1953 JEEP DJ diagram

H

ELECTRICAL
SYSTEM SUBJECT
PAR.

Directional
Signal
Lamps
H-138

Hazard
Warning
Lamps
H-139

Head
Lamp
Replacement H-130
Head
Lamp
Aiming Procedure H-131 Headlight Dimmer Switch H-127

License
Plate
Lamp
H-136
Main
Light
Switch. H-126

Marker
Lights .H-l40

Parking
and
Turn
Signal
Light
H-133
Stop
Light
Switch. H-l28
Tail,
Stop and
Turn
Signal
Lamp
.H-134

H-1. GENERAL
All
'Jeep' Universal vehicles are equipped with 12- volt electrical systems. Use caution around the higher
voltage
of the 12-volt system as accidental

short
circuits are more capable of damaging electri­
cal
units. Also, arcs around the 12-volt battery are
more apt to ignite any gas that may be escaping

from
it. In the following paragraphs
will
be found
information about the battery, distributor, coil,
generator, alternator,
voltage
regulator and start­ ing motor. These units with the connecting wires,

make
up the
engine
electrical system. The wiring
diagram
will
show the different circuits of the en­

gine
electrical system and the various units which
make
up
those
circuits.

With
plastic-covered wiring harnesses use only

rubber-insulated
wiring clips.

Caution:
All current production vehicles are 12- volt, negative ground. Whenever servicing a 12-
volt electrical system, use caution, as an accidental

short
circuit is capable of damaging electrical units. Disconnect battery ground cable before changing

electrical
components.

H-2.
Battery

The
battery is a storage reservoir for electrical
energy produced by the alternator or generator.
The
battery should store sufficient energy for
operation of the entire electrical system when the
alternator
or generator is not pr 1,scing output,

such
as when the ignition is first turned on. Of

particular
importance is maintaining the electrolyte
at the correct level, regularly checking with a
hydrometer, and maintaining clean, tight cable connections.

Battery
service information is given in this section.

Caution:
Do not allow flames or sparks to be
brought near the vent
openings
of the battery since
hydrogen gas may be present in the battery and might explode.

Note:
The liquid in the battery (electrolyte) is a
solution of sulphuric acid which, on contact, can

injure
skin or
eyes,
or damage clothes. If it is spilled
on the skin or spattered in the
eyes,
promptly flush
it
away with quantities of clear water only. If the

acid
is spilled on clothes, wet it thoroughly with a

weak
solution of ammonia, or with a solution of sodium bicarbonate or baking soda.
SUBJECT
PAR.

HORN
H-137

ELECTRICAL
COMPONENT
REPLACEMENT
H-150

WINDSHIPLD
WIPER SYSTEM
H-141
thru
149

SERVICE
DIAGNOSIS.
. .H-151

ELECTRICAL
SPECIFICATIONS
H-152

Caution:
When installing the battery, the nega­
tive terminal must be grounded. Reverse polarity of the battery can cause severe damage to the charg­ing system.

Battery
Inspection

a.
Check
the specific gravity of the electrolyte in
each cell of the battery. A hydrometer reading of 1.260 indicates that the battery is fully charged.

If
the reading is 1.225 or below, the battery
needs

recharging.
If one or more cells is 25 "points" (.025) or more lower than the other cells, this in­
dicates that the cell is shorted, the cell is about to

fail,
or there is a
crack
in the battery partition in
the case. Unless the battery is repaired or replaced, battery trouble
will
soon
be experienced.

b.
Check
the electrolyte level in each cell, add

distilled
water to maintain the solution [9,5 mm.] above the plates. Avoid overfilling. Replace
the filler caps and tighten securely. It is important to keep the electrolyte level above the plates at all
times because plates that are
exposed
for any
length of time
will
be seriously damaged.

c.
Check
the wing nuts on the hold-down frame for tightness. Tighten them only with finger pres­

sure,
never with pliers or a wrench. Excessive
pressure
could damage the battery case.

d.
Clean
the battery terminals and cable con­ nectors. Prepare a strong solution of baking soda

and
water and brush it around the terminals to
remove any corrosion that is present. The cell caps must be tight and their vents sealed to prevent
cleaning solution entering the cells. After cleaning,
connect cables to battery and coat the terminals

with
heavy grease.

e.
Inspect the battery cables and replace if badly
corroded
or frayed.
Check
tightness
of terminal
screws to ensure
good
electrical connections.
Check

the
tightness
of the negative ground cable con­nection at the frame to ensure a
good
ground
connection.
f.
Load
test
the battery. Connect a voltmeter across the battery. Run the starting motor for 15 seconds. If the
voltage
does
not drop below 10
volts the battery is satisfactory. If the
voltage
falls
below the figure given, yet the specific gravity is
above
1.225,
the condition of the battery is questionable.
g. Be sure the
engine
ground strap connection, 172

'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

'Jeep*
UNIVERSAL
SERIES
SERVICE
MANUAL

H

12968
FIG.
H-4—WIRING
DIAGRAM—MODELS
CJ-5, CJ-6, DJ-5, DJ-6
LATE
F4
ENGINE

1—
Left
Headlamp
2—
Left
Parking and Signal Lamp
3— Right Parking and Signal Lamp 4— Right Headlamp
5— Generator
6— Ignition Distributor
7—
Oil
Pressure Sending Unit
8— Junction Block
9—
Horn

10— Foot Dimmer Switch 11—
Stop
Light Switch — Front
12— Temperature Sending Unit
13— Ignition
Coil

14— Starting Motor 15— Battery Ground Cable
16— Battery
17— Voltage Regulator 18—
Fuse

19— Instrument Cluster

A—Hi-Beam
Indicator

B—Auxiliary
C—Instrument
Lights

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

G—Fuel
Gauge
H—Instrument Voltage Regulator
20— Ignition and Starter Switch 21—
Flashei
(Directional Signal)
22—
Horn
Button 23— Directional Signal Switch
24— 4-Way Flasher Switch
25—
Flasher
(4-Way)
26—
Fuse

27—
Main
Light Switch 28—
Stop
Light Switch — Rear
29—
Fuel
Gauge
Tank
Unit
30—
Back-Up
Light Switch
31— Right
Tail
and
Stop
Lamp
32— Right Back-Up Lamp
33—
Left
Back-Up Lamp
34—
Left
Tail
and
Stop
Lamp

in
which the key can be removed. Turning the key
to the
left
energizes
auxiliary
equipment
such as
windshield wipers, radio, and heater. The turn
signal
lights
will
operate
with the
ignition
key in
either the
left
or right
position.
The
ignition
switch is held in
position
by a
tension
spring on the back
of the instrument panel and a
notched
bezel on
the front of the instrument panel.
H-8.
Lighting System

The
wiring for the lighting
system
is shown in the
wiring diagrams, Figs. H-2 thru H-7 of the manual,
which indicate the various units in relation to their

position
in the vehicle. The lighting circuit is pro­
tected
by an overload circuit breaker
mounted
on the rear of the light switch.
The
main light switch controls the lighting
system
177

H

ELECTRICAL
SYSTEM

14365

FIG.
H-5—WIRING
DIAGRAM—F4
ENGINE
CURRENT
MODEL
1—
Left
Headlamp

2—
Left
Parking and Signal Lamp
3—
Right
Parking and Signal Lamp

4—
Right
Headlamp
5—
Marker
Lamp
— Amber
6—
Generator
7—
Distributor

8—
Ignition
Coil

9— Starting Motor
10— Battery Ground Cable
11—
12
Volt
Battery

12—
Flasher
(Directional Signal)
13— Instrument Cluster
A—Hi-Beam
Indicator

B—Auxiliary
C—Instrument Lights
D—Oil
Pressure
Indicator
E—Charging Indicator
F—Temperature Indicator
G—Fuel
Gauge
Indicator
H—Instrument Voltage Regulator
14—
Ignition
and
Starter
Switch
15—
Horn
Button 16—
Directional
Signal Switch 17— 4-Way
Flasher
Switch
18—
Flasher
(4-Way)
19—
Windshield
Wiper Motor Switch
20—
Main
Light
Switch

21—
Fuel
Gauge
Tank
Unit

22—
Back-Up
Light
Switch
23—
Marker
Lamp — Red 24—
Right
Tail
and Stop Lamp
25—
Right
Back-Up Lamp
26—
Left
Back-Up Lamp
27—
Right
Tail
and Stop Lamp
28—
Marker
Lamp — Red 29— Stop
Light
Switch
30— Foot Dimmer Switch

31—
Windshield
Wiper Motor Assembly

32—
Voltage Regulator
33— Temperature Sending
Unit

34—
Oil
Pressure
Sending
Unit

35— Spark
Plugs
&
Cables

36—
Horn

37— Junction Block
38—
Marker
Lamp — Amber
through a
two-position
push-pull switch located on
the
left
side
of the control panel.
The
foot-operated
headlight dimmer switch is
mounted on the floorboard to the
left
of the steering
column.

H-9.
PRESTOLITE
DISTRIBUTOR
—
DAUNTLESS
V-6 and

HURRICANE
F4
ENGINE

The
Prestolite distributor on the F4
engine
is
mounted on the right
side
of the
engine
and is op­
erated by a coupling on the oil pump shaft, see Fig.
D-l,
which is driven by a spiral gear on the cam­
shaft. The spark advance is fully automatic, being controlled by built-in centrifugal
weights.
The Pres­

tolite
distributor on the V-6
engine
(Fig. H-8) is mounted at the
left
front of the
engine
on the tim­
ing chain cover. It is driven by a spiral gear on the
camshaft. The spark advance is fully automatic,
being controlled by built-in centrifugal
weights,
and by a vacuum advance system. While
some
parts of the distributor may be checked or replaced
with the unit mounted on the
engine,
it is
best
to periodically remove it for a thorough check. Infor­ mation covering the parts which can be serviced
without removal is
given
below.
The
Prestolite distributor installed on the V-6 en­

gine
is similar in construction to the distributor in­
stalled on the F4
engines
except
for the addition of

a
vacuum advance mechanism.
The
same checking procedures outlined in Par. C- 10a, are used for the Prestolite V-6 distributor with

exception
of specifications.
H-10. Distributor Cap

The
distributor cap should be inspected for cracks,
carbon runners and
evidence
of arcing. If any of

these
conditions
exists, the cap should be replaced.
Clean
any corroded high
tension
terminals.

H-11.
Rotor
Inspect the rotor for cracks or
evidence
of
excessive

burning at the end of the metal strip.
After a distributor rotor has had normal use the
end of the rotor will
become
burned. If burning is found on top of the rotor it indicates the rotor is
too short and
needs
replacing. Usually when this condition is found the distributor cap
segment
will 178

'Jeep'
UNIVERSAL
SERIES
SERVICE
MANUAL

H

12967
FIG.
H-6—WIRING
DIAGRAM—LATE
V6
ENGINE

1—Left Headlamp

2—
Left
Parking and Signal Lamp
3—
Right
Parking and Signal Lamp

4—
Right
Headlamp
5— Voltage Regulator
6—
Alternator
7—
Oil
Pressure
Sender

8— Temperature
Sender

9—
Ignition
Distributor
10— Junction Block

11—
Horn

12—
Ignition
Coil

13— Starting Motor
14— Battery Ground Cable 15— Foot Dimmer Switch 21-
16— Stop
Light
Switch — Front 22-
17— Ballast 23-
18—
Flasher
(Directional Signal) 24-
19—
Fuse
25-
20— Instrument Cluster 26-

A—Hi-Beam
Indicator 27-

B—Auxiliary
28- C—Instrument Lights 29-

D—Oil
Pressure
Indicator 30-
E—Charging Indicator 31-F—Temperature Indicator 32-
G—Fuel
Gauge
33-
H—Instrument Voltage Regulator 34-
-Ignition
and
Starter
Switch

-Horn
Button

-Directional
Signal Switch
-4-Way
Flasher
Switch

-Flasher
(4-Way)

-Fuse

-Main
Light
Switch
-Stop
Light
Switch —
Rear

-Fuel
Gauge
Tank
Unit

-Back-Up
Light
Switch

-Right
Tail
and Stop Lamp

-Right
Back-Up Lamp

-Left
Back-Up Lamp

-Left
Tail
and Stop Lamp
be burned on the horizontal
face
and the cap will

also
need
replacing. H-12. Condenser

The
condenser
prolongs
the
life
of the distributor

points
by
preventing
arcing at the
contacts.
It
also
provides
a
hotter
spark by creating a reverse
surge

of current which rapidly breaks
down
the
magnetic

field of the coil by
demagnetizing
the core. Should
the
condenser
be leaky, a weak spark will result.

Check
the
condenser
lead for broken wires or
frayed insulation. Clean and
tighten
the
connec-
179

H

ELECTRICAL
SYSTEM

ffKHs)

3—<§)

FIG.
H-7—WIRING
DIAGRAM—V6
ENGINE
CURRENT
MODEL
1—
Left
Headlamp
2—Left Parking and Signal Lamp
3— Right Parking and Signal Lamp
4—Right Headlamp 5—
Marker
Lamp — Amber
6— Alternator 7— Voltage Regulator
8— Starting Motor
9— Battery Ground Cable
10— 12 Volt Battery
11—
Flasher
(Directional Signal)
12— Instrument Cluster
A—Hi-Beam
Indicator
B—Auxiliary

C—Instrument
Lights

D—Oil
Pressure Indicator
E—Charging
Indicator

F—Temperature
Indicator

G—Fuel
Gauge Indicator
H—Instrument Voltage Regulator
13— Ignition and Starter Switch
14—
Horn
Button
15— Directional Signal Switch
16— 4-Way Flasher Switch 17—
Flasher
(4-Way)
18— Windshield Wiper Motor Switch
19—
Main
Light Switch
20—
Fuel
Gauge
Tank
Unit
21—
Back-Up
Light Switch
22—
Marker
Lamp — Red
23— Right
Tail
and
Stop
Light 24— Right Back-Up Lamp
25—
Left
Back-Up Lamp 26—
Left
Tail
and
Stop
Light
27—
Marker
Lamp — Red
28—
Stop
Light Switch
29— Foot Dimmer Switch
30— Windshield Wiper Motor Assembly
31—
Ballast
Resistor 32— Ignition
Coil

33—
Spark
Plugs and Cables 34— Temperature Sending Unit
35—
Oil
Pressure Sending Unit 36—
Horn
37— Junction Block
38—
Marker
Lamp — Amber

lions
on the terminal
posts.
Be sure
condenser
is
mounted
firmly on the distributor for a
good
ground
connection.

Should a
condenser
tester
be available the capacity for
both
F4 and Prestolite V6
condenser
should
check from .25 to .28 microfarads. In the
absence

of
tester,
check by substituting a new
condenser.

H-13. Distributor Points
a. Examine the distributor
points.
If
they
show

wear,
poor
mating, transferred metal, or pitting,

then
new
ones
should be installed. Clean the
points

with a suitable
solvent
and a stiff bristled brush.
b. Check the
alignment
of the
point
for a full,
square
contact.
If not correctly aligned, bend the
stationary
contact
bracket slightly to provide align­
ment.

c. The
contact
gap should be set at .020"
[0,508
mm.],
on the F4 and .016"
[0,406
mm.] on the
Prestolite V6. Adjustment of the gap is accom­ plished by
loosening
the lock screw and turning adjusting eccentric screw until correct gap is
secured. Be sure that the fiber block on the breaker

arm
is resting on the
highest
point
on the cam while the adjustment is
being
made. Recheck the gap
after locking the adjustment.
d. Apply a thin film of cam lubricant to the cam to
lessen
fiber block wear.
e. Using Tool C-4094, check
point
contact
spring
pressure, which should be
between
17 and 20

ounces
[0,487
a
0,567
kg.] on the F4 and 17 to 22 oz.
[0,487
a
0,624
kg.] on the Prestolite V6.

Check
with a spring scale
hooked
on the breaker

arm
at the
contact
and pull at right
angle
to the
breaker arm. Make the reading just as the
points

separate. Adjust the
point
pressure by
loosening
the stud holding the end of the
contact
arm spring
and slide the end of the spring in or out as
neces­

sary.
Retighten the stud and recheck the pressure. Too low a- pressure will
cause
engine
missing at
high
speeds.
Too high a pressure will
cause
rapid
wear of the cam, block, and
points.
180

H

ELECTRICAL
SYSTEM
H-124. Testing Indicators and Gauges

Two
gauges
(fuel and temperature) and two in­ dicators (oil pressure and battery charge) that are
located in the instrument cluster are electrically operated.

The
fuel
gauge
is connected by a single wire to a
float-and-slide-rheostat sending unit in the fuel
tank.

The
temperature
gauge
is connected by a single

wire
to a resistance-type sending unit mounted on the engine.

The
battery charge indicator operates when there
is a difference in potential
between
the generator
and
the battery
.The
battery charge indicator lights
when the generator is not charging the battery. The
indicator
light
goes
out when the generator
begins

to charge the battery.

The
oil pressure indicator is connected by a single

wire
to a diaphragm switch located on the engine.
When
engine
oil pressure is low or zero and the
ignition switch is on, the oil pressure indicator
will

light. When
engine
speed is increased slightly above idle speed, raising the oil pressure to approximately 6 psi. [0,2 kg-cm2], the diaphragm switch
will
open the circuit and the indicator light
will
go out.

A
voltage
regulator maintains a constant
voltage
to the
gauges
in normal operation. On early vehicles,
this
voltage
regulator was mounted on the
rear
of
the instrument cluster. On current vehicles, the
voltage
regulator is integral with the fuel
gauge.

Should
trouble
develop
in the
gauges,
first check the regulator (fuel
gauge
on current production vehicle). If the
voltage
to the regulator is below 10 volts system low
gauge
readings
will
result.
Voltage in
excess
of 16 volts
will
not affect
gauge

readings but may result in premature wear of the
regulator contacts. If the
voltage
to the regulator is

within
the above limits, check the electrical con­ nections to the regulator (or fuel gauge), especially
the ground connection. If the readings of all the
gauges
is too high, or they all read too low, replace
the regulator (or fuel gauge).

If
the temperature
gauge
or heat indicator in the
instrument cluster have failed, the cause may
originate from the jumper bar shorting out against the instrument case.
Check
the jumper bar
between

the temperature
gauge
and heat indicator at the

rear
of the instrument case. On later production vehicles, the jumper bar is covered with an in­
sulating
sleeve
to protect it from shorting out
against the instrument case. If the jumper bar

does
not have this
sleeve,
either install one or

wrap
the bar with plastic electrical tape to
half

an
inch [12,7 mm.] from each end. When installing the jumper bar, be sure the curved
segment
is
closest to the fuel
gauge.

Should
only one of the two
gauges
register incor­
rectly,
check the lead wire from the
gauge
to the
sending unit for shorts or open connections. Next disconnect the
gauge
from the sending unit, and
connect the
gauge
to a new fuel tank sending unit

which
has been grounded to the vehicle.
If
the
gauge
registers incorrectly when operating the new unit,
replace the
gauge;
if correctly, replace the sending

unit.

Should
a new fuel tank unit not be available for testing, use a 12-volt
test
light in its place. When
the
gauge
is operating correctly, the pointer
will

move
approximately three-quarters across the
dial.

On
some
vehicles, the temperature
gauge
may
register on or
close
to the H (hot)
mark
when
coolant temperature is
190°F.
to
200°F.
[88°C.
a

93°C.].
In such cases, a 25-ohm,
1-watt
resistor
may be installed on the temperature
gauge
which

will
place the pointer just beyond the center
mark
at a coolant temperature of
190°F.
to
200°F.
Install

the resistor
between
the two terminals on the back
of the
gauge.
Insulate the
exposed
leads of the resistor with electrical tape.

If
the oil pressure indicator
does
not indicate cor­

rectly,
first check the light bulb. Next check all
connections and lead wires. If, after all possible

defects
are corrected, the indicator light
does
not go on and off properly, then the diaphragm type
switch in the cylinder block should be replaced.

H-12S.
LIGHTING SYSTEM The
wiring of the lighting systems is shown in
the wiring diagrams, which indicate the various units in relation to their positions in the vehicle.
The
wires in the various circuits are of different
colors or are marked by tracers to aid when check­
ing individual circuits.

The
lighting circuits of all models are protected by

an
overload circuit breaker mounted on the back of the main light switch and no replaceable fuse is
required.

The
upper and lower headlight beams are con­
trolled by a
foot
switch located on the toe board
to the left of the clutch pedal.
H-126.
Main
Light
Switch

This
switch is a dual functioning unit having two

push-pull
positions and a rotary action. When
pulled out to the first position, the front parking
and
tail
lights are turned on. When pulled all the
way out to the second position, the headlights and
tail
lights are turned on. Rotating the switch to
the right dims the instrument cluster lighting.

The
switch may be removed from the instrument
panel by first loosening the set screw in the control
knob and removing the knob. The retaining nut may then be removed and the switch removed
through the
rear
of the instrument panel.
FIG.
H-51—MAIN
LIGHT
SWITCH
(EARLY)

1—
Battery
4—Parking Lights
2—
Rear
Lights 5—Auxiliary

3—
Head
Lights
212