1953 JEEP DJ radiator

'Jeep*
UNIVERSAL SERIES SERVICE
MANUAL

G

FIG.
G-4—PRESSURE TESTING COOLING SYSTEM
1—Pressure Tester C-3499 previous radiator leakage. These
spots
may not be
damp if water only or methyl-alcohol-base anti­ freeze is in the cooling system since such coolants
evaporate readily. An ethylene-glycol-base anti­ freeze shows up existing leaks as it
does
not evapo­
rate.
The radiator may be tested for leaks by using

a
Pressure Tester Tool C-4080, as shown in Fig.

G-2.

When
the pressure cap opens, the sudden surge of

vapor
or liquid must blow out through the overflow
pipe. If the overflow pipe is dented or clogged,
the pressure caused by obstruction may cause dam­
age to the radiator or
hose
connections in the cool-
1
FIG.
G-5—RADIATOR PRESSURE
CAP
1—
Pressure
Cap

2—
Overflow
Tube

3—
Pressure
Seal 4—
Vacuum
Release Valve
5—
Radiator
Neck
FIG.
G-6—TESTING RADIATOR PRESSURE
CAP
1—
Radiator
Pressure Cap

2—
Adapter

3—
Pressure
Tester C-3499 ing system. To remove clogging material, run a
flexible wire through the overflow pipe.
G-6.
Radiator Removal
and
Replacement
a.
Drain
the radiator by opening the
drain
cock

and
removing the radiator pressure cap.

b.
Remove the upper and lower
hose
clamps and

hoses
at the radiator.

c.
Remove the four cap screws, lock washers and
flat washers that secure the radiator to the radiator
body support. Remove the radiator.

d.
To replace the radiator, reverse the removal

procedure.

G-7.
Radiator
Hoses
and
Heater Hoses

Air,
heat, and water deteriorate radiator and heater

hoses
in two ways: by hardening or cracking which
destroys flexibility and causes leaks; by softening
and
swelling which produces lining failure and
hose

rupture
and clogging. Examine
hoses
spring and

fall
for possible need of replacement or tightening.

If
hoses
are collapsed, cracked, or indicate a
soft

condition on the inside they should be replaced.
Correct
installation of a new heater
hose
is impor­
tant to prevent contact between the
hose
and the
exhaust manifold. On the
Hurricane
F4 engine the
molded curved end of the
hose
connects to the
hot water intake of the heater; the flexible end to the hot water valve on top of the cylinder head.
On
the Dauntless V-6 engine the heater inlet
hose

is connected to the
rear
of the intake manifold 165

'Jeep'
UNIVERSAL
SERIES SERVICE
MANUAL

G
cation period. It is
good
preventive maintenance to
replace a badly frayed, worn or cracked fan belt
before it breaks in operation.

To
replace the fan belt,
loosen
the attaching
bolts

at each generator or alternator brace-to-engine mounting and pivot the alternator or generator to­

ward
the
engine
to gain slack needed to install the new belt Remove the old belt. Position the new
belt over the fan pulley, over the crankshaft pulley,
then over the generator or alternator pulley.
Pull
the generator or alternator away from the
engine

until
belt tension is
firm.
Then tighten the generator

or
alternator mounting
bolts
and check the tension
as indicated above. Reset the generator or alternator as necessary for correct belt tension.
Finally,
torque
the generator or alternator mounting
bolts
25 to 35 lb-ft. [3,4 a 4,8 kg-m.].

Note:
On the Dauntless V-6
engine
when adjusting
the fan belt tension, the alternator mounting
bolts

should be torqued 30 to 40 lb-ft. [4,14 to 5,53

kg-m.].
If a fan belt tension
gauge
(W-283) is
avail­

able, proper tension should be 80 pounds [36,2 kg.].

G-l
9. Engine Overheating

An
engine
will
not be damaged by high coolant
temperatures unless the coolant boils. The pres­

surized
cooling system on the 'Jeep' vehicles raises the boiling point of the coolant solution. Should
overheating be encountered, and the fault is be­
lieved to be in the cooling system check for the
following:

a.
Proper coolant level. See
Filling
Cooling Sys­
tem Par. G-2.
b. Poor air flow.
Check
for dirty radiator core. (See Radiator Par. G-5).
Check
for faulty belt
pulley operation, worn or
loose
fan belt, or dam­ aged fan.
Clean,
repair, replace or adjust as neces­

sary.

c. Foaming coolant.
Check
for air leaks at water
pump,
hose
connection and filler cap. Tighten, re­

pair
or replace as necessary.

d.
Surging or "after boil".
Check
pressure cap and
replace if valves or gasket are faulty.
e.
External
leaks.
Check
the following for leaks:
Hoses and clamps, water pump, radiator, head gas­
ket, core plugs and drain cocks, as well as the cylin­ der head or block for
cracks.

f.
Internal
leaks.
Check
for faulty head gasket,
cracked
cylinder head or block.
g. Poor coolant flow.
Check
hose
condition, water pump, fan belt, and repair or replace as necessary. Inspect block for rust or scale, and clean and flush
the system, if necessary.

h.
Check
the temperature
gauge.
169

G
COOLING SYSTEM G-20.
SERVICE DIAGNOSIS

SYMPTOMS
PROBABLE REMEDY

Overheating:
Lack
of Coolant Refill radiator
Thermostat inoperative . Replace thermostat
Water
pump inoperative. Overhaul or replace
Incorrect
ignition or valve timing. Set
engine
timing
Excessive piston blowby Check pistons, rings and cylinder walls
Fan
belt
broken or badly worn Replace
belt

Radiator
clogged
Reverse flush and clean
Air
passages
in core
clogged
Clean with water and air pressure
Excessive carbon formation. Remove carbon from cylinder head(s) Muffler
clogged
or
bent
exhaust
pipe
Replace damaged part

Loss
of Cooling
Liquid:
Loose
hose
connections
Tighten
connections

Damaged
hose
Replace
hose

Leaking
water pump Overhaul or replace

Leak
in radiator Remove and repair
Leaky
cylinder head
gasket
Replace
gasket
Crack
in cylinder block. Small crack can be closed with
Radiator
or Block Sealer

G-21. COOLING SYSTEM SPECIFICATIONS

Radiator
Cap:
Relief
Pressure

Vacuum
Valve Release.
Thermostat:
Rating

Starts to Open

Fully
Open

Water
Pump:
Type.

Drive

Radiator:

Type

Cooling System Capacity: Without Heater

With
Heater..

Fan:
Number of Blades Diameter

Drive
Belt: Angle of V

Length
Width
HURRICANE
F4
7 and 15 psi. [0,5 kg-cm2 and 1,05 kg cm2]
lA to 1 psi. [0,04 a 0,07 kg-cm2]

190°F.
[87,8°C]
180°F.
[82°C]

202°F.
[94°C]

Centrifugal
V-Belt

Tube
8s Fin
11 qt. [10,4 ltr.] 12 qt. [11,5 ltr.]
15" [38 cm.]
38°

42%" [108 cm.] [1,74 cmJ
DAUNTLESS
V-6 15 psi. [1,05 kg-cm2]
1 psi. [0,07 kg-cm2]

190°F.
[87,8°C]
180°F.
[82°C]

202°F.
[94°C]

Centrifugal
V-Belt

Tube
& Fin
9 qt. [8.5 ltr.]
10 qt. [9,4 ltr.]
4

\SbA"
[39,7 cm.]

38°

43.92"
[111,5
cm.] Vg"
[0.952
cm.] G-22. ANTIFREEZE CHERT

Quarts
i
Quarts
Ethylene Glycol

U.S.
Imperial
Liters
Fahr.
Cent.

10-Quart
System

2
m
2

16°
-
8.8°

3
2V2
2%
4°

-15.5°

4
3H
-12°

-24.4°

5 4M -34°

-36.6°

6
5

5Vs
-62°

-52.2°

11-Quart
System

2 2

18° -
7.6°

3 2H
2%
8°

-13.3°

4
3%
-
6°

:
-21.10

5 4M 4M -23°

-30.5°

6
5

SVs
-47°

-43.8°

12-Quart
System

2
1 m 2 1

19° ;
- 7.2°

3
2*A
10°
!
-12.2°

4
I
3H
3M 0°
;
-17.7°

5 !
4M 4^ :
-15°

s
-26.1°

6 1 5
5%
-34°

-36.6°
170

'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

'Jeep*
UNIVERSAL
SERIES
SERVICE
MANUAL
H
FIG.
H-59—HEAD LAMP

1—
Door

2—
Retaining
Screw

3—
Retaining
Ring

4—
Sealed
Beam
Unit
5—
Mounting
Ring

6—
Adjusting
Screw 7—
Housing

8—
Wires

9—
Door
Screw 310669
to cross the vertical
tapes
at the measured height
of each lamp center respectively.

g.
Remove the head lamp doors.
h.
Clean
the head lamps.

H-132.
Aiming Head Lamps

a.
Turn
the headlights on low beam. Cover the lamp not being aimed. Be sure to use the horizontal reference line on the screen that is the same dimen­
sion as the vehicle lamp height.
b.
Turn
the vertical aiming screw counterclock­
wise until the lamp beam is considerably lower

than
the horizontal reference line on the screen.
Then,
turn
the screw clockwise until the top
edge

of the high intensity
area
is even with the horizontal

line.
See Fig. H-60.
I
(T)

JT)

1'.'' | '':'
11460

FIG.
H-60—HEADLIGHT AIMING
CHART
1—
Vertical
Tape,
Left
Lamp
Center

2—
Vehicle
Centerline

3—
—Vertical
Tape,
Right
Lamp
Center
4—
Zone
of Greatest Intensity
5—
2
*
(Two Inches)
6— 25'0
'
7—
2
*
(Two Inches)
8—
Height
of
Lamp
Centers
9—
Horizontal
Tape

Note:
Always bring the beam into final position
by turning both aiming screws clockwise so that
the unit is held under proper tension when the operation is complete.

c. Turn
the horizontal aiming screw counterclock­
wise until the beam is off.
Then,
turn
the same
screw
clockwise until the
left
edge
of the high
intensity area is 2" [5,08 cm.] to the right of the
lamp center line. See Fig. H-60.

d.
Cover the lamp that has been aimed and aim
the other lamp using the same procedure.
e.
Carefully
reinstall the head lamp doors.

H-133.
Parking
and
Turn Signal Light
The
parking lights are mounted in the radiator

guard
panel just below the headlights. These lights

are
on only when the main switch control knob is
pulled
out to the first notch.

To
replace a parking lamp, remove two screws allowing the lens and colored reflector to be re­
moved. Replace the lamp, which is recessed back

in
the housing.

If
the
complete
parking light assembly is to be
removed for service or replacement, disconnect the

wire
plug at the back of the housing.
Then
remove
the nuts and lock washers securing the parking light assembly and remove out the front of the

panel.

H-134. Tail, Stop
and
Turn Signal Light

Refer
to Fig. H-57 and H-58.

The
tail
lights are mounted in the
rear
corner
posts

of the body. They are on whenever the main switch
control
knob is pulled out to any position.

a.
To replace a lamp, remove the snap ring on

early
models
and remove the lens; on late
models
remove lens screws, lens and gasket.
Clean
lens
and
reflector before replacing.
b. To remove the parking and
tail
light housing,
disconnect wiring, remove the two nuts and lock
washers securing
tail
light assembly to body and remove from
rear
of body.

H-135-
Backup Lights •
Refer to Fig. H-61.

The
backup lights on late production vehicles are located on the
rear
of the vehicle directly below
the
tail
light. The backup lights are actuated
through a switch when the ignition is on and the

transmission
is in reverse. 215

STEERING
SYSTEM

FIG.
0-9—STEERING

BELLCRANK
ASSEMBLY

1— 5s'-18
Stollock
Lockout

2—
Plain
Washer

3— 7 us"-20
x
2 l2' Bolt

4—
71«
*-20
Stollock
Locknut
5—
Beilcrank
Support

6—
Special
Ground
Washer
7— Seal
8—
Bearing
9— Beilcrank
10— Beilcrank
Shaft

11—
Seals

12—
Bearings

13— } s *
b.
Torque the
Vfc"
[11,113
mm.] diameter elamp
bolt to
50-70
lb-ft. [6,9 a 9,7 kg-m.].

c.
Assemble the tie rod to the beilcrank lever,
making
sure to tighten the nut to the proper
torque value of 38 to 45 lb-ft. [5,2 a 6,2 kg-m.].

d.
Connect the drag
link
to the beilcrank arm,

adjust
the
ball
joint by screwing in the plug firmly against the
ball,
approximately 20 lb-ft. [2,8 kg-m.], then back off one quarter
turn
and lock

with
a new cotter pin.

0-19.
Beilcrank
Support
Bracket
Rivet
Replacement

The
procedure for replacing a rivet with a bolt
is as follows:

a.
Drill
a [4,76 mm.] pilot
hole
up through
the front rivet.

b.
Enlarge
the [4,76 mm.]
hole
with a %"
[8,73 mm.]
drill.

c.
Chisel
off the
bottom
rivet head and drive the

remainder
of the rivet upward and out, using
a
punch and hammer.

d.
Install
a %" [9,53 mm.] bolt and lock nut,
torque to
30-45
lb-ft. [4,1 a 6,2 kg-m] and stake
the nut.

e.
Clamp
a metal plate to the frame to protect
the radiator, then
drill
and remove the remaining two rivets, install bolts, lock nuts and torque as
specified.

O-20.
STEERING
COLUMN
AND
WHEEL SERVICE

Jeep
Universal
Series vehicles use a
one-piece
steer­
ing
shaft that is integral with the steering gear
assembly, as shown in Fig. 0-2. Alignment in­
structions in paragraph 0-4 apply.

0-21.
Steering
Wheel Removal •
Refer to Fig. 0-2.

a.
Carefully
pry the rubber horn cap from the housing slot.
b.
Remove steering shaft nut.

c.
Remove steering wheel and spring.

0-22.
STEERING GEAR SERVICE

Note:
The steering gear can be adjusted when the
gear is mounted in the vehicle by first disconnecting
the drag
link
from the steering arm. Refer to Par.
Q-5.
0-23.
Removal
of
Steering Gear
•
F4-Engine.

a.
Remove the directional signal unit from the steering column.

b.
Remove the steering column bracket attached
at the instrument panel.

c.
Remove upper section of the floor pan.

d.
Disconnect shift rods from the shift levers at
lower end of the steering column if applicable.

e.
Disconnect the horn wire at lower end of steer­
ing
gear assembly.

f.
Remove steering gear arm from the steering gear assembly.

g.
Remove
bolts
attaching the steering gear hous­
ing
to the frame.

h.
Remove the steering gear assembly by bringing

it
up through the floor pan opening.

•
V6 Engine.

a.
Remove oil pan
skid
plate.

b.
Remove
left
exhaust pipe.

c.
Disconnect connecting rod (drag
link)
from
steering gear arm.

d.
Disconnect steering gear assembly from frame.

e.
Remove steering wheel from steering column.
f. Disconnect accelerator linkage.
g.
Remove upper floor pan assembly.
h.
Disconnect directional signal switch.
i.
Jack-up
vehicle, and remove steering gear and
320

BODY

10728

FIG.
T-2—WINDSHIELD
—
CJ-3B

1—
Windshield
Assembly
2—
Filler
Strip

3—
Weatherstrip 4—
Windshield
Glas3

5—
Screw

6—
Clamp
7—
Screw
and Lockwasher
8—
Screw
r
9— —Weatherstrip

Floor
pan
noise
on early CJ-5 and CJ-6
models
may be corrected by installing the new floor pans.
T-2.
Windshield

•
Model
CJ-3B
The
entire windshield and frame assembly may be
lowered down on top of the hood.
This
is accom­ plished by unlatching the retaining catches mount­
ed on the cowl
above
the instrument panel. When lowered do not
fail
to strap it down with the strap provided which is mounted at the top of the

radiator
guard.

A
stationary
type
windshield is used on all vehicles
equipped with
soft
or canvas
tops.
A hinged ven­ tilator mounted in the center of the panel directly
under the
glass
is provided for ventilation. The

glass
is installed in the same manner as on Models
CJ-5,
and
CJ-6.

Vehicles equipped with metal enclosure employ a
stationary windshield which is the same as that used with the canvas top
except
that it has a higher

silhouette
and is wider.
Glass
installation is the same as
CJ-5,
CJ-5
A, CJ-6,
and
CJ-6
A.

T-3.
Windshield
»
Model
CJ-5, CJ-5A, CJ-6, CJ-6A,
DJ-5, DJ-6

The
windshield and frame may be lowered to the

hood
by unlatching the two clamps at each side
of the windshield. When in the lowered position, always secure the windshield by passing the strap
at the top of the windshield through the
loop
on the
hood
and drawing the strap up firmly.
To
remove the windshield from the
body
on early
models, first,
pull
the windshield wiper vacuum
hose
352

'Jeep*
UNIVERSAL
SERIES
SERVICE
MANUAL

U
DESCRIPTION
—
Continued

AXLES

W-99* Gauge — Pinion & Ring
Gear
Setting
W-104-B* Puller — Tapered Roller Bearing Removing
W-126* Driver — Pinion Bearing Cup
W-128* Installer — Differential Inner Oil Seal W-129 Spreader — Differential
Carrier
Housing
W-138* Driver & Adapter —
King
Pin Bearing
W-144* Wrench — Wheel Bearing Adjusting Nut W-147* Driver — Pinion Oil Seal W-163* Puller
—-
Axle Shaft Drive Flange
W-186* Driver — Axle Shaft Oil Seal
W-188* Driver — Differential Case Bearing W-251* Puller — Pinion Oil Seal
W-262*
Sleeve
— Pinion Bearing Installing

W-263
Semi-Floating
Rear
Axle Shaft Oil Seal W-264* Driver — Pinion Outer Bearing Cup
W-297* Torque Wrench — Pinion Bearing Adjusting W-343* Remover
85
Installer —
Rear
Axle Bearing (Flanged Axle)
W-344* Installer — Pinion Inner Bearing Cups

C-319-A
Puller —
Rear
Wheel Hub (Tapered Axle Shaft)
C-690 Checking Scale —
King
Pin Bearing Preload DD-914-P Press — Tapered Roller Bearing Removing
DD-914-9 Reducer Ring — Differential & Pinion Bearings (Use with DD-914-P)

C-3
716 Driver — Differential
Carrier
Bearing C-4142
Gear
Rotating Tool —
Trac-Lok
Differential
**Jeep*
exclusive
tool

Steering
Group

C-3646 Puller, Steering Shaft Arm

Brake
Group

W-172 Puller, Parking Brake Drum
U-12.
STflNDfiRD
AND
RECOMMENDED
TOOLS

Tool
Description
ENGINE

W-292
Tester — Cooling
System
Thermostat
C-119 Indicator — Cylinder Bore C-385 Compressor — Piston Ring
C-647 Fixture — Spring Testing
C-823
Hone
— Cylinder Bore Refinishing
C-3012 Reamer — Cylinder Ridge
C-3250 Pliers — Radiator fis Heater
Hose
Wire Clamp
C-3411
Gauge — Pressure & Vacuum
C-3422-A Compressor — E-type Valve Spring
C-3501
Hone
— Cylinder
Deglazing
C-3514
Flusher — Cooling
System

C-3886 Fixture — Carburetor Holding C-3896-A Tachometer — Portable
C-3943 Gauge — Compression Checking
C-3952 Torque Wrench, 150
lb-ft.
Swivel Head C-3953 Stand, Engine Repair
C-3959 Light — Ignition Timing
C-4065 Wrench — Oil Filter Removing
C-4080 Tester — Cooling
System
fig
Pressure Cap

ELECTRICAL

40B Hydrometer — Battery Service
W-291 Tester — Instrument
C-3674
Aimers —
Headlight
(Pair)
C-3829 Tester —
Diode
Polarity
C-3888 Tester — Volt-Ampere C-3950 Tester — 12V 60 Amp. Carbon Pile Resistor 361