1953 JEEP DJ Service Manual

'Jeep'
UNIVERSAL
SERIES SERVICE
MANUAL

Dl
Dl-104.
SERVICE
DIAGNOSIS

Poor Fuel Economy
Ignition Timing Late or Spark Advance Inoperative

Carburetor
Float Setting Too High
Accelerator Pump Improperly Adjusted
Fuel
Pump Pressure High

Fuel
Line
Leakage

Fuel
Pump Diaphragm Leakage
Cylinder
Compression Low
Valves Do Not Seat Properly
Spark
Plugs
Defective

Spark
Plug Cables
Defective

Ignition
Coil
or Capacitor
Defective

Carburetor
Air Cleaner Dirty

Brakes
Drag
Wheel Alignment Incorrect

Tire
Pressure Incorrect Odometer Inaccurate

Fuel
Tank
Cap Clogged or
Defective

Muffler or Exhaust Pipe Clogged or Bent

Lack
of
Power
Cylinder
Compression Low
Ingitdon Timing Late

Carburetor
or
Fuel
Pump Clogged or
Defective

Fuel
Lines Clogged
Air
Cleaner Restricted
Engine Temperature High Valves Do Not Seat Property

Valve
Timing Late Intake Manifold or Cylinder Head
Gasket Leaks
Muffler or Exhaust Pipe Clogged or Bent
Spark
Plugs Dirty or
Defective

Breaker
Point Gap Incorrect
Breaker
Points
Defective
Ignition
Coil
or Capacitor
Defective

Electrical
Connection Loose
Broken
Valve Spring

Broken
Piston Ring or Piston
Cylinder
Head Gasket
Defective

Distributor Cap Cracked

Low
Compression
Valves Not Seating Properly Piston Rings Seal Poorly
Valve
Spring Weak or Broken
Cylinder
Scored or Worn
Piston Clearance Too Great

Cylinder
Head Gasket Leaks

Burned
Valves and
Seats
Valves Stick or Are Too Loose in Guides
Valve
Timing Incorrect

Valve
Head and Seat Have Excessive Carbon
Engine Overheats

Valve
Spring Weak or Broken

Valve
Lifter Seized or Collapsed
Exhaust
System Clogged
Valves Sticking

Valve
Stem Warped

Valve
Stem Carbonized or Scored

Valve
Stem Clearance Insufficient in Guide

Valve
Spring Weak or Broken

Valve
Spring Distorted
Oil
Contaminated

Overheating
Cooling System Inoperative
Thermostat Inoperative Ignition Timing Incorrect

Valve
Timing Incorrect
Carbon
Accumulation Excessive

Fan
Belt Loose
Muffler or Exhaust Pipe Clogged or Bent

Oil
System Failure
Piston Rings Worn or Scored
Popping,
Spitting,
Detonation
Ignition Timing Incorrect

Carburetion
Improper

Carbon
Deposit
in Combustion
Chambers Excessive
Valves Not Seating Properly
Valve
Spring Broken
Spark
Plug Electrodes Burned
Water or Dirt in
Fuel
Fuel
Line
Clogged
Valve
Timing Incorrect

Excessive
Oil
Consumption
Piston Rings Stuck in Grooves, Weak,
Worn,
Broken, or Incorrectly Fitted

Crankshaft
Main Bearings or
Connecting Rod Bearings Have
Excessive Clearance
Gaskets or Oil Seals
Leak

Cylinder
Bores Worn, Scored,
Out-of-Round or Tapered
Pistons Have Too Great Clearance to Cylinder Bores
Connecting Rods Misaligned High Road Speed
High Temperature

Crankcase
Ventilation System Inoperative
Bearing Failure
Crankshaft
Bearing Journal Rough or Out-of-Round

Oil
Level Low
Oil
Leakage

Oil
Dirty
Oil
Pressure Low or Lacking
(Oil
Pump Failure)

Drilled
Passages
in Crankshaft or
Crankcase
Clogged

Oil
Screen Dirty
Connecting Rod Bent 105

Dl

DAUNTLESS
V-6
ENGINE
E-105.
DAUNTLESS V-6 ENGINE SPECIFICATIONS

ENGINE:
Type

Number
of Cylinders Valve Arrangement
Bore
Stroke

Piston
Displacement

Firing
Order Compression Ratio

Number
of
Mounting
Points:

Front.

Horsepower
(SAE)

Horsepower
(max. brake) Torque (max.
2400
rpm.)
Cylinder
Numbers,
Front to Rear:
Right Bank

Left
Bank
Cylinder Block Material
Cylinder Head Material English

90°
V-6 6

In
head
3.750"
3.400"

225 cu. in.
1.6.5.4.3.2

*9.0:1

2

33.748

160 @
4200
rpm. 235
lb-ft.

2, 4, 6 1, 3, 5

Cast
Iron
Cast
Iron Metric

9,525
cm.

8,636
cm. 3,69 ltr.

32,49
kg-m.

PISTONS:
Material
Description Clearance Limits:
Top
Land
Skirt
Top

Skirt
Bottom

Ring Groove Depth*. No. 1
No. 2, 3
Cylinder Bore: Out-of-Round (max.). Taper (max.)
Cast
Aluminum Alloy

Cam
Ground, Tin Plated

.0125"
to
.0295" .0005"
to
.0011"

.0005"
to
.0011"

.1880"
to
.1995"
.1905"
to
.1980"

.003"
.005" 0,318 a
0,749
mm.

0,0127
a
0,0279
mm.

0,0127
a
0,0279
mm.

4,775
a
5,067
mm.
4,839
a
5,029
mm.

0,076
mm. 0,127 mm.

PISTON
RINGS:
Function: No. 1 and No. 2 Ring.. No. 3 Ring
Location
Material: No. 1...
No. 2 No. 3.

Oil
Ring Type
Oil
Ring Expander
Width: No. 1
No. 2. .
No. 3

Gap:
No. 1 and No. 2
No. 3

Side
Clearance in Groove: No. 1
No. 2
No. 3 Compression

Oil
Control

Above
Piston
Pin

Iron,
Chrome Plated
Iron,
Pre lubricated
Steel

Dual
Rail,
With Spacer Humped Ring

.0785"
to
.0790" .0770"
to
.0780"
.181" to .187"
.010" to .020"
.015" to .035"
.002" to
.0035"
.003" to .005"

.0015"
to
.0085"
1,993 a
2,007
mm.
1,956 a 1,981 mm. 4,60 a 4,75 mm.
0,25 a 0,51 mm.
0,38 a 0,89 mm.
0,051 a
0,089
mm.
0,076
a 0,127 mm.

0,038
a
0,220
mm.

PISTON
PINS:
Material
Length

Diameter

Type Clearance in
Piston

Clearance in
Connecting
Rod.

Distance
Offset
Toward High-Thrust
Side
of Piston.
Steel,
SAE 1018, SAE 1118

3.060"

.9394"
to
.9397"

Pressed in
Connecting
Rod
.0004"
to
.0007" .0007"
to
.0017"

.040"
7,772
cm.

23,861
a
23,868
mm.

0,0102
a
0,0178
mm.
0,0178
a
0,0431
mm.
1,016 mm.
*State
of California Exhaust Emission Control Engine 7.4 Compression Ratio.
106

'Jeep*
UNIVERSAL
SERIES
SERVICE
MANUAL

Dl
Dl-105.
DAUNTLESS
V-6
ENGINE
SPECIFICATIONS—Continued

CONNECTING
RODS:
Material
Installation
Bearings: Type........
Material.
Length Clearance

End
Play
(total
for two
connecting
rods)

CRANKSHAFT:
Material ,

End
Thrust
End
Play

Main
Bearings: Number Type
Material:
Length, Over-All: No. 1, No. 3, and No. 4
No. 2
Clearance

Main
Journal Diameter.
Crankpin
Journal Diameter
Flywheel Run Out, max

CAMSHAFT:
Material
Bearings: Number Material Clearance

Journal
Diameter: No. 1 No. 2
No. 3.
No. 4
Location Camshaft Drive

Chain
Links
Camshaft Sprocket Material
Crankshaft Sprocket Material

VALVE
SYSTEM:
Valve Lifters Diameter Clearance in Cylinder Block
Leak-down Time
(seconds)

Rocker Arms: Ratio Clearance on Shaft
Valves: Intake: Material
Head Diameter

Seat
Angle
Stem
Diameter

Stem
Clearance in Guide
Exhaust:
Material Head Diameter

Seat
Angle
Stem
Diameter

Stem
Clearance in Guide
Valve Springs — Pressure at Length: Valve Closed English
Pearlitic Malleable Iron

From
Top of Cylinder Bore
Removable, Steel-Backed Aluminum .737"

.0020"
to
.0023"
.006" to .014" Metric
18,72 mm.

0,0508
a
0,0584
mm. 0,153 a
0,356
mm.
Pearlitic Malleable Iron
Second
Main Bearing .004" to .008"

Removable

Moraine 100
.864"

1.057"

.0005"
to
.0021"
2.4995"

2.0000"

.015" 0,102 a
0,203
mm.
21,95 mm.

2,685
cm.

0,0127
a
0,0533
mm.
6,349
cm.
5,080
cm.
0,381 cm.

Cast
Iron Alloy
Steel-Backed Babbitt
.0015"
to
.0040"

1.755"
to
1.756"

1.725"
to
1.726"

1.695"
to
1.696"

1.665"
to
1.666"

In
Cylinder Block, at Center of V
Chain
and Sprocket 54
Aluminum,
Nylon
Coated Sintered Iron
0,0381
a
0,1016
mm.

4,458
a
4,460
cm.
4,382
a
4,384
cm.
4,305
a
4,307
cm.

4,229
a 4,231 cm.
Hydraulic

.8422"
to
.8427"

.0015"
to
.0030"
12 to 60
1.6:1

.0017"
to
.0032"

Steel,
SAE 1041
1.625"
45°

.3415"
to
.3427"
.0012"
to
.0032"

GM-N82152
(21-4N)
1.3750"
45°

.3402"
to
.3412"
.3397"
to
.3407"

.0015"
to
.0035"
(top)
.002" to .004"
(bottom)

1.640"
at 59 - 64 lb.
1.260"
at 168 lb. 21,39 a 21,40 mm.

0,0381
a
0,0762
mm.

0,0432
a
0,0812
mm. 4,128 cm.

8,674
a
8,704
mm.

3,4925
cm.
8,641 a
8,666
mm.

8,628
a
8,653
mm.

0,0381
a
0,0889
mm. 0,051 a 0,102 mm.
4,16 cm. at
26,76
-
29,03
kg. 3,20 cm. at
76,20
kg.
107

Dl

DAUNTLESS
V-6
ENGINE
D1-10S. DAUNTLESS V-6 ENGINE SPECIFICATIONS—Continued

LUBRICATION SYSTEM:
Type of Lubrication:

Main
Beasings
Connecting
Rod Bearings

Piston
Pins. Camshaft Bearings
Rocker Arms
Timing
Chain

Cylinder
Walls

Oil
Pump: Type
Drive
Normal Oil Pressure
Oil
Pressure
Sending
Unit. .

Oil
Intake
Oil
Filter
System

Filter
Type

Crankcase
Capacity:
Without
Filter

With
Filter.
English

Pressure
Pressure Splash
Pressure
Pressure
Splash and
Nozzle
Splash and
Nozzle

Gear

Camshaft Gear

33
psi. at
2400
rpm.
Electrical

Screened
Tube

Full
Flow Type
Throwaway Element and Can
4 qt.
5
qt. Metric
2,32 kg-cm2 at
2400
rpm.
3,8
ltr.
4,7 ltr. 108

'Jeep*
UNIVERSAL SERIES SERVICE
MANUAL

E

FUEL
SYSTEM
Contents

SUBJECT
PAR.

GENERAL
E-1 Dash

FUEL
EVAPORATIVE EMISSION
?*^r
CONTROL SYSTEM
..E-2
Canister
.E-3 . Demand Valve E-4

Fuel
Tank.
.E-5
Inspection Test. E-8
Sealed Gas Cap. E-7

Servicing
System E-9
Vapor
Separator or Expansion
Tank
E-6

CARBURETOR
—
HURRICANE F4 ENGINE.
. .
......
..... ,. . .E-10 Accelerating Pump System.............. .E-19 Accelerating Pump Maintenance E-20

Carburetor
Reassembly
E-2
2

Carburetor
Disassembly E-21
Choke
System E-17
Dash
Pot Adjustment E-44

Fast
Idle Adjustment E-18
Float
Adjustment E-12
Float
System. E-ll
High-Speed System . .E-15
Idle
Adjustment .E-14

Low-Speed
System . E-13
Metering Rod Adjustment E-16

CARBURETOR
~r
DAUNTLESS V-6 ENGINE
.E-25
Accelerator Pump Adjustment E-41 Accelerator Pump System. . E-30

Air
Horn Body Assembly E-39
Air
Horn Body Removal and Disassembly.
E-33

Carburetor
Cleaning and Inspection E-36
Carburetor
Removal E-32
Choke
System E-31

Curb-Idle
Speed and Mixture Adjustment. .E-42

E-1. GENERAL
The
fuel system of the Jeep Universal vehicle,
whether equipped with a Hurricane F4 or Daunt­

less
V-6 Engine,
consists
of the fuel tank, fuel lines, fuel pump, carburetor and
air
cleaner.
Fig. E-1, E-2.
Vehicles equipped with a
Fuel
Evaporative
Emis­

sion Control System
also
include a
non-vent

pressure and vacuum
sensitive
gas cap, a liquid
expansion and vapor separator tank, a carbon filled vapor
storage
canister, and a vapor purge line. Service information pertaining to the
Fuel
Evap­

orative Emission Control System is outlined in

Par.
E-2 through
E-9.
Refer to Figs. E-3 and E-4.
The
most
important
attention
necessary to the fuel
system is to
keep
it clean and free from water. It should be periodically inspected for leaks.

CAUTION—Whenever
a vehicle is to be stored for

an
extended
period, the fuel system should be com­

pletely
drained, the
engine
started and allowed to
run
until the carburetor is emptied.
This
will
avoid
oxidization of the fuel, resulting in the formation of
SUBJECT
PAR.
Pot Adjustment .E-44

nal
Carburetor Adjustments.........E-40

Idle
Adjustment
.
E-43 System . . .E-26

Bowl
Body Assembly E-38

Fuel
Bowl Body Disassembly E-34

Idle
System E-27

Main
Metering System E-28
Power System . E-29
Throttle
Body Assembly .E-37

Throttle
Body Removal, and Disassembly. .E-35

FUEL
PUMP
—
HURRICANE F4 ENGINE.
E-45, 54, 60

Cleaning
and Inspection.............
.E-57,
63 Disassembly E-46, 56, 62
Installation E-59, 65
Reassembly
.E-47,
58, 64
Removal
E-55, 61

Testing.
E-49, 50, 51, 52, 53, 66

Vacuum
Pump E-48

FUEL
PUMP
—
DAUNTLESS V-6 ENGINE
E-67
Removal
E-68

AIR CLEANER
—
CARBURETOR
E-69
ACCELERATOR
LINKAGE
.E-70

FUEL
TANK
AND
LINES
E-71
Float
Unit . .E-76
Fuel
Lines E-77
Fuel
Tank
. . .E-72

Fuel
Tank
Cap E-75

Fuel
Tank
Installation. E-74
Fuel
Tank
Removal E-73

SERVICE
DIAGNOSIS
E-78

SPECIFICATIONS.
E-79
gum in the units of the fuel system. Gum formation
is similar to hard varnish and may cause the fuel
pump valves or the carburetor
float
valve to be­
come
stuck or the filter screen blocked. Acetone or commercial fuel system cleaners
will
dissolve

gum formation. In
extreme
cases
it
will
be necessary
to dissassemble and clean the fuel system. In
most

cases, however, a
good
commercial fuel system sol­
vent
used in accordance with the manufacturer's
instructions or one pint [0,6 ltr.] of
acetone
placed
in
the fuel tank with
about
one gallon [4,5 ltr.]
of
gasoline
will
dissolve
any
deposits
as it
passes

through the system with the
gasoline.

E-2.
FUEL
EVAPORATIVE EMISSION CONTROL SYSTEM

Description and Operation

•
Refer to Figs. E-3 and E-4.

The
Fuel
Evaporative Emission Control System
is
designed
to reduce fuel vapor emission that 109

E

FUEL
SYSTEM

FIG.
E-1—FUEL SYSTEM—EARLY MODEL—F-4 ENGINE 1—
Fuel
Line
To Carburetor 4—Accelerator Treadle
2— Carburetor 5—Fuel Tank and Gauge
3— Choke Cable 6—Fuel Pump

FIG.
E-2—FUEL SYSTEM—EARLY
MODEL—V-6
ENGINE 1—
Fuel
Line
To Carburetor 5—Fuel Tank and Gauge

2—
Carburetor 6—Fuel Pump
3— Choke Cable 7—Fuel
Line
To Fuel Pump

4—
Accelerator
Treadle 8—Fuel Return
Line
normally
vents
to the atmosphere from the vehicle
fuel system.

The
fuel vapor system consists of internal fuel tank
venting, a vacuum /pressure fuel tank cap, a vapor
separator or expansion tank, vapor canister, and closed external carburetor venting. The same basic
system is used on all 'Jeep' vehicles, as shown in
Fig. E-3.

This
system involves means of trapping the fuel
vapors through the use of a charcoal canister which
absorbs the vapor and stores it until it can be re­ moved to be burned in the
engine.
This
removal is
performed by drawing
these
vapors through the purge line
into
the crankcase ventilation system

which
in
turn
enters the intake manifold. In ad­ dition to the canister, the fuel tank requires a sealed
gas cap and extra
vents
to a liquid separator or
expansion tank.
This
prevents liquid
gasoline
from entering the vapor system.
Thus,
as vapors are generated in the fuel tank,
they
flow through the

liquid
separator or expansion tank to the canister

and
are routed to the intake manifold through the 110

'Jeep*
UNIVERSAL
SERIES
SERVICE
MANUAL

E

FIG.
E-3—FUEL EVAPORATIVE EMISSION CONTROL SYSTEM- HURRICANE F4 ENGINE
A—Side
View

1—
Charcoal Canister
2— Purge
Line

3—
Fuel
Tank
4—
Fuel
Filler
Hose 5—
Non-Vented
Gas Cap
B—Plan
View

6—
Vapor
Separator
or Expansion Tank 7—
Fuel
Gauge

8—
Fuel
Line-to-Fuel Pump

9—
p.C.V.
Crankcase
Valve

10—Fuel
Pump

crankcase
vent system. The charcoal canister in­
corporates an integral demand valve
which
regu­

lates
vapors entering the canister as
well
as a
limit
fill
valve
to control air trapping during tank
fill.
The
Fuel
Evaporative Emission Control System
incorporates the following new or modified parts:

E-3.
Canister
The canister used for the vapor control system has
provisions for containing activated charcoal gran­ ules. The material used for the canister body is a

special,
fuel resistant, heat stabilized nylon. At the top of the canister there is the demand valve which
has connections; one vents the vapor to the canister
while the other connection joins the canister to the purge system. These
tubes
enter the canister on

opposite
sides of a baffle which permits uniform
vapor distribution throughout the canister. The
bottom
of the canister is fitted with a filter element
that allows fuel tank venting to atmosphere after vapors are trapped in the activated charcoal.

E-4.
Demand Valve

The
demand valve is integral with the canister. It
is essenitally a combination pressure regulator and

vacuum
relief valve.
This
valve regulates the rate
of vapor
flowing
from the fuel tank into the canister.
The
valve consists of a housing, a spring loaded
diaphragm,
a diaphragm cover, and a vacuum

relief
valve. The operation of the unit is such that
as tank vent pressure increases the diaphragm lifts,
permitting vapor to enter the canister. The pres­
sure
under which this occurs is 4" to 6"
H2O.
This

action regulates the flow of vapors into the canister
under severe soak and operation conditions (temp, changes), but generally prohibits the flow of vapor 111

E

FUEL
SYSTEM

9
©

FIG.
E-4—FUEL
EVAPORATIVE
EMISSION
CONTROL
SYSTEM-
DAUNTLESS
V-6
ENGINE
A—Side
View
1—
Charcoal
Canister

2—
P.C.V.
Crankcase
Valve

3—
Purge
Line

4—
Fuel
Tank
5—
Fuel
Filler
Hose
B—Plan
View
6—
Non-Vented
Gas Cap 7—
Vapor
Separator or Expansion
Tank

g—Fuei
Gauge

9—Fuel
Line-to-Fuel
Pump

10—Fuei
Return
Line

during
normal temperature vehicle operation, thus
minimizing
driveability problems. An additional
feature of this valve is a built-in vacuum relief

which
allows inward air flow under negative fuel

tank
pressure conditions. The valve housing con­
tains the normal tank vent and purge connections.

E-5.
Fuel Tank

The
fuel tank is external expansion type.
Fuel

tank
venting is accomplished by several vapor
lines which lead to the vapor separator or expan­
sion tank. The vapor lines which lead from the
fuel tank are located at the front and
rear
so that
during
any inclination of the vehicle, at least one
line
will
be open to vent at all times.
E-6.
Vapor Separator
or
Expansion Tank

The
vapor separator is chambered so that the
rear
fuel tank vent lines lead into a separate chamber

with
a fuel shutofl valve.
This
prevents solid fuel
from
flowing from the fuel tank to the vapor can­
ister during uphill operation or parking of the
vehicle. A single vapor vent line leads from the fuel
vapor separator to the vapor collection canister
where fuel vapors are stored until they can be drawn into the
engine
and burned.

The
expansion tank allows expansion of the fuel as

required
during temperature changes and simul­ taneously
becomes
a liquid trap that only allows
vapors to pass.
E-7.
Sealed
Gas Cap

The
sealed gas cap is designed to allow no vapors to
discharge into the atmosphere under normal
operation of the system. If the system
becomes
plugged or a failure of the demand valve occurs 112