1953 JEEP DJ light

'Jeep5
UNIVERSAL SERIES SERVICE
MANUAL

D
Driver
W-238 is equipped
with
an
adapter
ring

which
correctly positions the guides. See Fig. D-23. Start a new exhaust valve guide, blunt (nontapered)
end
first,
into
the valve guide bore in the top of the cylinder block. When properly positioned, the
top end of the guide is exactly
1
"
[25,4 mm.] below
the level of the top of the block as shown in Fig.
D-24.
Start
a new intake valve guide, tapered end
first, into position from the
bottom
of the cylinder

head.
When properly positioned, the end of the
guide is just flush with the end of the valve guide
bore in the cylinder head as shown in Fig. D-24.

Run
a reamer (Tool
C-3 8)
through the new
guides

after they have been correctly positioned.

D-62. Tappets
and
Cover

The
valve tappets are lubricated through oil troughs cast in the crankcase. The troughs are
filled by oil sprayed from the connecting rod ends

and
passages are drilled through the tappet
guides
to
carry
the oil to the tappets. A
groove
around the center of the tappet shank carries the oil up and down the guide.

Check
the threads and fit of the exhaust valve ad­

justing
screw in the exhaust valve tappets. The fit of a screw should be such that a wrench is required to
turn
it into or out of the tappet as
these
are of
the self-locking type. Replace the worn part, either
the screw or the tappet, or both, if there is
loose­

ness
between
the parts.
D-63.
Crankshaft Rear Bearing Seal

Oil
leakage through the
rear
main bearing is pre­ vented by a metal supported neoprene lip type

seal
which can readily be installed without remov­
ing the crankshaft.

Should
trouble be experienced with oil leaking

from
the
rear
main bearing there are several points

which
should be checked.

a.
Be sure that the identifying paint daub on the
bearing
cap is the same as that appearing on the
center bearing web.

b.
The bearing to crankshaft clearance must not
exceed .0029"
[0,0736
mm.].

c.
Place sealer on the faces of the
rear
bearing cap

from
the
rear
oil
groove
to the oil seal grooves.

d-
Be sure the rubber oil seals extend about 34" [6 mm.] below the
bottom
face of the cap.

e.
Be sure the oil pan gasket is not leaking.
f.
Check
to be sure the oil leak is not at the cam­
shaft
rear
bearing expansion plug or from the
crankcase.

D-64.
Floating Oil
Intake •
Refer to Fig. D-25 and D-26.

The
floating oil intake is attached to the
bottom

of the crankcase with two screws. The float and
screen causes it to ride, raise and lower with the
amount of oil in the pan.
This
prevents water or
dirt,
which
may have accumulated in the
bottom

of the oil pan, from circulating through the
engine

because the oil is drawn horizontally from the top

surface.
Whenever removed, the float, screen, and
tube should be cleaned thoroughly to remove any
accumulation
of
dirt.
Also clean the oil pan.

Fluctuating
oil pressure can usually be traced to

an
air leak
between
the oil float support and the

crankcase.

Be
sure the float support flange is flat.
Clean
both
the flange and the crankcase surfaces thoroughly
before installing a new gasket. Be sure the retaining
screws are tight.
D-65. Oil
Pump

The
oil pump is located externally on the left side
of the engine. In operation oil is drawn from the

crankcase
through the floating oil intake then passes through a drilled passage in the crankcase
to the pump from which it is forced through

drilled
passages to the crankshaft and camshaft
bearings. When it is necessary to remove an oil
pump,
first remove the distributor cover and
note
the position of the distributor rotor so that the pump may be reinstalled without disturbing the
ignition timing. To install the pump without dis­

turbing
the timing, the pump gear must be cor­

rectly
meshed with the camshaft driving gear to
allow
engagement
of the key on the distributor shaft with the pump shaft slot, without changing the position of the distributor rotor. Distributor
can
be installed only in one position as the slot and

driving
key are machined off-center.

The
oil pump consists of an inner and outer rotor

within
the pump body. An oil relief valve is mounted in the pump body which controls the oil

pressure.
To disassemble the pump, Fig. D-27, first remove the gear which is retained by straight

pin.
It
will
be necessary to file off one end of the
pin
before driving it out with a small drift. By re­
moving the cover the outer rotor and the inner

rotor
and shaft may be removed through the cover opening.
Failure
of the pump to operate at

full
efficiency may usually be traced to excessive
end float of the rotors or excessive clearance be­ tween the rotors. The clearance
between
the outer

rotor
and the pump body should also be checked.
Match
the rotors
together
with one
lobe
of the inner

rotor
pushed as far as possible into the notch of the outer rotor. Measure the clearance
between
the

lobes
of the rotors as shown in
Fig.
D-28.
This
clear­ ance should be .010"
[0,254
mm.] or less.
If
more, replace both rotors. Measure the clearance

between
the outer rotor and the pump body as
shown in Fig. D-29. Should this clearance exceed .012" [0,305 mm.] the fault is probably in the
pump body and it should be replaced. End float
of the rotors is controlled by the thickness of the cover gasket which is made of special material that

can
be only slightly compressed. Never use other

than
a standard factory gasket.
Check
the cover
to be sure the inner surface is not rough or scored

and
that it is flat within .001" [0,025 mm.]
tested

with
feeler
gauges,
Fig. D-30. Measure thickness of
the rotors which must be within .001" [0,025 mm.]
of each other. Assemble the rotors in the pump body and install the cover without the gasket.
When
the cover screws are tightened to normal
tension, there should be interference
between
the
rotors and the cover making it impossible to
turn
the pump shaft by hand. Remove the cover and re- 57

'Jeep*
UNIVERSAL SERIES SERVICE
MANUAL

D

10262

FIG.
D-26—FLOATING OIL INTAKE AND PAN 1—
Oil
Float

2—
Gasket

3—
Oil
Float Support

4—
Screw and Lockwasher 5—
Oil
Pan Gasket
6—
Oil
Pan 7—
Bolt
and Lockwasher
8—
Drain
Plug
9—
Drain
Plug Gasket
place it with the gasket in position. The rotors
should then rotate freely, providing that end float of the rotors is
less
than the thickness of the gasket
when compressed or .004" [0,102 mm.]. After as­
sembling the gear on the pump shaft, check the
running
clearance
between
the gear and pump body with a feeler
gauge.
This
clearance should be

from
.022" to .051" [0,559 a 1,295 mm.].

Pump
output is controlled by a pressure relief valve.

CAUTION:
The oil pressure relief spring is
cali­

brated.
Never stretch this spring to alter the relief valve pressure setting. Adjust this setting by the use of shims only. Shims are available that can be
added
between
the retainer and the spring to in­
crease pressure. When shims are present, removing
shims
will
decrease pressure.

This
adjustment
will
change the pressure at higher

speeds
but not at idle speed. Safe minimum pres­

sure
is 6 psi. [0,4 kg-cm2] at idle, at which point
the oil pressure light
goes
out; and 20 psi. [1,4
kg-cm2] at
2000
rpm. (32 mph. [51 kph.]).

D-66.
Oil Pan

Examine
the oil pan carefully for evidence of cor­

rosion,
dents, or other damage. Special attention
should be given to the mounting flange to be sure of proper alignment and a tight seal at the cylinder
block, oil pan, and
engine
front plate. Whenever
the oil pan is removed, it is
best
to install a new

oil
pan gasket.

D-67.
Flywheel

The
flywheel is mounted on the
rear
flange of the
crankshaft.
The crankshaft, flywheel, and clutch
assembly are statically and dynamically balanced
separately and as a unit; therefore,
these
com­

ponents
should be assembled in their original
rela­

tive positions to maintain this balance.

D-68.
Flywheel Inspection

Clean
the flywheel thoroughly with cleaning sol­ vent. Inspect the clutch face of the flywheel for

a
burned or scuffed condition or rivet grooves.

Check
the flywheel for run-out or improper mount­
ing according to the installation procedure given

in Par.
D-87.

If
the inner ends of the flywheel ring gear
teeth
are
only slightly burred cr snubbed, remove the burrs
and
reshape the
teeth
using a small emery wheel. 59

D
HURRICANE
F4
ENGINE d.
Remove the intake valve adjusting screw lock-
nuts from each of the rocker arm valve lash ad­

justing
screws. Remove the screws from the rocker
arms.

D-76.
Inspection and
Repair

Run
a round wire brush through the bore of the

rocker
arm shaft and clean out the drilled oil holes.
Clean
out the oil
holes
in the rocker arm shaft

brackets,
and the oil
holes
and
grooves
in the bores
of the rocker arm.
Inspect
the diameter of the shaft at the rocker arm

bearing
areas. Replace the shaft if there are scores

or
abrasion marks along the length of the shaft.
Check
the shaft for alignment by rolling it across

a
smooth level surface. If the shaft
will
not
roll
freely, or if it rolls with a bumping motion, the
shaft is out of alignment and must be replaced.
Inspect
the threads of the adjusting screw
hole
in
the rocker arms and if necessary clean with a

proper
size tap. Replace the adjusting screw lock-
nut or the adjusting screw if either part is damaged

or
deformed.

Inspect
the threads in the tapped
hole
in the top
of the rocker arm shaft brackets and if necessary

clean
with a proper size tap. Replace the bracket

if
either side is worn or scored.

D-77.
Reassembly

a.
Install
two rocker arm shaft plugs, one in each
end of the shaft. Slide two
rocker
arm
shaft brackets
onto
the center of the shaft. Align the tapped
holes

in
the brackets with the drilled
holes
in the top of
the shaft and install the rocker arm shaft lock
screws,
making sure the points of the screws enter
the drilled
holes
in the shaft.

b.
Screw the intake valve adjusting screws into
the rocker arms and install the locknuts.

c.
The rocker arms are paired; that is, two of the
arms
are angled to the right and two are angled to
the left. One of each type is used on each end of
the rocker arm shaft. Slide a rocker arm with the

adjusting
screw end of the rocker arm angling

away
from the bracket
onto
the shaft so that the
adjusting
screw is on the same side of the shaft
as the mounting
hole
in the bracket.

d.
Temporarily
secure the end bracket in place by
installing
a rocker arm cover stud in the tapped
opening in the top of the support.
e. Assemble the parts on the
opposite
end of the
rocker
arm shaft repeating
steps
c and d above.

D-78. ENGINE REASSEMBLY
The
engine
reassembly procedure in the following

paragraphs
is given in the sequence to be followed
when the
engine
is being completely overhauled.
Individual
inspection,
repair,
and fitting operations
previously covered in detail are made throughout
the reassembly procedure. The reassembly pro­
cedure
does
not cover accessories. If a new cylinder

block
fitted with pistons is used, many of the
operations
will
not be required.
Mount
the cylinder block in an
engine
repair stand.
If
an
engine
stand is not available, perform the fol­
lowing reassembly operation in a manner designed to protect personnel against an accident and the

engine
and its parts against damage.

Note:
During
engine
reassembly, use Perfect Seal

Aerosol
Spray
Sealer
Part
No.
994757
on all
engine
gaskets to ensure against vacuum, oil, gasoline and

water
leaks. Apply to head gaskets, valve covers,
water
pumps, oil pan gaskets, radiator and heater
hose
connections, felt gaskets, gasoline and oil line
connections, stud bolts,
spark
plug threads, and
grease retainer washers. Refer to manufacturer's in­
structions on container for proper application pro­
cedure.

D-79.
Install
Oil
Gallery
Plug

Coat
plug threads with a suitable sealing compound

and
install the plugs in the front and
rear
ends of
the oil gallery in the cylinder block and the
rear

end of the cylinder head. Torque the plugs 20 to 25 lb-ft. [2,8 a 3,4 kg-m.].

There
is also a pipe plug
(}/g,f
[3,2 mm.] slotted, headless) in the opening in the main oil gallery inside the cylinder block at No. 2 cylinder and another pipe plug
(}/g
"
square-head) in the opening

in
the oil passage directly below the oil pump intake
passage. If
these
two pipe plugs were removed,
make
certain they are reinstalled in the locations
described above or the counterweight of the

crankshaft
might strike the projecting head of the
square-head
plug.

D-80.
Install
Tappets

Turn
the block upside down. Beginning at the

rear
end of the cylinder block, install the intake

and
exhaust valve tappets in the tappet bores in the cylinder block in the following order: one
exhaust, two intake, two exhaust, two intake, and
finally
one exhaust valve tappet.

Check
the tappet to bore fit of each tappet as it
is installed in the block. If the stem-to-block

clearance
tolerance of .0005" to .002" [0,0127 a
0,051 mm.] is
exceeded
install a new tappet fitting
within
this tolerance or ream the bore to accomo­ date the next oversize tappet which is available

in
.004" oversize.

D-81.
Install
Camshaft and
Thrust
Plate

Lubricate
all camshaft bearings and cam surfaces generously with clean, light
engine
oil.
Carefully,

so not to damage or score the camshaft front bear­
ing,
install the camshaft, locating it properly in the bearings. Do not allow the
rear
end of the cam­shaft to strike sharply against the expansion plug

installed
in the
rear
end of the bore.
Install
the camshaft thrust plate. Slide the thrust
plate spacer
onto
the end of the camshaft with the
beveled inner
edge
of the spacer facing the cam­
shaft. If the same camshaft is being reinstalled,
install
any shims previously removed. These shims
are
placed
between
the camshaft shoulder and the

spacer.
Torque the thrust plate attaching
bolts
20
to 26 lb-ft. [2,8 a 3,6 kg-m.].

End
play of the camshaft is determined by running
clearance
between
the
rear
face of the camshaft
gear and the thrust plate. The standard clearance 62

'Jeep'
UNIVERSAL SERIES SERVICE
MANUAL

D
is .004" to .007"
[0,102
a 0,178 mm.] as measured
by a dial indicator. Should a check
show
too little
end play, place a shim of suitable thickness
between

the camshaft shoulder and the spacer. Too much
end play may be corrected by removing shims or
dressing off the spacer a slight amount. See Fig. D-33.
D-82. Install Crankshaft and Bearings

Fit
the three upper main bearings
into
their
respective
locations
in the cylinder block. Fit the
three lower main bearings
into
their respective
bearing caps.

NOTE:
It is
possible
to incorrectly install the front main bearing. The bearing is properly installed in
the cap with the narrower of the two radial oil

grooves
toward the front
edge
of the cap. If this
bearing is not properly installed, the oil
grooves
in
the two halves of the bearing will not match at the
parting line and premature failure of the bearing

will
result.
Lubricate
all bearing surfaces
generously
with
clean, light
engine
oil. Place the crankshaft in

position
in the cylinder block and install the main
bearing caps. Torque the
bolts
65 to 75 lb-ft.
[9,0 a 10,4 kg-m.] rotating the crankshaft after
each bearing cap is
tightened

D-83. Check Crankshaft End-Play

End
play of the crankshaft is set by the running
clearance
between
the crankshaft thrust washer
and the front
face
of the front main bearing. The
standard end play is .004" to .006"
[0,102
a 0,152
mm.] which is controlled by .002"
[0,051
mm.]
shims placed
between
the thrust washer and the
shoulder on the crankshaft. Check the end play
with a dial indicator as shown in
Fig.
D-34. If clear­ ance is incorrect, adjustment is made by adding or
removing shims.
Install
the thrust washer with the
beveled
inner

edge
toward the front bearing.
10668

FIG.
D-33—VALVES, CAMSHAFT,
AND
TIMING GEARS
1— Nut
2—
Left
Rocker Arm
3—
Rocker
Arm Shaft Spring
4—
Rocker
Shaft
Lock
Screw 5—
Rocker
Shaft
6— Nut 7—
Right
Rocker Arm
8—
Rocker
Arm Shaft Bracket
9—
Intake
Valve Tappet Adjusting Screw
10—
Intake
Valve Upper Retainer
Lock

11—
Oil
Seal
12—
Intake
Valve Spring Upper Retainer 13—
Intake
Valve Spring
14—
Intake
Valve Push Rod 15—
Intake
Valve
16—
Intake
Valve Tappet
17—
Camshaft

18—
Camshaft
Front Bearing
19—
Camshaft
Thrust Plate Spacer
20—
Camshaft
Thrust Plate
21— Bolt and Lockwasher
22— Bolt 13—Lockwasher
24—Camshaft
Gear
Washer 25—
Crankshaft
Gear

26—
Camshaft
Gear

27— Woodruff Key No. 9
28—
Exhaust
Valve Tappet
29— Tappet Adjusting Screw
30—
Spring
Retainer
Lock

31— Roto Cap Assembly
32—
Exhaust
Valve Spring
33—
Exhaust
Valve
34—
Rocker
Shaft Support Stud
35—
Washer

36—
Rocker
Arm Cover Stud 63

D
HURRICANE
F4
ENGINE

FIG.
D-34—GAUGING
CRANKSHAFT
END
PLAY
FIG.
D-35
—
DRILLING FLYWHEEL
D-84.
Install
Crankshaft Timing
Gear

Install
the woodruff key in the longer of the two keyways on the front end of the crankshaft.
Install

the crankshaft timing gear on the front end of the crankshaft with the timing
mark
facing out, away from the cylinder block. Align the
keyway in the gear with the woodruff key and then

drive
or press the gear
onto
the crankshaft firmly against the thrust washer.

D-85.
Install
Crankshaft
Rear
Bearing Seal

When
installing the crankshaft
rear
bearing seal

around
the crankshaft, apply a thin coat of light cup grease to both halves of the seal except for the
ends which are already treated with sealing com­ pound. When installing the
rear
main bearing cap

in
the crankcase, place a small amount of plastic- type gasket cement on both sides and face of the
cap to prevent oil leakage. Insert the rubber
packings shown in
Fig. D-3
7
into the
holes
between
the bearing cap and the case. Do not trim
these

packings. The packings are of a predetermined
length that
will
cause them to protrude approxi­ mately 34* [6 mm.] from the case. When the oil

pan
is installed, it
will
force them tightly into the

holes
and effectively seal any opening
between

the bearing cap and the crankcase.

D-86.
Install
Front
End Plate
Assemble the gasket to the front end plate making

certain
that it is positioned properly down to the

bottom
of the crankcase.
Install
the front end plate
on the cylinder block and tighten in place.

D-87.
Install
Flywheel

Be
sure the crankshaft flange and flywheel mating
surfaces are clean to permit proper flywheel align­ ment. With the crankshaft in the cylinder block,
FIG.
D-36—
REAMING FLYWHEEL

FIG.
D-37—REAR
BEARING
CAP
PACKING

64

D

HURRICANE
F4
ENGINE

FIG.
D-40—TIMING
GEARS Be
sure
to install a new rubber oil
seal
ring on each

intake
valve stem before installing the retainer

locks.
With
the retainer and spring compressed position a
seal
ring
on the valve stem just above the

lock
recess, then install the locks and release the
spring.

Adjust
the valve tappets to the proper specified

clearance.
Refer to Par. D-108, and specifications
at the end of this section for specifications and
adjustment procedure.

D-91.
Install
Camshaft
Timing
Gear

Turn
the camshaft or crankshaft as necessary so
that the timing marks on the two gears
will
be
together
after the camshaft timing gear is installed.

Refer
to Fig. D-40.
Install
the woodruff key in the key way on the front end of the camshaft.
Start
the large timing gear on the camshaft with the timing

mark
facing out. Do not drive on the camshaft gear, or the camshaft may
dislodge
the plug at the

rear
of the cylinder block causing an oil leak.
Install
the camshaft gear retaining screw and
torque it 30 to 40 lb-ft. [4,1 a 5,5 kg-m.] drawing
the gear
onto
the camshaft in the process. Standard
running
tolerance
between
the timing gears is .000" to .002" [0 a 0,051 mm.] which should be
checked with a
dial
indicator.

D-92.
Install
Timing
Gear
Oil Jet

Install
the timing gear oil jet in the tapped
hole

in
the front of the cylinder block. Position the oil

hole
in the side of the oil jet so that it
will
direct the

oil
stream against the camshaft driven gear just
ahead
of the point of
engagement
with the
crank­
shaft drive gear.

D-93.
Install
Oil Pump

The
oil pump is driven from the camshaft by means of a
spiral
(worm) gear. The distributor, in

turn,
is driven by the oil pump by means of a

tongue
on the end of the distributor shaft which
engages
a slot in the end of the oil pump shaft.
Because the
tongue
and the slot are both machined off center, the two shafts can be meshed in only
one position. Since the position of the distributor shaft determines the timing of the engine, and is
controlled by the oil pump shaft, the position of the oil pump shaft with respect to the camshaft is

important.

Turn
the crankshaft to bring
together
the timing
marks
on the crankshaft and camshaft gears. See

Fig.
D-4 0.
Install
the oil pump mounting gasket on
the pump.
With
the wider side of the shaft on top
(nearer
the top of the cylinder block), start the

oil
pump drive shaft into the opening in the left side of the cylinder block with the mounting
holes
in
the body of the pump in alignment with the
holes
in
the cylinder block. Insert a long-blade screw­

driver
into the distributor shaft opening in the

opposite
side of the block and
engage
the slot in the oil pump shaft.
Turn
the shaft so that the slot is positioned at what would be roughly the nine-

thirty
position on a clock face. Remove tne screwdriver and, looking down the

distributor
shaft
hole
with a flashlight, observe the position of the slot in the end of the oil pump shaft
to make certain it is properly positioned. Replace the screwdriver and, while turning the screw­

driver
clockwise to guide the oil pump drive shaft
gear into
engagement
with the camshaft gear, press
against the oil pump to force it into position. Remove the screwdriver and again observe the
position of the slot. If the installation was properly made, the slot
will
be in a position roughly equiva­
lent to eleven o'clock position on a clock face with
the wider side of the shaft
still
on the top. If the
slot is improperly positioned, remove the oil pump
assembly and repeat the operation.

Coat
the threads of the capscrews with gasket
cement and secure the oil pump in place with two
lockwasher-equipped capscrews installed through the body of the oil pump and into the cylinder block

and
one lockwasher-capscrew installed through
the oil pump mounting flange.

D-94.
Install
Timing
Gear
Cover

Apply
a thin coat of gasket paste to the timing
gear cover. Position the gasket on the cover and

carefully
locate the cover on the front of the front mounting plate. Attach the cover and timing

indicator
and tighten the bolts.

D-95.
Install
Pistons and Connecting Rods
Before installing each piston and connecting rod assembly in the cylinder block, generously lubricate
the entire assembly with
engine
oil. Space the ring
gaps
around the piston so that no two
gaps
are
aligned vertically and are not located over the
T-slot
in the piston
skirt.
Insert the assembly in
the correct cylinder with the connecting rod
identifying number toward the camshaft side of
the cylinder block. When installing each assembly, rotate the crankshaft so that the
crankpin
is in
the down position. Fit a piston ring compressor
tightly around the piston rings. Reach up from the
bottom
of the cylinder block and guide the end of
the connecting rod over the crankshaft
journal
as
the piston is tapped down into the cylinder bore

with
hammer handle. 66

'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