL SERIES SERVICE
MANUAL

Dl
both are clean. Any foreign material on either of

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

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

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

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

Refer
to Fig. Dl-9.

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

lifter
area.
It is
good
practice to clean out bolt

holes
with compressed air.

b.
Install
a new cylinder head gasket on the
cylin­

der
block. Dowels in the block
will
hold the gasket

in
position. Always handle gaskets carefully to

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

Dl-79.
Install
Clutch
and Flywheel Housing

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

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

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

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

D1-80.
Install
Camshaft

Insert
camshaft into camshaft bearings of
engine

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

properly
seated in bearings.
12695

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

2—
Push
Rod 3—
Valve
Lifter

4—
Camshaft
14203

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

fully
place on the
engine
block dowel pins.

d.
Clean
and lubricate the cylinder head
bolts
with

a
sealing compound
(Part
No. 994757, or equiv­

alent).

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

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

kg-m.].

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

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

kg-m.].
Do not overtighten.

h.
See Section Fl and F2 for
engines
equipped

with
exhaust emission control.

D1-81.
Install
Valve Lifter
and Push Rod

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

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

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

cylinder
head with four attaching screws.
Install

the positive crankcase ventilation valve on right

rocker
arm cover. 99