1953 JEEP DJ engine

1953-71

SERVICE MANUAL

JeeP
UNIVERSAL
4-WHEEL DRIVE
CJ-3B CJ-5A
CJ-5
CJ-6
CJ-6A
2-WHEEL DRIVE DJ-5
DJ-6

Copyright®
1977

FI Jeep Corporation Corporate Publications
Printed
in USA
Reprinted
6-77

SM-1046
SECTION
INDEX

NAME
Section

General
Data
A

Lubrication
B

Tune-Up
C

Hurricane
F4 Engine
D

Dauntless V-6 Engine
Dl

Fuel
System
E

Exhaust
System
F

Exhaust
Emission Control System F4 Engine
Fl

Exhaust
Emission Control System V6-225 Engine
F2

Cooling System
G

Electrical
H

Clutch
I

3-Speed
Transmission
J

4-Speed
Transmission
Jl

Transfer
Case
K

Propeller Shafts
L

Front
Axle
M

Rear
Axle
N

Steering 0

Brakes
P

Wheels 0

Frame
R

Springs
Shock Absorbers
S

Body
T

Miscellaneous
U

IMPORTANT
DEALER
INFORMATION

This
manual, SM-1046, covers current 'Jeep' Universal Series vehicles, and
past models,
except
as
noted
hereinafter:
SM-1037 should be retained in your service
library
for
information related to the
6-volt
electrical system, or the
single brake system.

SM-1002-R5
(no longer available) should be retained
for information related to the
CJ-2A, CJ-3A
or
DJ-3A

models
equipped with the L4-134
engine.

The
above
three manuals provide
full
service coverage since inception of the
'Jeep' Universal and
1
Jeep' Dispatcher model vehicles.

'Jeep*
UNIVERSAL
SERIES SERVICE
MANUAL

A
GENERAL
DHTfl

Contents

SUBJECT
PAR.

General
A-l

Vehicle
Description .A-2

Vehicle
Identification A-3
Identification
Number Location A-4
Serial
Number Location A-5

Engine
Code Number A-6

Plate-And-Trim
Option Plate A-7

General
Specifications A-8

A-1.
GENERAL
This
manual is provided for the guidance of all
automotive service men, vehicle owners, and service salesmen who
repair,
maintain, or adjust
the 'Jeep' Universal Series vehicles. The informa­tion herein was prepared from the service man's
viewpoint to
give
him the accurate and concise
data
he may need to service the entire vehicle.

The
information is not elementary as it is intended
for automotive service men who are familiar with
automotive construction and repair in general. It is not intended, nor would it be possible in such

limited
space, to cover every possible repair that he may encounter. All specifications are in accord

with
Engineering Specifications and should be

adhered
to in all work on the vehicle.
The
manual sections follow logical division into

major
components of the vehicles. The first
page

of each section has a detailed index of the
contents
of that section. Subject matter covers all models

included
in this manual unless an exception for a

particular
model is specifically mentioned.
Specifications and components covered were for

standard
production models of 'Jeep' vehicles
current
at the time the manual was approved for

printing.
'Jeep' Corporation reserves the right to
discontinue models at any time or change specifi­
cations or design of any of its models without
notice and without
incurring
any obligation.

A-2.
Vehicle Description

This
manual covers all standard production 'Jeep'

Universal
models currently being produced at the time this manual was approved for publication.

Significant
changes made in each model since it
was first produced are included in the manual.
A
description of each model follows.
General

specifications for each model are listed in Par. A-8. Detailed specifications covering major vehicle units

are
listed at the end of each section of the manual.
CJ-3B
—
This
is a 4-wheel-drive 'Jeep' Universal
model, equipped with the four-cylinder

Hurricane
F4-134 engine. Wheelbase is 80".

CJ-5

CJ-5A
— These are 4-wheel-drive 'Jeep' Universal models, equipped with either the Daunt­

less
V-6 engine, or the four-cylinder

Hurricane
F4-134 engine. Wheelbase is 81".

CJ-6
CJ-6A
— These are 4-wheel-drive 'Jeep' Universal models, equipped with either the Daunt­
less
V-6 engine, or the four-cylinder

Hurricane
F4-134 engine. Wheelbase is 101".

DJ-5
DJ-6
— These are 2-wheel-drive 'Jeep' Universal models, equipped with the four-cylinder

Hurricane
F4-134 engine. DJ-5 wheel- base is 81". DJ-6 wheelbase is 101".

A-3.
Vehicle Identification
Each
'Jeep' vehicle model series has one or more

serial
number prefixes to identify it. Complete
identification of a specific vehicle requires the

prefix
plus the
serial
number.
Serial
numbers are
consecutive for each prefix grouping. Prefix infor­
mation following
will
identify the 'Jeep' models
shown by
serial
number prefix from model inception to date.-.
••
' . -

Note:
Vehicles with a
serial
number prefix of five
(5) or more digits that have an S, 5, or 7 as the last
digit are equipped with
Exhaust
Emission
Control.

A
number 1 in the sixth (6th) digit within a seven (7) digit vehicle
serial
number prefix indicates

Left
Hand
Drive;
a 2 indicates Right
Hand
Drive;
a
3 indicates
Left
Hand
Drive
California
Exhaust

Emission
Control
Engine;
a 4 indicates Right
Hand
Drive
California
Exhaust
Emission
Control
Engine.
3

A

GENERAL
DATA

'Jeep'
Serial
No.

'Jeep'
Serial
No.

Model
Prefix
Model
Prefix

CJ-3B
453-GB2

CJ-3B

454-GB2
57348
8105

8105014

CJ-5
57548

CJ-6

57648
8305 8405
8305A 8405A
8305S 8405S

8305AS 8405AS

8305014 8405014

8305015 8405015
8305016 8405016
8305017 8405017

CJ-5A
8322

CJ-6A
8422
8322A 8422A
8322S 8422S
83
2 2AS
8422AS
.

DJ-5
8505
DJ-6

8605
8505A 8605A
8505S 8605S

8505AS 8605AS

8505014
8505015
8505016
8505017

Any
prefix not given here for one of the listed models indicates a special vehicle whose differences

from
standard are not covered in this manual.

A-4. IDENTIFICATION
NUMBER
LOCATION

All
'Jeep* vehicles and
some
of their major com­
ponents have identifying numbers.
Paragraphs
fol­ lowing
will
describe the location of identifying
numbers.

A-5.
Vehicle
Serial
Number
The
vehicle
serial
number is stamped on a metal
plate located on the dash under the hood. It is on
the left side of the vehicle for models
CJ-5, CJ-5A,

CJ-6,
CJ-6A,
DJ-5 and DJ-6 as shown in Fig.
A-l.
It
is on the right side of the vehicle for model

CJ-3B,
as shown in
Fig.
A-2. Refer to Par. A-3 for
specific information on codes.
FIG.
A-l—CJ-5, CJ-5A, CJ-6, CJ-6A,
DJ-5, DJ-6

VEHICLE
SERIAL
NUMBER LOCATION
FIG.
A-2
CJ-3B
VEHICLE

SERIAL
NUMBER LOCATION A-6.
Engine Code Number

The
engine identification number consists of a

prefix
followed by a five-digit or six-digit
code

number.
The prefix identifies the
particular
engine.
The
F4-134 engine
code
number is stamped on the
FIG.
A-3—ENGINE CODE NUMBER LOCATION

HURRICANE
F4-134

FIG.
A-4—ENGINE CODE NUMBER LOCATION DAUNTLESS
V-6
4

'Jeep'
UNIVERSAL SERIES SERVICE
MANUAL

A
water pump
boss
at the front of the
engine,
as
shown in Fig. A-3. The Dauntless V-6
code
number is stamped on the right front face of the cylinder
block, just
below
the rocker arm cover as shown in
Fig.
A-4.

A-7.
Paint-and-Trim Option Plate
A
Paint-and-Trim
Option Plate is installed on late
production 'Jeep' vehicles. The paint
code
on the plate identifies the paint colors. The trim
code
on
the plate identifies the color of all trim parts in the
interior
of the vehicle.

To
identify paint or trim on vehicles manufactured

before
the Paint-and-Trim Option Plate was in­
stalled, see your 'Jeep' dealer.
'Jeep' Universals have the plate located on the
right hand side of the dash under the hood, as shown in Fig. A-5.
FIG.
A-5—PAINT
AND
TRIM

OPTION
PLATE LOCATION
5

GENERAL
DATA
A-8. GENERAL SPECIFICATIONS

MODEL:
CJ-3B
CJ-5,
CJ-5A
DJ-5
CJ-6,
CJ-6A
DJ-6

Engine:.
Number
of
Cylinders

Bore.
.

Stroke.
Displacement
Compression
Ratio:
Late
Production —
Standard
—
Optional.
—
Optional.

Early
Production —
Standard

—
Optional.

—
Optional.

Compression
Pressure

Horsepower
(max.
Brake)
Horsepower
(SAE)

Torque
(Max. at 2000
rpm.).
. . .

Engine:
Number
of
Cylinders

Bore

Stroke

Displacement

Compression
Ratio

Horsepower
(max.
Brake).
Horsepower
(SAE)

Torque
(Max. at 2400
rpm.).
. . .

Wheelbase

Tread
(front and
rear)
,

Height
(Over
all)
Length
(Over
all).

Width
(Over
all)

Ground
Clearance
F-4

4
3.125 [7,93 cm.]
4.375 [11,11 cm.]
134.2 cu. in. [2,20 ltr.]
7.4:1 7.8:1
6.9:1
120 to 130 psi.
[8,4 a 9,2 kg-cm2] 75 <§ 4000 rpm.
15.63
114 lb-ft. [15,8 kg-m.]

80"
[2,03 m.]
487-'f6/' [1,23 m.|
6634" [1,68 m.j

129%"
[3,30 m.]
68%"
[1,75 m.] 8" [20,32 cm.]
F-4

4
3.125 [7,93 cm.]
4.375 [11,11 cm.]
134.2 cu. in. [2,20 ltr.]
6.7:1 7.1:1
6.3:1 7.4:1
7.8:1
6.9:1
120 to 130 psi.
[8,4 a 9,2 kg-cm2] 75 @ 4000 rpm. 15.63
114 lb-ft. [15,8 kg-m.]

V-6
6
3.750" [9,525 cm.]
3.400" [8,636 cm.]
225 cu.
in.
[3,69 ltr.] 9.0:1
160 @ 4200 rpm. 33.748
235 lb-ft. [32,49 kg-m.]
81"
[2,06 m.]

48K6"
[1,23 m.]

67"
[1,70 m.]

138%"
[3,51 m.]
71%"
[1,82 m.] 8" [20,32 cm.]
F-4

4
3,125 [7.93 cm.]
4.375 [11,11 cm.]
134.2 cu. in. [2,20 ltr.]
6.7:1 7.1:1
6.3:1 7.4:1
7.8:1
6.9:1
120 to 130 psi.
[8,4 a 9,2 kg-cm2] 75 @ 4000 rpm.
15.63
114 lb-ft. [15,8 kg-m.]

V-6
6
3.750" [9,525 cm.]
3.400" [8,636 cm.]
225 cu. in. [3,69 ltr.] 9.0:1
160 @, 4200 rpm. 33 748
235 lb-ft. [32,49 kg-m.]
101"
[2,57 m.]
48^6* ]1,23 m.]

67"
[1,70 m.]
1583/4" [4,02 m.]
71%"
[1,82 m.] 8" [20,32 cm.]

CAPACITIES:
U.S.

Imperial
Metric

Fuel
Tank
(Approximate):
Early
Models

Late
Models

Cooling
System

F4
Models

V-6
Models
Note: If not equipped
with
heater deduct 10.5 gal.
16 gal.
12 qt.
10 qt.
1 qt. 8.8 gal.
13.3 gal.
10 qt. 8 qt.
.8 qt. 39,75 ltr.
60,57 ltr.
11,4 ltr. 9,5 ltr.
0,9 ltr.

CJ-
3B

CJ-5
CJ-6
DJ-5

DJ
-6

lb. kg. lb.
kg. lb.
kg. lb.
kg. lb.
kg.

WEIGHTS
(Approximate):
Gross
Vehicle
Weight
(GVW).
3500
1587 3750 1701 3900 1769 3200 1451 3200 1451

Shipping
— V6
Engine
—
'—
2240 1016 2302 1044 1900 862 2033 922

F4
Engine
2132
967 2163
981 2225
1009 1796 814 1858 842

Curb
— V6
Engine
— —

2351 1066 2413 1094 2011 912 2144 972

F4
Engine
2243
1017 2274 1031
2336 1060 1907 865 1969 893

For
Canvas
Half-Top
Model, add 35
17 38
17 38
17 38
17 38 17

For
Canvas
Full-Top
Model, add 56
25 56 25 60 27 56 25 60 27

For
Hard
Top Model, add
~~
340
154 340 154 6

'Jeep*
UNIVERSAL SERIES
SERVICE
MANUAL

B
LUBRICATION
AND
PERIODIC SERVICES

Contents
PAR. SUBJECT
PAR.
SUBJECT

GENERAL
.B-l
Chassis
Lubrication
B-7
Engine
Lubrication System B-4, B-6

Special
Lubricants B-2

Fresh
Lubricant.
.B-3

LUBRICATION CHARTS
. Pages 8, 9

SERVICE
MAINTENANCE SCHEDULE.
.B-8
Air
Cleaner
B-2
5,
B-2
6
Air
Filter
—
F.E.E.C.
System Canister
B-2
4

Axle
U-Bolts B-49 Body
Lube
Points: B-65 Hood Hinge Pivot Points B-66

Glove
Compartment Door
Latch
B-6
7
Tailgate Hinges .B-68

Brakes,
Adjust .B-41
Brake
Linings .B-42

Brake
Master Cylinder B-40
Charging
Circuit
B-l9
Clutch
. B-43, B-44
Cooling System—Radiator. B-28, B-29 Differentials
........
.B-50, B-51, B-52, B-53

Distributor
B-14, B-l5

Engine
Oil B-9
Engine
Oil
Filter
B-10, B-ll

Engine
Tune-Up B-20
Exhaust
Emission Control System
B-2
2

Exhaust
Manifold Heat Control Valve. . . .B-l2

Exhaust
System
B-2 3
Fan
Belt . .B-21
Front
Axle U-Joint B-54, B-55

Generator
.B-16
Headlights B-61
Heater Controls B-62
Lights
and Controls B-59 Positive Crankcase Ventilation Valve. . . .B-l3
Shock Absorbers B-48
Spark
Plugs. B-17
Speedometer Cable. .B-60

Spring
Bushings.. . .B-46

Spring
Shackles .B-47
Steering
Gear
B-2 7
B-l. GENERAL
All
'Jeep' Universal vehicles require periodic
lubri­

cation and other maintenance services for normal
vehicle
usage
and application to promote satis­ factory operation and prevent
excessive
wear. Un­
der severe operating or atmospheric conditions
these
services should be performed more
often
than
under normal conditions. It should also be remem­
bered that common short trips and
stop-and-go
driving
are more severe on lubrication
points
than
Starting
Circuit
B-l8

Tie
Rod and Drag
Link
Sockets
.
B-45

Tires
B-64

Transmission
and Transfer Case—
Lubricant
Level
Check B-30

General
B-31

Transfer
Case B-32
Transmission
.B-33

Transmission
and Transfer
Case
—

Lubricant
Change .B-34
General
.B-35

Transfer
Case B-36
Transmission
B-3
7, B-38

Transfer
Case Linkage B-39

Universal
Joints and Slip Joints.
.......
.B-58

Wheel
Bearings..
.........
. . .B-56, B-57
Windshield
Wiper and Washer B-63

LUBRICATION
OF

OPTIONAL EQUIPMENT
B-69
Centrifugal
Governor. .B-71
Pintle Hook .B-70

Powr-Lok
or
Trac-Lok
Differential B-72

PARTS REQUIRING
NO LUBRICATION.
. . .B-73

Alternator
Bearings. B-76
Clutch
Release Bearings.
.............
.B-74
Shock Absorbers B-78
Springs
B-7
7
Starter
Motor Bearings B-75

Water
Pump Bearings B-74

LUBRICATION REQUIREMENTS FOR OFF-HIGHWAY OPERATIONS
B-79

Air
Cleaner B-82

Chassis
Lubrication
B-83

Engine
Oil B-80
Engine
Oil
Filter
B-81
Differentials .B-86
Front
Axle U-Joints. B-84
Transfer
Case and Transmission .B-85
constant
speed
driving on highways, and even more
intensified in extreme cold or hot weather; there­ fore, vehicles driven under
these
conditions must
be lubricated and serviced more
often
than nor­ mally operated vehicles. The specifications of
types
and
amounts of lubricant given in the Lubrication

Chart
and
text
of this section should be closely
followed. The off-highway operation lubrication
notes,
given in the last part of the section, should
be followed when applicable. 7

B
LUBRICATION D0®
® ® ®

FIG.
B-l—-LUBRICATION CHART
—
4-WHEEL DRIVE
VEHICLES

CHART NO.
ITEM
TO BE

LUBRICATED

10.
11.
13.
14.
Chassis
Bearings. . .

Spring
Shackle and Pivot Bushings...

Universal
Joints Propeller Shaft
Front
Axle
Steering
Gear
Housing

Rear
Wheel BearingstS

Front
Wheel Bearings
.

Transmission:
3
Speed
4 Speed °

Transfer
Case
Differentials
Front.

Rear

Speedometer Cable

Generator
— F4
Distributor
— F4
Oiler
Wick

Pivot.
Gam

Distributor
Cam — V6.

Air
Cleaner — F4
—
V6

Engine
— F4

Engine
— V6.
FREQUENCY

1000 miles — 1.600 km.

Each
2,000
miles

/With
Lube
Fitting;
(Each
2,000
miles [Without
Lube
Fittings:
\No Lubrication

Each
2,000
miles

f
Check
each
2,000
miles

\
Change each
12,000
miles

Check
each
2,000
miles

fWith
Lube
Fittings:

1
Sparingly each
2,000
miles
J
Without
Lube
Fitting:

|
Disassemble to lubricate
\each
12,000
miles
Disassemble to lubricate
each
12,000
miles

I
Check
each
2,000
miles
l
Change each
12,000
miles

/Check
each
2,000
miles
l
Change each
12,000
miles

!Check
each
2,000
miles

\
Change each
12,000
miles

f
Check
each
2,000
miles

\
Change each
12,000
miles
.
Disassemble to lubricate each
12,000
miles

Each
2,000
miles

Each
2,000
miles
Each
2,000
miles

Each
2,000
miles
Each
2,000
miles

At
each breaker point replacement

/Each
2,000
miles

\Each
6,000
miles
Change each
2,000
miles
or 60 days
Change each
6,000
miles
or 60 days
QUANTITY
U.S.
Imperial Metric

As
required
As
required

As
required

As
required
As
required

As
required

As
required

2H
Pts. 2 pts. 1,2 ltrs.
6 H pts. 5
M
pts. 3,2 ltrs.

3Mpti«
3 pts. 1,5 ltrs. 2
M
pts. 2 pts. 1,2 ltrs.
2
Yi
pts. 2 pts. 1,2 ltrs.
As
required

Several
Drops

Several
Drops
One
Drop
One
Drop
2 c.c.

As
required
1 H pts. 1 pt. 0,6 ltrs.
4 qt. m 314 qt. 3,8 ltrs.
4 qt.
11
3 34 qt. 3,8 ltrs.
LUBRICANT

TYPE

Chassis
Lubricant

Chassis
Lubricant

Chassis
Lubricant
GL3

MIL-L-2105-B

Wheel
Bearing
Lubricant

Wheel
Bearing
Lubricant
GL4
GL4 GL4

MIL-L-2105-B

MIL-L-2105-Bttt

Graphite
Grease

Engine
Oil

Engine
Oil

Engine
Oil

Engine
Oil

Cam
Lubricant
Cam
Lubricant

Engine
Oil

Engine
Oil

Engine
Oil
GRADE

No. 1 No.
1
No. 1 No. 1
No. 1

SAE-140
No. 1

SAE-140

SAE-80
No. 2
SAE-

No. 80
2
No. 2 No. 2

SAE-90
SAE
80

SAE-90
SAE
80

SAE-90
SAE
80

SAE-80
SAE-80
SAE
SAE
80
80

Light
Same as
engine

Same as
engine

Same as
engine

Same as
engine

SAE-40
or 50
SAE-20

Above 90
°F.

use SAE 30 or 10W-30
Not lower than
32°F.
[0°C.|

use SAE 20W or SAE 10W-30 Between
-f-10°F.
and 90
8F.

use SAE 20W or 10W-30 Between
-10°F.
and
+10°F.

use SAE 10W or 10W-20 Between
32eF.
[0°C.]
and 0°F.
l-17°Cl

use SAE 10W or SAE 10W-30
*4-Speed transmission and transfer case require separate lubrication of each unit.

tttFor
Powr-Lok
and
Trac-Lok
differential use only 'Jeep* Differential Oil,
Part
No. 94557.
SI
When filter is changed at the same time, add one quart.

®
Do not mix lithium and sodium base lubricants. Use lithium base lubricant as specified Below
-10°F.

use SAE 5W or 5W-20
Below 0°F. [-17°C.J
use SAE 5W or SAE 5W-20 8