1953 JEEP DJ wheel bolts
[x] Cancel search: wheel boltsPage 7 of 376
'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
Page 16 of 376
B
LUBRICATION
Note:
Hard
shifting of the transmission gear in
cold weather is a positive indication that the
lubri
cant
is of the wrong viscosity or of poor quality
which
allows it to congeal.
B-38.
Optional
4-Speed
Transmission
and
Transfer Case
The
four-speed transmission and transfer case re
quire
separate lubrication for each unit as
they
have no cross-over oil passage. At each transmission
service check, the
fill
plugs of
both
four-speed
transmission
and transfer case should be pulled
and
the lubricant refilled to level if necessary.
B-39.
Transfer
Case
Linkage
The
transfer case shift linkage should be lubricated
periodically.
All
bearing surfaces that are assembled
with
studs and cotter pins should be disassembled, cleaned, and coated with a
good
waterproof grease.
The
bearing surfaces that cannot be disassembled
should be lubricated with a lubricant that
will
penetrate the bearing
area.
These bearings include
the two on the cross shaft assembly and the
threaded stud.
The
type
of penetrating lubricant recommended is
DuPont
"PM 7", No. 2911, or its equivalent.
B-40.
Brake Master Cylinder
Clean
the top of the
fill
cap and also the housing
area
around it. Remove the cap and observe the
fluid
level. It should be
half
an inch
below
the top
of the fill-hole. If not, add brake fluid to
half
inch
[1,3 cm.]
below
the top of the fill-hole. Use
only heavy-duty brake fluid conforming to speci
fication
SAE-J-1703.
Be sure to handle the brake
fluid
in clean dispensers and containers that
will
not introduce even the
slightest
amount of other
liquids
or foreign particles. Replace and tighten
the
fill
cap.
B-41.
Adjust Brakes
Refer
to Section P.
B-42.
Brake Linings
Refer
to Section P.
B-43.
Adjust Clutch
Refer
to Section I.
B-44.
Clutch Cross Shaft (Lever Type)
Lubricate
the clutch cross shaft in accordance with
specifications given in the
Lubrication
chart: see
Item
1. Chassis Bearings.
B-45.
Tie Rod and Drag
Link
Sockets
The
tie rod and drag
link
sockets
are equipped
with
lubrication
fittings
and should be lubricated
per
specifications given in the
Lubrication
chart: see Item 1. Chassis Bearings.
B-46.
Front
and
Rear Spring
Bushings
The
condition of the spring bushings is indicated
by the alignment of the spring pivot and spring
shackle
bolts.
Check
the alignment of
these
bolts,
and
check that nuts are
tightened
securely.
B-47.
Spring
Shackles
Rubber
bushings are provided on the spring
shackles.
These rubber bushings have no lubrication
fitting and it is very important that
they
never be lubricated.
B-48.
Shock Absorbers
Visually
check for broken mounts or bolts, worn
or
missing bushings on the shock absorbers. Refer
to Section S.
B-49.
Front and
Rear
Axle
U-Bolts
Torque
the front and
rear
axle U-bolts. Refer to Section S.
B-50. Front
and
Rear
Axle
Differentials
—
Lubricant Levels
The
lubricant
level of all front and
rear
differentials should be at the level of the fill-hole.
B-51.
Front and
Rear
Axle
Differentials
—
Changing
Lubricant
B-52.
Conventional Differentials
To
remove the lubricant from the front or
rear
differential,
it is necessary to remove the housing cover. Let the lubricant
drain
out, and then flush
the differential with a flushing oil or light
engine
oil
to clean out the housing
(except
Powr-Lok
or
Trac-Lok
Differentials). Do not use water, steam,
kerosene, or
gasoline
for flushing.
Reinstall
the housing cover, replacing the gasket whenever necessary, torquing the cover
bolts
to 15 to 25 lb-ft. [2,1 a 3,4 kg-m.].
Remove the filler plug, and
refill
the differential
housing as specified in the
Lubrication
Specifica
tions.
B-53.
Powr-Lok
or
Trac-Lok Differential
Some vehicles may be equipped with the
Powr-Lok
or
Trac-Lok
Differential as optional equipment.
Special
lubricant and ordinary multipurpose gear
lubricants
must
not be used. Use only
'Jeep*
Differ
ential
Oil,
Part
No. 94557.
Powr-Lok
or
Trac-Lok
differentials may be cleaned
only by disassembling the unit and wiping with
clean
rags. Do not flush the unit. Refer to Sec
tion N.
B-54.
Front Axle Universal Joint
—
Lube
Check
the level of the front axle universal joint
lubricant
at each front wheel by removing the
fill-hole plug. The lubricant should be level with
the fill-hole. If required, add lubricant as specified
in
Lubrication
Specifications.
B-55.
Front
Axle
Universal
Joint
— Service
On
all 4-wheel drive vehicles the front axle
uni
versal
joint should be serviced by removing the shaft and thoroughly cleaning the universal joints
and
housing. For the correct procedures, refer to
Section M. 16
Page 41 of 376
'Jeep*
UNIVERSAL SERIES
SERVICE
MANUAL
D
insulator
mountings attached to the frame side
rail
brackets. The
rear
of the engine-transmission
assembly is supported by a rubber insulator
mounting under the
rear
of the transmission on
the frame center cross member.
This
cross member
is bolted to the frame side
rails
so that it can be
dropped when removing the transmission or engine-
transmission
assembly. The rubber insulators allow
free side and vertical oscillation to effectively
neutralize
engine
vibration at the source.
The
rubber
insulator mountings should be inspected
for separation and deterioration by jacking the
power plant away from the frame, near the sup
ports. Vibration cannot be effectively absorbed by
separated or worn insulators. They should be re placed if faulty.
D-4.
Engine
Ground
Strap
To
be sure of an
effective
ground for the electrical
circuits,
a ground strap bridges the right front
engine
support to the chassis. The connections of this strap must be kept clean and tight for proper
operation of the electrical system.
D-5. ENGINE REMOVAL
Should
the
engine
require overhauling, it is neces
sary
to remove it from the vehicle. The following procedure covers removal of the
engine
only.
The
engine, transmission and transfer case may be
removed as a unit by removing (in addition to the following procedure) the radiator guard and the
access plates in the floor pan.
a.
Drain
the cooling system by opening the
drain
cocks at the
bottom
of the radiator and lower right
side of the cylinder block.
b.
Disconnect the battery at the positive terminal
to avoid the possibility of short
circuit.
c. Remove the air cleaner horn from the carburetor
and
disconnect the breather
hose
at the oil filler
pipe.
d.
Disconnect the carburetor choke and throttle controls by loosening the clamp
bolts
and set
screws.
e. Disconnect the fuel-tank-to-fuel-pump line at the fuel pump by unscrewing the connecting nut.
f- Plug the fuel line to prevent fuel leakage.
g. Remove the radiator and radiator grille support
rods.
h. Remove the upper and lower radiator
hoses
by
loosening the
hose
clamps and slipping the clamps
back
on the
hose.
If so equipped, remove the heater
hoses
(one to the water pump, one to the
rear
of
the cylinder head) in the same manner.
i.
Remove the four
bolts
from the fan hub and re
move
the fan hub and fan blades.
j.
Remove the four radiator attaching screws. Re
move
the radiator and shroud as one unit, k. Remove the starting motor cables. Remove the
starting
motor.
I.
Disconnect the wires from the alternator or
generator. Disconnect the ignition
primary
wire
at the ignition coil.
NOTE:
ON
ENGINES EQUIPPED WITH EX
HAUST
EMISSION CONTROL, REMOVE THE
AIR
PUMP,
AIR
DISTRIBUTION
MANI
FOLD,
AND
ANTI-BACKFIRE (DIVERTER)
VALVE.
SEE SECTION
Fl
FOR PROCEDURE.
m.
Disconnect the oil pressure and temperature
sending unit wires at the units.
n.
Disconnect the exhaust pipe at the exhaust
manifold by removing the stud nuts.
o.
Disconnect the
spark
plug cables at the plugs
and
remove the cable bracket from the rocker arm cover stud.
p.
Remove the rocker arm cover by removing the
attaching stud nuts.
q.
Attach a lifting bracket to the
engine
using
existing head bolt locations. Be sure the
bolts
selected
will
hold the
engine
with the weight
balanced.
Attach lifting bracket to a boom hoist,
or
other lifting device, and take up all slack,
r.
Remove the two nuts and
bolts
from each front
engine
support. Disconnect the
engine
ground strap.
Remove the
engine
supports.
Lower
the
engine
slightly to permit access to the two top
bolts
on
the flywheel housing.
s. Remove the
bolts
which attach the flywheel
housing to the engine.
t.
Pull
the
engine
forward, or
roll
the vehicle back
wards,
until the clutch clears the flywheel housing.
Lift
the
engine
from the vehicle.
D-6. ENGINE DISASSEMBLY
Engine
disassembly is presented in the sequence to be followed when the
engine
is to be completely
overhauled after removal from the vehicle. Some
of the operations of the procedure are also ap
plicable
separately with the
engine
in the vehicle,
provided
that wherever necessary the part of the
engine
to be worked on is first made accessible by
removal
of
engine
accessories or other parts.
When
the disassembly operations are performed
with
the
engine
out of the vehicle, it is assumed,
in
this procedure, that all of the accessories have been removed
prior
to starting the disassembly
and
the oil has been drained.
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 repair
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.
NOTE:
If the
engine
is being disassembled because
of possible valve failure, check the valve tappet
clearance
before disassembly. Improper valve
clearance
could be the possible cause of valve
failure,
indicating a need for more frequent valve
checks and adjustments. 41
Page 44 of 376
D
HURRICANE
F4
ENGINE
Note:
Check
the condition of the rubber O-rings.
Defective O-rings could be the major cause of oil
leakage into cylinders. Always discard and replace
all
O-rings removed as only new O-rings should be installed at reassembly.
D-18.
Ream
Cylinder
Bore Ridges
To
prevent breaking the piston lands, the ridge
at the top of each cylinder bore must be removed
first.
To remove this ridge, use a cylinder ridge
reamer,
as shown in Fig. D-3 following the instruc
tions furnished by the reamer manufacturer. Use
care
not to cut below the top of the upper ring
travel
in the bore. Keep each piston top covered
with
an oil-soaked cloth to prevent cuttings from
falling
into the cylinder.
Note:
This
operation should be performed at this
time before the
engine
is rotated for the sequence
steps
following.
D-19.
Remove Oil Pan
Rotate the
engine
to the upside down position.
Remove the screws and lockwashers that attach
the oil pan to the cylinder block. Remove the oil
pan
and gasket.
Discard
the gasket.
D-20.
Remove Piston and Connecting
Rod
Assemblies
Remove the stamped locking nuts from the lower
end of each connecting rod bearing bolt. Remove
the connecting rod nuts. Remove the bearing cap evenly. Push the connecting rod and piston as
sembly out of the cylinder block with the handle end of a hammer until the piston rings are free from
the cylinder bore. Remove the piston and connecting rod assembly
from
the top of the cylinder block. Reassemble the
connecting rod bearing cap with the bearings in
place in the rod from which it was removed. Rotate
the crankshaft and follow the same procedure until
all
the piston and connecting rod assemblies are
removed.
Pistons and connecting rod assemblies may be removed for repair with the
engine
in the vehicle after draining the cooling system, removing the
oil
pan and the cylinder head, and reaming the ridges as previously described.
D-21.
Remove
Timing
Gear
Cover
Remove the bolts, nuts, and lockwashers, that at
tach
the timing gear cover to the engine. Remove
the cover, timing pointer, and cover gasket.
Dis
card
the gasket. Remove the crankshaft oil seal
from
the timing gear cover and discard the seal. Remove the oil slinger and spacer from the
crank
shaft.
D-22.
Remove
Timing
Gears
Use puller W-172 for pulling both the crankshaft
and
the camshaft gears.
With
the threaded cap-
screws supplied, adapt the puller to the crankshaft
FIG.
D-5—PULLING TIMING GEARS
1—
Puller
W-172 2—
Camshaft
Gear
gear and
pull
the gear.
With
the special hook-type
puller
bolts
that fit behind the camshaft gear
flange,
pull
the camshaft gear. Remove the Wood
ruff
Keys.
D-23.
Remove
Front
End Plate
Remove the screws and lockwashers that attach the
front end plate to the cylinder block. Remove the
front end plate and gasket.
Discard
the gasket.
D-24. Remove
Clutch
Remove four
bolts
and lockwashers diagonally
opposite
that attach the clutch assembly to the
flywheel, leaving two
opposed
bolts
to be
loosened
alternately until the clutch spring pressure is re
lieved.
Then,
support the clutch assembly with
one hand while removing the two remaining bolts.
For
information on disassembly, inspection, repair
and
assembly of the clutch refer to Section I. In
structions for removing the clutch when the
engine
is in the vehicle are also given in Section I.
D-25.
Remove Flywheel
The
flywheel is attached to the crankshaft with two tapered dowel
bolts
and four special bolts.
Remove
these
attaching parts. Use a pry bar be tween the flywheel and the back of the
engine
and
carefully
loosen
the flywheel from the crankshaft.
If
the flywheel is to be removed with the
engine
in
the vehicle, the transmission and clutch must
first be removed as detailed in Section I.
D-26.
Remove
Crankshaft
Slide
the crankshaft thrust washer and all end-play
adjusting
shims off the front end of the crankshaft.
Pull
the two pieces of
rear
main bearing cap packing out of position
between
the side of the bearing cap
and
the cylinder block.
Note
the marks on the bearing caps and cylinder
block for bearing number and position. 44
Page 65 of 376
'Jeep'
UNIVERSAL
SERIES
SERVICE
MANUAL
D
FIG.
D-38—CHECKING
FLYWHEEL
RUN-OUT
place the flywheel on the mounting
bolts
in the
crankshaft.
When installing a new crankshaft or
flywheel, replace the tapered dowel
bolts
with
straight snug-fitting special
bolts
provided using
Flywheel
Dowel Bolt Installing Tool Kit W-231 as shown in Fig. D-35 and D-36. Assemble the
crankshaft
and flywheel in proper relation; then in
stall
the straight
bolts
previously used and tighten
securely. Next, use the [13,9 mm.]
drill
to
enlarge the tapered holes. Ream the
holes
with the 5fo" [14,3 mm.] straight reamer and install the
two special flywheel
bolts
with nuts and lock
washers in place of the two tapered dowel
bolts
formerly
used.
This
procedure overcomes the
necessity of reaming special tapered holes.
Tighten
the nuts alternately and evenly until each
is tightened 35 to 41 lb-ft. [4,8 a 5,7 kg-m.].
After
installation check the run-out of the flywheel
with
a
dial
indicator attached to the
engine
plate
as illustrated in
Fig.
D-38. Mount the
dial
indicator
with
the contact button of the indicator resting against the clutch face of the flywheel. Set the
indicator
at zero and rotate the flywheel. Maximum
allowable run-out is .008"
[0,203
mm.] near the
outer
edge
of the
rear
face of the flywheel.
With
the flywheel housing installed temporarily,
the alignment can be checked with a
dial
indicator. Without the clutch installed on the flywheel, a
dial
indicator can be mounted on one of the flywheel bolts. Set the
dial
indicator with the button resting
against the
rear
face of the flywheel housing. Ro
tate
the flywheel, noting the run-out on the
indi
cator.
Maximum allowable run-out is .005" [0,127
mm.].
Relocate the
dial
indicator so that the
button is against the side of the
rear
opening to
check the
radial
run-out. Rotate the flywheel and
note
the run-out which should not exceed .006" [0,152 mm.].
D-88.
Install
Flywheel Housing
Be
certain that the mating surfaces of the flywheel housing and cylinder block are clean and smooth.
Place
the flywheel housing in position and attach to the cylinder block and
engine
rear
plate. The
long
bolts
through the lugs on the
engine
crankcase
and
those
below are installed with the nuts on the
flywheel housing side.
Install
the other
bolts
from
the
rear
except the screw used to attach the top
side of the starting motor. Tighten securely.
D-89.
Install
Clutch
To
install the clutch assembly with the
engine
out
of the vehicle use a clutch plate aligning arbor.
Place
the clutch driven plate in position against
the flywheel. Insert the arbor into the clutch driven plate and clutch shaft bushing and expand the arbor
in
the bushing to hold it in place. Hold the clutch
pressure plate assembly in position against the
clutch
driven plate and install the attaching
bolts
and
washers, tightening the
bolts
alternately and
evenly. Remove the arbor.
D-90.
Install
Valves and Springs
Oil
the valve stems. Insert all intake and exhaust valves in the valve
guides
from which they were
removed.
Install
one exhaust valve spring and exhaust valve
spring
retainer (Roto Cap) for each exhaust valve.
Slip
the top end of the spring
onto
the
bottom
end
of the valve guide and, with a large screwdriver,
snap the spring and retainer over the tappet ad
justing
screw. Make certain that the two closely wound coils of each spring are at the top (placed up to seat against the block.) See Fig. D-39.
Turn
the crankshaft as necessary to bring each
exhaust valve tappet to its lowest position. Using a
valve spring lifter, compress each exhaust valve
spring,
while holding the valve down, so that the
stem
extends
through the valve spring retainer
far
enough to permit installation of the valve
spring
locks. Heavy lubricating oil or grease
placed on the inside surface of the valve locks
will
help to hold the locks on the valve stem until the valve spring lifter can be removed. When installa
tion of exhaust valves is complete, remove any
cloths used to block the valve compartment floor
openings.
Install
the intake valves and springs in the cylinder head placing the ends of the springs
having the closed coils down against the cylinder
head.
FIG.
D-39—VALVE
TAPPETS
AND
SPRINGS
65
Page 68 of 376
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
Page 79 of 376
'Jeep*
UNIVERSAL SERIES SERVICE
MANUAL
Dl
12710
FIG.
D1
-3—HYDRAULIC VALVE
LIFTER
ASSEMBLY, CROSS-SECTIONAL VIEW
1—
Snap
Ring
6—Ball Retainer
2— Rod
Seat
7—Plunger Spring
3—
Oil
Inlets
8—Lifter
Body
4—
Plunger
9—Bronzed
Cap
5— Feed
Hole
sages
in the block and cylinder head.
The
water cooled system is pressurized to provide efficient
engine
cooling. It consists of a centrifugal-
type water pump, mounted on the timing chain cover, and is driven by the
engine
fan pulley. The
pump provides coolant flow equally to both
cylin
der banks under control of a thermostat. Coolant
flow is around the cylinders and through the
cylinder
head to dispel the heat of combustion in
the engine.
Dl-3.
Engine Mounts
The
engine-transmission unit is mounted to the chassis at three points by rubber pads. The two
front mounts are bolted to the
engine
cylinder
block and the frame members. These mounts sup port most of the
engine
weight, and absorb
vibra
tion which would otherwise be caused by changes
in
engine
output torque. The single
rear
mount is
placed
between
the transmission and the trans mission support. It supports part of the engine'
and
transmission weight, and locates the
rear
of
the
engine
with respect to the centerline of the
vehicle.
Dl-4. ENGINE REMOVAL
To
remove the
engine
from the vehicle follow the
procedurers listed below:
a.
Remove hood. b. Disconnect battery cables from battery and
engine. c. Remove air cleaner.
d.
Drain
coolant from radiator and engine.
e.
Drain
engine
oil.
f. Disconnect alternator wiring harness from con nector at regulator.
cj.
Disconnect the fuel evaporative purge line con nected to the
P.C.V.
valve.
h.
Disconnect upper and lower radiator
hoses
from
the engine.
i.
Remove right and left radiator support
bars,
j.
Remove radiator from the vehicle.
k.
Disconnect
engine
wiring harnesses from con
nectors located on
engine
firewall.
I.
On
engines
equipped with exhaust emission con
trol,
remove the air pump, air distribution manifold,
and
anti-backfire (gulp) valve. See Section F2 for
procedure.
m.
Disconnect battery cable and wiring from en
gine
starter assembly.
n.
Remove
engine
starter assembly from engine,
o.
Disconnect
engine
fuel
hoses
from fuel lines at
right
frame
rail,
p. Plug fuel lines.
q.
Disconnect choke cable from carburetor and cable support bracket mounted on engine,
r.
Disconnect exhaust pipes from right and left
engine
manifolds.
s. Place
jack
under transmission and support trans
mission weight.
f. Remove
bolts
securing
engine
to front motor mounts.
u.
Attach suitable sling to
engine
lifting
eyes
and,
using hoist, support
engine
weight.
v. Remove
bolts
securing
engine
to flywheel housing.
w. Raise
engine
slightly and slide
engine
forward
to remove transmission main shaft from clutch plate spline.
Note:
Engine and transmission must be raised
slightly to release the main shaft from the clutch
plate while sliding the
engine
forward.
x. When
engine
is free of transmission shaft raise
engine
and remove from vehicle,
y. Place
engine
on suitable blocking or
engine
stand and remove sling from engine.
Dl-5.
ENGINE DISASSEMBLY
Engine
disassembly is presented in the sequence to be followed when the
engine
is to be completely
overhauled after removal from the vehicle. Some of the operations of the procedure are also applicable separately with the
engine
in the vehicle,
provided that wherever necessary the part of the
engine
to be worked on is first made accessible by removal of
engine
accessories or other parts.
When
the disassembly operations are performed
with
the
engine
out of the vehicle, it is assumed,
in
this procedure, that all of the accessories have
been removed
prior
to starting the disassembly and
the oil has been drained.
Page 80 of 376
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