1953 JEEP DJ spark plugs

'Jeep'
UNIVERSAL
SERIES SERVICE
MANUAL

D
Lubricate
the connecting rod bearing surfaces
generously with
engine
oil and install the bearing
cap with the numbered side matched to the num­
bered side of the connecting rod. Torque the nuts
evenly 35 to 45 lb-ft. [4,8 a 6,2 kg-m.]. The con­
necting rod cap nuts are locked with stamped nuts.

Used
stamped nuts should be discarded and re­
placed with new
ones.
These locking stamped nuts
should be installed with the flat face toward the
connecting rod nut.
Turn
the locking nut finger
tight and then 34
turn
more with a wrench. Refer
to Par. D-36 for detailed information on fitting pistons and rings in the cylinder bores.

D-96.
Install
Crankshaft
Pulley

Align
the keyway in the pulley with the woodruff key installed in the crankshaft. Drive the pulley

onto
the crankshaft and secure it in place with
the crankshaft pulley nut. Insert a block of wood

between
one of the counterweights on the
crank­

shaft and the side of the cylinder block to prevent the crankshaft from turning, then tighten the nut.

D-97.
Install
Oil Pan
Before installing the oil pan, make a final internal
inspection particularly making certain that the
inside of the cylinder block is clean. Apply a thin
coat of gasket paste on the oil pan. Place the new

oil
pan gasket in position. Set the oil pan in posi­
tion on the cylinder block and install the oil pan.
Torque
the attaching
bolts
12 to 15 lb-ft. [1,7 a 2,1

kg-m.].
Install
the oil pan
drain
plug and gasket

and
tighten the plug securely.

D-98.
Install
Cylinder
Head

Make
certain that the entire top of the cylinder

block
assembly, the lower surface of the cylinder

head,
and the cylinder head gasket are clean. Blow

all
dirt
or carbon out of the blind tapped bolt
holes

in
the cylinder block before the cylinder head and gasket are installed. Using aerosol spray sealer

Part
No. 994757, spray a thincoat on both surfaces
of the head gasket, position the new cylinder head gasket with the crimped
edges
of the gasket metal down (See Fig. D-31).
This
gasket position allows a
positive seal along the narrow surfaces of the
cylin­

der
head
between
the combustion chambers and
eliminates the possibility of burning combustion
10102

FIG.
D-41—CYLINDER
HEAD
BOLT
TIGHTENING
SEQUENCE
gases
reaching
an
asbestos
portion of the cylinder
head gasket.
Install
the cylinder head bolts. Tighten

the
bolts
with a torque wrench to 60 to 70 lb-ft. 8,3 a 9,7
kg-m.]
in the sequence shown in
Fig.
D-41.
Do not overlook installing the cylinder head bolt

in
the intake
manifold
directly under the
car­

buretor
opening.

D-99.
Install
Rocker Arm Assembly

a.
Insert
ball
ends of the intake valve push rods through the cylinder head and cylinder block and
seat them in the cupped head of the intake valve
tappets.

b.
Install
the
rocker-arm
assembly on the 'four

rocker-arm-mounting
studs. Align the rocker arms
so that the
ball
ends of the intake valve tappet

adjusting
screws fit into the cup ends of the push
rods.

c.
Install
the four rocker-arm-attaching nuts.
Thread
each nut down evenly in sequence, one

turn
at a time, until the torque is 30 to 36 lb-ft. [4,1 a 5,0 kg-m.].

d.
Cement a new gasket on the rocker arm cover.
Install
the cover placing an oil seal then a flat

washer
and nut on each cover stud. Cement a new gasket on the exhaust valve cover.
Install
the cover and crankcase ventilation fittings using a
new gasket back of the vent cover and new copper
ring
gaskets under the attaching screw heads.

Torque
the valve tappet cover nuts 7 to 10 lb-ft. [1,0 a 1,4 kg-m.].
D-100.
Install
Distributor and
Spark
Plugs

To
correctly install the distributor, it
will
be neces­

sary
to place No. 1 piston in the firing position.
To
locate the firing position of No. 1 piston, first

turn
the
engine
until No. 1 piston is moving up on
the compression stroke as indicated by compression

pressure
being forced through the
spark
plug open­

ing.
Turn
the
engine
slowly until the 5° before top
center
mark
on the timing gear cover is in align­
ment with the
mark
on the crankshaft pulley. Oil
the distributor housing where it bears on the
cylin­
der
block and install the distributor. Mount the

rotor
on distributor shaft and
turn
the shaft until
the rotor points towards No. 1
spark
plug terminal
tower position (when cap is installed, about 5
o'clock) with the contact points just breaking.
Move the rotor back and forth slightly until the

driving
lug on the end of the shaft enters the slot cut in the oil pump gear and slide the distributor
assembly down into place. Rotate the distributor body until the contact points are just breaking.
Install
the hold down screw.

Connect
the core
primary
wire to the distributor.

Clean
and adjust the
spark
plugs, setting the elec­

trode
gaps
at .030" [0,762 mm.].
Install
the plugs
to prevent any foreign matter entering the com­
bustion chambers during the remaining operations.
Torque
the
spark
plugs 25 to 30 lb-ft. [3,5 a 4,6

kg-m.].

Install
spark
plug cables, placing them in the dis­

tributor
cap terminal towers starting with No. 1

and
installing in a counter clockwise direction of
the firing order sequence (1-3-4-2). 67

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

D

HURRICANE
F4
ENGINE
D-112.
SERVICE
DIAGNOSIS

Poor
Fuel
Economy Ignition Timing Slow or Spark Advance Stuck

Carburetor
Float High
Accelerator Pump Not Properly Adjusted
High
Fuel
Pump Pressure

Fuel
Leakage
Leaky
Fuel
Pump Diaphragm
Loose Engine Mounting Causing High
Fuel
Level

in
Carburetor

Low
Compression Valves Sticking

Spark
Plugs Bad

Spark
Plug Cables Bad Weak
Coil
or Condenser Improper Valve Tappet Clearance

Carburetor
Air Cleaner Dirty
High Oil Level in Air Cleaner Dragging Brakes

Front
Wheels Out of Alignment
Tires
Improperly Inflated Inaccurate Odometer

Faulty
Fuel
Tank
Cap

Clogged
Muffler or Bent Exhaust Pipe

Lack
of Power
Low
Compression Ignition System (Timing Late)
Improper Functioning Carburetor or
Fuel
Pump

Fuel
Lines
Clogged
Air
Cleaner Restricted
Engine Temperature High Improper Tappet Clearance
Sticking Valves Valve Timing Late

Leaky
Gaskets
Muffler
Clogged
Bent Exhaust Pipe

Defective
Spark Plugs—Clean or Replace
Defective
Breaker Points—Replace
Points

Incorrect Breaker Point Gap—Reset
Points

Defective
Condenser or Coil—Replace
Loose Electrical Connections—Locate and Tighten
Broken Valve Spring—Replace Spring Broken Piston or Rings—Replace
Defective
Head Gasket—Replace Gasket
Cracked
Distributor Cap—Replace Cap

Low
Compression
Leaky
Valves
Poor Piston Ring Seal Sticking Valves
Valve Spring Weak or Broken
Cylinder
Scored or Worn
Tappet Clearance Incorrect
Piston Clearance too Large
Leaky
Cylinder Head Gasket
Burned Valves and
Seats
Sticking Valves or too Loose in Guides Improper Timing
Excessive Carbon Around Valve Head and Seat Overheating
Valve Spring Weak or Broken Burned Valves and Seats—Continued
Valve Tappet Sticking
Valve Tappet Clearance Incorrect
Clogged
Exhaust System
Valves Sticking Warped Valve Improper Tappet Clearance
Carbonized or Scored Valve
Stems
Insufficient Clearance Valve Stem to Guide
Weak or Broken Valve Spring Valve Spring Cocked Contaminated Oil
Overheating Inoperative Cooling System
Thermostat Inoperative Improper Ignition Timing
Improper Valve Timing
Excessive Carbon Accumulation

Fan
Belt too Loose

Clogged
Muffler or Bent Exhaust Pipe

Oil
System Failure
Scored or Leaky Piston Rings

Popping-Spitting-Detonation
Improper Ignition
Improper Carburetion
Excessive Carbon
Deposit
in Combustion
Cham­
bers
Poor Valve Seating Sticking Valves
Broken Valve Spring Tappets Adjusted too Close

Spark
Plug Electrodes Burned
Water or Dirt in
Fuel
Clogged
Lines Improper Valve Timing
Excessive Oil Comsumption Piston Rings Stuck in Grooves, Worn or Broken Piston Rings Improperly Fitted or Weak Piston Ring Oil Return
Holes
Clogged
Excessive Clearance, Main and Connecting Rod
Bearings

Oil
Leaks at Gaskets or Oil Seals
Excessive Clearance, Valve Stem to Valve Guide (Intake)

Cylinder
Bores Scored, Out-of-Round or Tapered Too Much Clearance, Piston to Cylinder Bore
Misaligned Connecting Rods
High Road
Speeds
or Temperature
Crankcase
Ventilator Not Operating
Bearing Failure
Crankshaft
Bearing Journal Out-of-Round

Crankshaft
Bearing Journal Rough

Lack
of Oil
Oil
Leakage
Dirty
Oil

Low
Oil Pressure or Oil Pump Failure
Drilled
Passages
in Crankcase or Crankshaft
Clogged

Oil
Screen Dirty Connecting Rod Bent 70

'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

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

'Jeep1
UNIVERSAL
SERIES
SERVICE
MANUAL

Dl

FIG.
D1-43—INTAKE
MANIFOLD
SEAL
INSTALLATION

1—Seal 2—Cylinder Head ing
hole
at left side of timing chain cover. If timing

chain
and sprockets have not been removed from
engine, install distributor with rotor in position
noted during distributor removal. Fasten distributor
to timing chain cover with retaining bracket and
mounting screws. If distributor is aligned, torque
screw
18 to 20 lb-ft. [2,5 a 2,8 kg-m.].

Dl-100.
Install Spark Plugs

Install
spark
plugs in cylinder heads. Torque 25
to 33 lb-ft. [3,5 a 4,6 kg-m.].
Install
spark
plug cable retainers on brackets welded to rocker arm
covers. Fit cables into retainers and connect to
spark
plugs, as indicated by cable numbers molded
into distributor cap and by
spark
plug firing order
pressed into each rocker arm cover.

Dl-101.
Install Intake Manifold
and
Carburetor
Assembly

a.
Install
a new rubber intake manifold seal at
front and
rear
rails
of cylinder block. Be sure
pointed ends of seals fit snugly against block and
cylinder
heads. See Fig. Dl-43.

b.
Set intake manifold in place on cylinder block

between
cylinder heads.
Thread
two cap
bolts
through manifold into each cylinder head as guide
bolts.
Lift
the manifold slightly and insert each
of two gaskets into position
between
manifold
and
corresponding cylinder head. Be certain that
the gasket is installed with its three apertures
FIG.
Dl-44—INTAKE
MANIFOLD

GASKET
INSTALLATION

1—Gasket
2—Guides Bolts aligned with ports of the head and manifold. One
gasket should be installed in position on the left
side, as shown in Fig. Dl-44, and its counterpart

reversed
for right side installation.

c.
Install
manifold attaching bolt in open bolt

hole
at right side of intake manifold. See
Fig.
Dl-46.
Open
bolt
hole
is held to
close
tolerances, so that
the bolt in this location serves to locate the mani­
fold front and
rear.

d.
Install
remaining manifold-to-cylinder head bolts, with longer
bolts
at forward location. Begin­
ning
with the number 1 and 2 bolts, see
Fig.
Dl-45,
tighten gradually and equally until both
bolts
are
snug.
This
will
prevent the manifold from shifting due to
full
torque being applied to only one bolt.

Then
continue in the sequence illustrated in Fig.

Dl-45
until the rest of the
bolts
are also snug.

Finally,
using the same sequence, torque all
bolts
to 45 to 55 lb-ft. [6,2 a 7,6 kg-m.].
12750

FIG.
Dl-45—INTAKE
MANIFOLD
BOLT
TIGHTENING
SEQUENCE

103

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

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