1953 JEEP DJ fuel

E

FUEL
SYSTEM E-79.
FUEL
SYSTEM SPECIFICATIONS
(Continued)

MODEL
EARLY
MODEL
HURRICANE
F4
EARLY
MODEL
DAUNTLESS
V-6

AIR CLEANER:
Type
Oil
Bath

Oil
Bath

FUEL
TANK: 10H
gal. [39,75 ltr.]
10lA
gal. [39,75 ltr.]

Location
Under
Driver's Seat

Under
Driver's Seat

FUEL
PUMP:
AC
or
Carter
A.C.

Model
5594032
21955

6440515

Type..
Diaphragm,
serviceable unit
Disposable unit

FUEL
FILTER:
Tank
unit only
Left
side of engine, plus tank unit

MODEL
LATE
MODEL
HURRICANE
F4
LATE
MODEL
DAUNTLESS
V-6

AIR CLEANER:
Type...
Oil
Bath

Dry
Type

FUEL
TANK:
Capacity
16 gal. [60,57 ltr.]
16 gal. [60,57 ltr.]
Between frame
rails,
rear
of vehicle Between frame
rails,
rear
of vehicle

FUEL
PUMP:
Make.
Carter

A.C.

Model.
. 4574-S

6440515

Type
Diaphragm,
serviceable unit
Disposable unit

FUEL
FILTER:
Left
side of engine, plus tank unit
Left
side of engine, plus tank unit 136

'Jeep*
UNIVERSAL SERIES SERVICE
MANUAL

F EXHAUST SYSTEM

Contents

SUBJECT
PAR.

GENERAL
.F-l Dauntless V-6 Engine Exhaust System....
F-3

Hurricane
F4 Engine Exhaust System....
F-2

MAINTENANCE
REQUIREMENTS
F-4

EXHAUST SYSTEM SERVICING
F-5
SUBJECT
PAR.

Exhaust
Manifold Installation. .F-6
Exhaust
Pipe(s) Replacement F-8

Heat
Control Valve Replacement F-7

Muffler
Replacement F-9
Tail
Pipe Replacement F-10

EXHAUST SYSTEM SPECIFICATIONS.
.
F-11

F-L
GENERAL
The
major components of the exhaust system (Figs.
F-l,
F-2 and F-3) are the exhaust manifold(s), ex­
haust pipe(s), muffler and tail pipe. Differences in
the exhaust system occur depending on whether the vehicle is equipped with the Hurricane F4 or
Dauntless V-6 engine.

Note:
For service information on exhaust emission
control systems, refer to Section Fl and F2 of this

manual.
F-2. Hurricane
F4 Engine Exhaust System

On
the Hurricane F4 engine, the exhaust and in­
take manifolds are separate units. The intake mani­
fold is cast as an integral part of the cylinder head

and
is completely water jacketed.
This
construction

transfers
heat from the cooling system to the in­
take riser and assists in vaporizing the fuel when
the
engine
is cold.

With
this construction, there is no heat control
valve on the
engine
and the only function of the exhaust manifold is to gather and direct the exhaust
FIG.
F-l—HURRICANE F4 ENGINE EXHAUST
SYSTEM
—
EARLY
MODEL
1—
Exhaust
Pipe
2—
Clamp

3—
Exhaust
Pipe Extension
4—
Clamp

5— Tail
Pipe 6—
Muffler
7—
Clamp

8—
Support
Strap

9—Bolt

10—Support
Strap
11—Bracket

12—
Insulator

13—
Bracket

14—
Nut
and
Lockwasher
15—
Washer

16—Bolt

17—
Gasket

18—
Bolt
19— Nut
137

F

EXHAUST
SYSTEM
12844

FIG.
F-2—DAUNTLESS
V-6
ENGINE
EXHAUST
SYSTEM
—
EARLY
MODEL
1—
Right
Exhaust
Pipe
19—Lockwasher

2—Tall
Pipe 20—Bolt

3—
Bolt
21—Bracket

4—
Bolt
22—Insulator

5—
Muffler
23—Nut 6—
Exhaust
Pipe
Extension
24—Bolt
7—
Crossover
Exhaust
Pipe
25—Clamp

8—
Bracket
26—U-Bolt 9—
Lockwasher
27—Saddle

10—
Nut
28—U-Bolt
11—
Saddle
29—Saddle

12—
Washer
30—Insulator

13—Bolt
31—U-Bolt
14—
Bracket
32—Nut

15—
Reinforcement
3
3—Lockwasher

16—
Nut
34—U-Bolt

17—
Lockwasher
35—Saddle

18—
Nut

gases
into the exhaust pipe.

When
assembling the manifold, to the cylinder
block
(Fig.
F-4)
new gaskets should be installed
and
the nuts drawn up evenly until they are tight
to avoid leakage. Torque manifold nuts to 29-35 lb-ft [4,0 a 4,84 kg-m.].

F-3.
Dauntless
¥-6
Engine
Exhaust System

Each
of two cylinder banks of a Dauntless V-6 engine has an exhaust manifold. On late production engines the right exhaust manifold is equipped

with
a heat collector manifold which supplies heated air to the air cleaner. See Fig. F-5.
Each
cylinder
exhausts through its own individual port
into a branch of its exhaust manifold. These
branches
conduct exhaust
gases
into the main mani­
fold branch which connects the exhaust pipe to
the muffler. A thermally-actuated heat control valve is located at the
rear
of the right exhaust

manifold.
This
valve has a bimetal thermostatic
spring
which holds it closed when the engine is

cold.

In
closed position, the valve deflects exhaust
gases

upward
through a passage in the intake manifold to the left exhaust manifold.
This
aids in vaporizing

fuel,
speeds
engine warm-up, and reduces oil
dilution.

Since
the valve plate is offset-mounted, the valve

will
be forced partially open at higher engine speed
and
load.
This
prevents excessive back pressure. 138

'Jeep'
UNIVERSAL
SERIES SERVICE
MANUAL

Fl
b. Connect tachometer to
engine.

c.
Warm
up
engine
and stabilize temperatures.

d.
Adjust
engine
idle to
speed
desired, using throt­
tle idle
speed
adjusting screw.

e.
Carburetors without Idle
Limiter
Cap turn idle mixture screws out (counterclockwise) until a
loss

of
engine
speed
is indicated; then, slowly turn mix­
ture screw in (clockwise-leaner) until maximum

speed
(RPM) is reached. Continue turning in (clockwise) until
speed
begins
to drop; turn mixture
adjustment back out (counterclockwise-richer) un­

til
maximum
speed
is just regained at a "lean as
possible" mixture adjustment.

Fl-14.
Distributor

Check
the distributor number for proper appli­
cation.
Check
the distributor cam dwell angle and
point condition and adjust to specifications or re­ place as required. (Specifications listed at the end
of this section)
Check
ignition timing and set at

0°
or
TDC.

Fl-15.
Anti-iackfire
Diverter Valve

The
anti-backfire valve remains closed
except
when
the throttle is closed rapidly from an
open
position.

To
check the valve for proper operation, accelerate
the
engine
in neutral, allowing the throttle to
close

rapidly.
The valve is operating satisfactorily when
no exhaust system backfire occurs. A further check
to determine whether the valve is functioning can be made by removing from the anti-backfire valve
the large
hose
Which
connects to the check valve.
Accelerate the
engine
to allow the throttle to
close

rapidly.
The valve is operating satisfactorily if a
momentary interruption of rushing air is audible.

Fl-16.
Check Valve

The
check valve prevents the reverse flow of ex­
haust
gases
to the pump in the
event
the pump
should, for any reason,
become
inoperative or should exhaust pressure ever
exceed
pump pressure.

To
check this valve for proper operation, remove the air supply
hose
from the pump at the
distri­

bution manifold.
With
the
engine
running, listen for exhaust leakage at the check valve which is
connected to the distribution manifold.

Fl-17.
Air
Pump

Check
for proper drive belt tension with belt tension
gauge
W-283. The belt strand tension should be

50-60
pounds on a belt with previous service, meas­

ured
on the
longest
accessible span
between
two pulleys. When installing a new belt, adjust the
tension to
60-80
pounds tension. DO NOT PRY
ON
THE DIE
CAST
PUMP
HOUSING.

To
check the pump for proper operation, remove the air
outlet
hose
at the pump.
With
the
engine

running,
air discharge should be
felt
at the pump

outlet
opening. The pump
outlet
air pressure, as determined by the relief valve, is preset and is not
adjustable.

The
air pump
rear
cover assembly, housing the pressed in inlet and discharge tubes, and the pres­
sure relief valve are the only pump
components

recommended for service replacement. These parts
are
to be replaced only when damaged as a result
of handling or in the
event
the relief valve was
tampered with.

Fl-18.
Carburetor
Air
Cleaner

Every
6000
miles
[9,600
km.] clean the inside
sur­

face at the sump and
refill
to indicated oil level with
SAE
40 or 50
engine
oil
above
32 F; SAE 20

below
32 F. Wash filter
element
in kerosene and

drain.
Reassemble the air cleaner.

More
frequent cleaning and replacement is advis­ able when the car is operated in dusty areas or on
unpaved roads. Accumulated dirt restricts air flow,
reducing fuel
economy
and performance.

Fl-19.
REMOVAL
PROCEDURES

The
following paragraphs
give
the procedures for removing the major units of the Exhaust Emission

Control
System and the required equipment
needed.

Fl-20.
Air
Pump

Loosen
the air pump adjusting strap to facilitate

drive
belt removal. Remove the air pump air dis­
charge hose(s) and air filter attachment. Separate
the air pump from its mounting bracket. At time of installation, torque tighten the air pump mount­ing
bolts
to
30-40
lbs-ft. [4,15 a 5,53 kg-m.]. Adjust
the belt strand tension to
50-60
pounds on a belt
with previous service and
60-80
pounds on a new
belt.

Fl-21.
Anti-Backfire
Diverter Valve

The
anti-backfire diverter valve removal requires disconnecting the
hoses
and bracket to
engine
at­
taching screws.

Fl-22.
Air
Distribution
Manifold
and
Injection Tubes

In
order to remove the air distribution manifold
without bending the tubing, which could result in
fractures
or leakage, it is necessary to remove the
exhaust manifold as an assembly from the
engine.

After
the exhaust manifold assembly is removed
from
the
engine,
place the manifold in a vise and

loosen
the air distribution manifold
tube
retaining nuts at each cylinder exhaust port. Tap the injec­
tion
tubes
lightly to allow the air distribution mani­
fold to be pulled away partially from the exhaust manifold. The stainless steel injection
tubes
in the
exhaust manifold may have
become
partially fused
to the air distribution manifold and, therefore, may
require
application of heat to the joint in order to
separate. While applying heat to the joint, rotate
the injection
tubes
with pliers being careful not to
damage the
tubes
by applying excessive force.

At
time of installation, the air injection
tubes
must
be positioned into the exhaust manifold prior to
placing the exhaust manifold assembly on the en­ gine.

Note:
Two different length injection
tubes
are used.

The
shorter length injection
tubes
must be inserted into cylinders 1 and 4. 145

'Jeep'
UNIVERSAL
SERIES
SERVICE
MANUAL

F2

14043

FIG.
F2-6—REPLACING VACUUM MOTOR ASSEMBLY

A—Drill
VW
Hole
B—Sensor
Unit
Replacement Position
1—
Motor
3—Sensor
Unit

2—
Spot
Welds
4—Retaining
Strap
•e.
Drill
a
%j
inch [2,78 mm.] hole in snorkel tube

at
point
"A"
as shown in Fig.
F2-6.
f.
Use the motor strap retainer and the
sheet
metal

screw
provided in the motor replacement kit to secure the retainer and motor to the snorkel tube.
g. Make sure the screw
does
not interfere with the
operation of the damper assembly. Shorten screw
if
required.

F2-9.
Replacement
of Air
Cleaner Sensor

a.
Remove two sensor retaining clips by
prying.
See

Fig.
F2-7.

b.
Pull
vacuum
hoses
from sensor.

c.
Note
carefully the installed position of the sensor so that you can install new sensor in same position.

Then
remove sensor.

d.
Install
sensor and gasket assembly in air cleaner

m
same position as noted in
step
c.
This
is to eliminate the possibility of interference with the air

filter
element.
e.
Install
sensor retaining
clip,
meanwhile support­
ing
sensor at B around the outside rim to prevent 14042

FIG.
F2-7—REPLACING SENSOR ASSEMBLY

1—Sensor
Retaining
Clip
damage to the temperature sensing spring. See

Fig.
F2-7.

f.
Reinstall
vacuum hoses.

F2-10.
AIR
PUMP
The
air injection pump is a positive displacement
vane type which is permanently lubricated and
requires
no periodic maintenance.

The
pump contains an integral relief valve which
controls the
air
supplied to the
engine
exhaust ports

during
high speed operation to limit maximum exhaust system temperatures.

F2-11.
AIR
FILTER
The
air injection system draws clean air from the
carburetor
air filter through an inlet hose, into the

air
pump and from the pump through two
outlets
(one for each cylinder head).

F2-12.
AIR
DELIVERY MANIFOLD

The
air delivery manifolds constructed of cold
rolled
steel with a zinc plating, distribute the air

from
the pump to each of the air delivery tubes in

a
uniform manner.

Two
check valves are included to prevent the
reverse
flow of exhaust
gases
to the pump should
the pump drive
fail.
This
reverse flow would dam­
age the air pump and connecting hose.

F2-13.
AIR
INJECTION TUBES
The
air injection tubes of stainless steel are in­ serted into machined
bosses
of the cylinder head.

The
tubes project into the exhaust ports directing
air
into the vicinity of the exhaust valve stem.

F2-14.
ANTI-BACKFIRE VALVE
The
anti-backfire valve is used to provide a "gulp" of air into the
engine
induction system during
rapid

throttle opening and subsequent closure.
During
rapid
throttle closure, the valve
opens
for approxi­
mately one (1) second and bleeds air into the
intake
manifold through a fitting in the carburetor.

Its
function is to bleed an adequate amount of

air
below the carburetor throttle plate to compen­ sate for the
overrich
fuel mixture normally inducted
into the combustion chamber during
rapid
throttle

closure.

Filtered
air from the pump is provided to the
anti-backfire
valve by means of a connecting hose.

An
exhaust system backfire
will
result if the valve

fails
to function properly.

F2-15.
ENGINE COMPONENTS
The
following item varies in design or specifications

from
those
on vehicles not equipped with the Ex­

haust
Emission
Control
System.

F2-16.
Carburetor

Check
carburetor number for proper application. Specifications are listed in this section.

Proper
carburetor idle mixture adjustment is im­ perative for
best
exhaust emission control.

The
idle adjustment should be made with the en­
gine
at normal operating temperature, lights and accessories off and the air cleaner in place.
Adjust
155

F2
EXHAUST EMISSION CONTROL SYSTEMS
the throttle
stop
screw to idle the
engine
at 650
to 700 rpm.

F2-17. Carburetor Idle Setting
The
"Lean
Best
Idle"
Method of Idle Setting is as
follows:

a.
Any scheduled service of ignition system should
precede this adjustment

b.
Connect tachometer to engine.

c.
Warm
up
engine
and stabilize temperatures.

d.
Adjust
engine
idle to speed desired, using throt­
tle idle speed adjusting screw.
e.
Turn
idle mixture screws out (counterclockwise)

until
a
loss
of
engine
speed is indicated; then slowly
turn
mixture screws in (clockwise-leaner)
until
maximum speed (rpm) is reached. Continue

turning
in (clockwise) until speed begins to drop;

turn
mixture adjustment back out (counterclock­
wise-richer)
until maximum speed is just regained

at
a "lean as possible" mixture adjustment.

F2-18. Distributor
The
ignition distributor used with the
Exhaust
Emission
Control
System is the same as that used
on
engines
without
Exhaust
Emission
Control.
Check
the distributor cam dwell angle and point
condition.
Check
ignition timing and adjust to specifications shown on the last
page
of this section.

F2-19.
Anti-Backfire
Valve

The
anti-backfire valve remains closed except when
the throttle is closed rapidly from an open position.
To
check the valve for proper operation, accelerate
the
engine
in neutral, allowing the throttle to close

rapidly.
The valve is operating satisfactorily when
no exhaust system backfire occurs. A further check
to determine whether the valve is functioning can
be made by removing from the anti-backfire valve
the large
hose
which connects the valve to the

pump.
With
a finger placed over the open end of
the
hose
(not the valve), accelerate the
engine
and allow the throttle to close rapidly. The valve is
operating satisfactorily if a momentary air rushing
noise is audible.

F2-20.
Check
Valve

The
check valves in the lines to the air distribution manifolds prevent the reverse flow of exhaust
gases

to the pump in the event the pump should, for

any
reason,
become
inoperative or should exhaust

pressure
ever exceed pump pressure.

To
check this valve for proper operation, remove the air supply
hose
from the pump at the check

valve.
With
the
engine
running, listen for exhaust
leakage at the check valve which is connected to
the distribution manifold.

F2-21.
Air
Pump

Check
for proper drive belt tension with belt tension
gauge
W-283. The belt strand tension should be 60 pounds measured on the
longest
accessible span
between two pulleys. DO NOT PRY ON THE

DIE
CAST
PUMP
HOUSING. To
check the pump for proper operation, remove
the air
outlet
hose
at the pump.
With
the
engine

running,
air discharge should be felt at one of
the pump
outlet
openings. The pump
outlet
air
pressure,
as determined by the relief valve, is preset
and
is not adjustable.

The
air pump
rear
cover assembly, housing the pressed in inlet and discharge tubes, and the pres­
sure
relief valve are the only pump components
recommended for service replacement. These parts
are
to be replaced only when damaged as a result
of handling or in the event the relief valve was
tampered with.

F2-22.
Intake Manifold

Intake
manifold leaks must not be overlooked. Air
leakage at the intake manifold may be compen­
sated for by
richer
idle mixture setting, however, this
will
usually cause uneven fuel-air distribution
and
will
always result in
loss
of performance and
exhaust emission control. To check for air leakage
into the intake manifold, apply kerosene or naph­
tha,
on the intake manifold to cylinder head joints

and
observe whether any changes in
engine
rpm

occur.
If an air leak is indicated, check the mani­
fold to cylinder head bolt torque. The correct torque is 25-35 lbs. ft. [3,46 a 4,84 kg-m.]. If the

leak
is
still
evident,
loosen
the manifold assembly

and
torque-tighten the bolts evenly.
Start
from the center and use proper torque values. Replace the
manifold
gasket if the leak
still
exists.
Clean
both
mating surfaces and check for
burrs
or other ir­

regularities.

Always
torque the bolts evenly to the specified
torque value to prevent warpage.

F2-23.
Carburetor
Air
Cleaner
—Oil
Bath

Every
6,000
miles [9,600 km.] disconnect attach­

ing
hoses
and unscrew the wing nut from the top
of the air cleaner and lift it off the carburetor.

Lift
the cover and filter element off the oil sump.

Clean
the inside surface of the sump and
refill
to

indicated
oil level with SAE 40 or 50
engine
oil
above 32 F; SAE 20 below 32 F.
Wash
filter element in kerosene and
drain.
Reassemble the air

cleaner
and install on carburetor.

More
frequent cleaning and replacement are advis­ able when the car is operated in dusty areas or on

unpaved
roads. Accumulated
dirt
restricts air flow,
reducing
fuel economy and performance.

F2-24.
REMOVAL PROCEDURES
The
following paragraphs
give
the procedures for removing the major units of the exhaust emission
control
system and the required equipment needed.

F2-2S.
Air
Pump

Loosen
the air pump mounting bracket bolts. Re­ move the air pump air hose(s). Separate the air pump from its mounting bracket. At time of install­
ation,
torque tighten the air pump mounting bolts
to
30-40
lbs.-ft [4,15 a 5,53 kg-m.].
Adjust
the
belt strand tension to 60 pounds. 156

'Jeep'
UNIVERSAL
SERIES
SERVICE
MANUAL

H
11514

FIG.
H-2—WIRING
DIAGRAM—MODEL
CJ-3B
(Serial No.
35522
and
after)

1—
Left
Headlamp
2—
Left
Parking and Signal Lamp
3— Right Parking and Signal Lamp
4— Right Headlamp 5— Battery Ground Strap
6— Generator 7— Ignition
Coil

8— Junction Block
9—
Horn

10— Distributor
11— Battery
12—
Voltage
Regulator 13— Starting Motor
14—
Oil
Pressure Signal Switch 15— Temperature Sending Unit
16—
Solenoid
Switch 17— Foot Dimmer Switch
18—
Stop
Light Switch 19— Directional Signal Flasher
20— Fuse
21—
Light
Switch 22— Directional Signal Switch
23—
Horn
Button 24— Ignition and Starter Switch 25—Instrument Cluster
A—Upper Beam Indicator
B—Turn
Signal Indicator C—Instrument Lights

D—Oil
Pressure Indicator
E—Charging
Indicator F—Temperature Gauge

G—Fuel
Gauge
H—Instrument
Voltage
Regulator
25—Fuel Gauge Tank Unit
27—
Left
Tail
and
Stop
Lamp
28— Right
Tail
and
Stop
Lamp 175

H

ELECTRICAL
SYSTEM
11474

FIG.
H-3—WIRING
DIAGRAM—MODELS
CJ-5, CJ-6, DJ-5 AND DJ-6—F4
ENGINE
(Model CJ-5 after Serial No.
49248,
Model CJ-6 after Serial No.
12577)

1—
Left
Headlamp
B—Turn
Signal Indicator 17—Directional Signal Switch
2—
Left
Parking and Directional Lamp C—Instrument Lights 18—Light Switch
3— Right Parking and Directional Lamp
D—Oil
Pressure Indicator
19—Stop
Light Switch
4— Right Headlamp E—Charging Indicator 20—Foot Dimmer Switch
5— Battery Ground Cable F—Temperature Gauge 21—Directional Signal Flasher
6— Generator
G—Fuel
Gauge 22—Fuse 7— Distributor H—Instrument Voltage Regulator
23—Solenoid
Switch
8— Ignition
Coil
12—Right
Tail
and
Stop
Lamp 24—Temperature Sending Unit
9— Starting Motor 13—Left
Tail
and
Stop
Lamp 25—Oil Pressure Signal Switch
10— Voltage Regulator 14—Fuel Gauge
Tank
Unit 26—Horn
11— Instrument Cluster 15—Ignition and Starter Switch 27—Junction Block
A—Upper
Beam Indicator 16—Horn Button
whereas the Dauntless V-6
engine
Delco starter
ignition
switch. If trouble
develops
in this switch, drive is of the clutch
type.
it must be replaced.
The
ignition
switch
serves
both
to
energize
the

The
starter circuit is
opened
when the
ignition
key
ignition
system
and
also
to
engage
the starter
sole-

is allowed to return to the "Ignition On"
position.
miod switch. With the key in the vertical
position,
No repairs or adjustments can be
made
to the the electrical
system
is off. This is the
only
position
176