Jeep CJ-2A User Manual

Your Operation and Care Manual

Universal Jeep Model CJ-2A

Foreword

IN YOUR possession is a motor vehicle that has been thoroughly tested and inspected. Like any other piece of machinery, to maintain it in first class condition, you should lubricate it at the time prescribed with the proper grade of oil and grease and keep all working parts and oil holes clean and free of dirt and grit. You should also periodically have it systematically inspected at an Authorized Willys-Overland Service Station. In the following pages we have set forth the knowledge every owner should have of his vehicle, that he may know to take the best care of it and handle it in such a way that he will get maximum service. Information is also available covering external adjustments and minor emergency repairs. Read and follow these instructions carefully; we are sure that you will then enjoy the satisfactory operation that you rightfully anticipate. Should adjustment or repair seem necessary beyond your ability, don't experiment; have the work done by a competent repair man. It will always prove best and cheapest in the end to have the work done by the Dealer from whom you purchased your car. Many Willys-Overland Dealers have factory trained mechanics and all are familiar with the construction and adjustments through the cooperation of the manufacturer. Do not attempt any adjustments as long as the vehicle is operating satisfactorily. Be sure to obtain the Owner Service Policy, provided by your Dealer on delivery of your new vehicle.

Caution

Accept and use only Genuine Factory Parts

Imitation parts are usually of inferior quality and can do serious damage to other mechanical parts of your vehicle. Genuine parts are sold by all authorized Willys-Overland Dealers. Be sure non other than genuine parts are placed in your vehicle. Presence of parts other than those furnished by Willys-Overland will void the manufacturer's Warranty. NOTE: Parts replaced under the terms of the Warranty must be left with the Willys-Overland Dealer who makes the replacement, if full credit is expected. This is important for Owners to know, when travelling outside the territory in which their vehicle was originally purchased, particularly when credit for old parts cannot be established to the satisfaction of the Dealer. In this connection, a forwarding address should be given by the Owner in order to insure the credit reaching him.

Standard Warranty

THE only Warranty under which new Willys-Overland Motor Vehicles are sold is that of the Manufacturer, being the Standard Warranty recommended by the Automobile Manufacturer's Association, and is as follows:

"This is to certify that we, WILLYS-OVERLAND MOTORS, INC., TOLEDO, OHIO, U.S.A. warrant each new motor vehicle manufactured by us, to be free from defects in material and workmanship under normal use and service, our obligations under this Warranty being limited to making good at our factory any part or parts thereof, including all equipment or trade accessories (except tires) supplied by the Car Manufacturer, which shall, within ninety (90) days after making delivery of such vehicle to the original purchaser or before such vehicle has been driven 4000 miles, whichever event shall first occur, be returned to us with transportation charges prepaid, and which our examination shall disclose to our satisfaction to have been thus defective; this warranty being expressly in lieu of all other warranties expressed or implied and of all other obligations or liabilities on our part, and we neither assume nor authorize any other person to assume for us any other liability in connection with the sale of our vehicles. This warranty shall not apply to any vehicle which shall have been repaired or altered outside of an Authorized Willys-Overland Service Station in any way so as, in the judgment of the Manufacturer, to affect its stability or reliability, nor which has been subject to misuse, negligence or accident"

The Manufacturer makes no warranty against, nor assumes any liability for any defect in metal or other material in any part, device or trade accessory which cannot be discovered by ordinary factory inspection.

WILLYS-OVERLAND MOTORS, INC. NOTE -- Willys-Overland Motors, Inc., reserves the right at any time or times to revise, modify, discontinue or change any models of its vehicles, or any part or parts thereof, without notice; and, without it or the Seller, incurring any liability or obligation to the Purchaser.

Jeep CJ2A Specifications on The CJ2A Page

Engine "Go-Devil" L-Head

Number of cylinders........................................4

Bore...............................................................3 1/8"

Stroke............................................................4 3/8"

Piston Displacement........................................134.2 cu. in.

Compression Ratio..........................................6.48 to 1

Horsepower -- SAE........................................15.6

Horsepower (actual @ 4,000 RPM)................60

Torque (max. @ 2,000 RPM).........................105 Lbs. Ft.

Dimensions and Capacities

Wheelbase......................................................80"

Tread..............................................................48 1/4"

Overall Width..................................................59"

Overall Height (Top up)...................................69 3/8"

Overall Height (Top down)..............................52 3/8"

Overall Length.................................................122 3/4"

Road Clearance...............................................8 5/8"

Weight -- Maximum Payload............................800 lbs.

Shipping (Less water, oil and fuel).....2,037 lbs.

Curb (Including water, oil and fuel)....2,137 lbs.

Gross (Loaded)................................2,937 lbs.

Maximum Approved Draw Bar Pull

(Continuous Operation)................................1,200 lbs.

Fuel Tank Capacity...........................................10.5 gals.

Cooling System Capacity...................................11 qts.

Lamp Bulbs Head Lamp (7 in. Sealed Beam Type)

Upper Beam.................................................45 watts

Lower Beam................................................35 watts

Parking Lamp Bulb............................................3 CP-SC

Tail Lamp Bulb..................................................21-3 CP-DC

Instrument Lamp Bulb........................................3 CP-SC

Fuse (Thermal Type) -- On Light Switch............30 Amperes

Lubrication Capacities Engine Crankcase -- oil filter empty (quarts)..5 US / 4 1/4 Imp.

Transmission and Transfer Case (pints)..........6 1/2 US / 5 1/2

Imp.

Differential - Front Axle (pints)......................2 1/2 US / 2 Imp.

Differential - Rear Axle (pints).......................2 3/4 US / 2 1/4

Imp.

Oil Bath Air Cleaners (pints)..........................1 1/4 US / 1 Imp.

Brake System Fluid (pints).............................3/4 US / 5/8 Imp.

Location of Serial Number: Plate on outside left frame side rail at the front and on instrument panel. Location of Engine Number: Stamped on water pump boss.

79.37 mm.

111.12 mm.

2199.53 cc.

203.20 cm.

122.55 cm.

149.86 cm.

176.21 cm.

133.03 cm.

311.78 cm.

21.90 cm.

362.88 kg.

961.63 kg.

1006.99 kg.

1369.87 kg.

544.32 kg.

39.74 litres

10.41 litres

No. 63 No. 1158 No. 63

4.73 litres

3.7 litres

1.18 litres

1.30 litres

591.40 cc.

354.84 cc.

Lubrication Specifications

Chassis Lubrication Transmission and Transfer Case Differentials -- Front and Rear Steering Gear Wheel Bearings Universal Joints (Front Axle Shaft) Universal Joints (Propeller Shaft) Power Take-Off Housing Air Cleaner Governor Engine

Type Lube. Chassis Lube. Mineral Gear Oil Hypoid Oil Steering Gear Lube. Wheel Bearing Lube. Universal Joint Lube. Chassis Lube. Mineral Gear Oil Engine Oil Engine Oil Engine Oil

Winter No. 0 SAE 80 SAE 90 SAE 140 No. 2 No. 0 No. 0 SAE 80 Same Grade as used in engine Same Grade as used in engine See Below

Summer No. 1 SAE 90 SAE 90 SAE 140 No. 2 No. 1 No. 1 SAE 90 Same Grade as used in engine Same Grade as used in engine See Below

Above 90º F.................SAE 30

Not Lower than 32º F...SAE 20 or 30

As Low as +10º F........SAE 20 W

As Low as -10º F.........SAE 10 W

To temperatures below -10º F, use SAE 10 W plus 10% kerosene

Valve and Ignition Timing

Inlet opens 9 degrees before top centre Inlet closes 50 degrees after bottom centre Exhaust opens 47 degrees before bottom centre Exhaust closes 12 degrees after top centre Spark Setting

Spark set top centre with automatic spark controls at rest, when using low octane fuel.

Firing Order Tappet setting for valve timing Number of flywheel teeth

Piston Measurements From Top Centre

.039" (9.91 mm.)

3.772" (95.81 mm.)

3.799" (96.49 mm.) .054" (0.14 mm.) "IGN" 5º BTC

1-3-4-2 .020" (0.51 mm.) 97

CJ2A Operation and Care Manual -- Inspections and Precautions

At assembly a restrictor is placed between the intake manifold and the carburetor to limit the road speed to approximately 42 mph. To protect the vehicle, leave the restrictor in position for the first 500 miles of road operation, or equivalent in industrial operation, after which remove and discard it.

It is an obligation of the Selling Dealer to carefully inspect and adjust your Universal Jeep before delivery. After your vehicle has been operated 1000 miles, return it to your dealer for the 1000 Mile Inspection in accordance with Factory Form, Ser. 3455. This inspection is free with the exception of engine oil and anti-freeze solution used.

1000 Mile Free Inspection

Check steering system and front wheel alignment. Check spring clip nuts and spring shackles. Check rear axle for oil and leaks. Adjust body bolts. Test service and hand brakes -- inflate tires. Check cooling system for leaks and anti-freeze and fan belt adjustment. Adjust clutch pedal. Check operation of transmission and transfer case -- Check for oil level and leaks. Check battery, generator output, headlamps and horn. Tighten universal joint companion flange bolts. Check operation of ammeter, heat indicator, fuel and oil gauges. Tighten cylinder head nuts -- Check timing and distributor points. Set spark plugs -- Adjust carburetor -- Check throttle controls. Check engine for oil leaks -- Check fuel line connections. Adjust valve tappets, if required. Change engine oil (charge for oil) -- Lubricate vehicle. Clean and refill air cleaner. Clean fuel pump sump and strainer. Check extra equipment attaching screws -- Check for oil level and leaks.

FILL IN FOR YOUR REFERENCE Vehicle Serial Number ____________________ Engine Serial Number ____________________ Purchase Date __________________________ Ignition Key Number _____________________

WILLYS-OVERLAND MOTORS, INC.

Proper Operation

DRIVING A NEW "JEEP" Do not run your "Universal Jeep" faster than 40 miles an hour for the first 500 miles or if used on the farm or for industrial operation, use care when pulling heavy loads in the lower gear ratios. If the vehicle is operated at high speeds while new or used for heavy pulling for a long period, the closely fitted parts might possibly become overheated, resulting in scored pistons, cylinders or burned bearings. During its entire life, never race the engine while making adjustments or when the vehicle is standing idle. It the vehicle is not properly lubricated, our Warranty is null and void. Be sure to have your Willys-Overland Dealer inspect your vehicle at the end of 1000 miles or equivalent usage and every 2500 miles thereafter.

SPECIAL PRECAUTIONS

There are several points of difference between the Universal Jeep and a conventional vehicle to receive attention. As a general precaution and for your information we are listing these "cautions" below: The Jeep is equipped with a transfer case and four-wheel drive to provide additional traction and a lower gear ratio for use on difficult terrain. Use the front wheel drive only when necessary. Consider the front wheel drive and the transfer case as a lower gear ratio than the standard transmission low gear and use it only when greater power is required. The use of four-wheel drive on hard surfaced highways will result in rapid tire wear and hard shifting of the transfer case, particularly when the front wheels are steered even at a slight angle from the straight ahead position. If hard shifting occurs, disengage the clutch, start engine, shift transmission into reverse gear, back the vehicle a few feet, and disengage clutch. If transfer case is in low range, shift into high then shift front axle into "out" position (lever forward). Two drain cocks are provided to drain the cooling system. A drain cock is located under the left side of the radiator, however, it is necessary to drain the cylinder block separately. The cylinder block drain is located at the right front corner of the block directly under the generator. Loosen the radiator cap to break the seal and permit complete draining. Check the level of the lubricant often in the transmission and transfer case. Be sure the lubricant is at filler level in both units at all times. As a standard, the clutch pedal is adjusted with 1" free travel. As the clutch wears this becomes less. Be sure that there is free travel at all times to prevent continuous operation of the clutch release bearing and rapid wear and slippage of the clutch. This adjustment is made by lengthening or shortening the clutch control cable. The ventilator valve, mounted in the intake manifold, must be free to operate. If it is stuck open very uneven engine operation at low speed will result. Be sure the exhaust manifold heat control valve is free at all times and the thermostatic control spring is above the stop. Six screws are used to attach the front wheel brake backing plate and spindle to the spindle housing. These screws are standard in dimensions and thread pitch, however, they are made of special steel and receive special heat treatment. Safety demands that only genuine factory screws be used at this point.

CJ2A Operation and Care Manual -- Getting Started

FIG. 1 - VEHICLE CONTROLS

1. Windshield Wiper Arm

2. Windshield Wiper Blade

3. Windshield Centre Lock

4. Windshield Glass

5. Hand Wiper Handle and Knob

6. Windshield Tubular Frame

7. Windshield Frame and Glass Assembly

8. Windshield Inner Adjusting Arm

9. Windshield Outer Adjusting Arm

10. Adjusting Wing Screw

11. Top Bow Storage Retainer

12. Instrument Panel Light

13. Choke Control

14. Windshield Clamp

15. Ammeter

16. Hand Brake Handle

17. Ignition Switch

18. Starter Switch

19. Underdrive Shift Lever

20. Front Axle Drive Shift Lever

21. Transmission Shift Lever

22. Heat Indicator Gsuge

23. Accelerator Pedal

24. Speedometer

25. Brake Pedal

26. Clutch Pedal

27. Headlamp Dimmer Switch

28. Instrument Panel Light Switch

29. Oil Gauge

30. Main Lighting Switch

31. Fuel Gauge

32. Throttle Control

33. Rear Vision Mirror

34. Horn Button

35. Steering Wheel

36. Windshield Wiper Motor

TO MAKE VEHICLE READY.

• Fill the radiator with clean, soft water.

• Put gasoline in the tank.

• Fill the oil reservoir through the filler pipe at the right side of the engine until the oil indicator stick registers “FULL”.

(See “Lubrication Specifications”.)

• Supply all parts requiring lubrication with oil or lubricant.

• See that the tires have proper pressure (See “Tire Pressure”.)

• Adjust the rear view mirror to correct position for driver. If adequate view is not obtainable, the mirror may be

adjusted by loosening the screw through the mounting bracket or by tilting in the ball and socket connection.

CONTROLS AND SWITCHES.

• The position of all controls and switches is shown in Fig. 1.

• The horn is operated by pressing the button located at the top center of the steering wheel.

• The instrument panel light switch is located along the lower edge of the instrument panel to the left of the steering

post. The windshield wiper control is mounted on the wiper motor housing.

• The main light switch No. 30 controlling both the head and tail lamps is conveniently located on the instrument panel

to the left of the steering post. It is of the plunger type – pull all the way out for the “full on” position, half-way for “parking” and all the way in is the “off” position.

• In addition to the main light switch, the high and low beams of the headlamps are controlled by a selector foot switch,

located on the toe board to the left of the clutch pedal. Pressing and releasing the switch button, with the foot, alternately changes the beam from high to low and vice versa.

TO START ENGINE.

• Put the transmission gearshift lever No. 21, Fig. 1 in neutral. Place the transfer case low and high shift lever No. 19 in

direct gear or in the rear position and disengage the front axle by placing the shift lever No. 29 in the forward position.

• Pull the choke control button No. 13 one-fourth of the way out which also opens the throttle slightly.

• Place the key in ignition lock No. 17 and turn it to the right, closing the ignition circuit.

• Disengage the clutch.

• Depress the foot starting switch at No. 18.

• Should the engine fail to start at once, pull the choke all the way out and press the starting switch. When the engine

starts, push the choke in about one-third of the way.

• Set the choke control at the best operating position and as the engine warms up, push the choke all the way in. Do not

run with the choke out as fuel is wasted and the engine fouled.

• Should the engine fail to start, see the “Emergency Chart”.

FIG. 2 -- SIDE SECTIONAL VIEW OF ENGINE

1. Fan Assembly

2. Water Pump Bearing and Shaft Assembly

3. Water Pump Seal Washer

4. Water Pump Seal Assembly

5. Water Pump Impeller

6. Piston

7. Wrist Pin

8. Thermostat Assembly

9. Water Outlet Elbow

10. Thermostat Retainer

11. Exhaust Valve

12. Intake Valve

13. Cylinder Head

14. Exhaust Manifold Assembly

15. Valve Spring

16. Valve Tappet Self-Locking Adjusting Screw

17. Engine Plate -- Rear

18. Camshaft

19. Flywheel Ring Gear

20. Crankshaft Packing -- Rear End

21. Crankshaft Bearing Rear Drain Pipe

22. Crankshaft Bearing -- Lower

23. Valve Tappet

24. Crankshaft

25. Oil Pump and Distributor Drive Gear

26. Connecting Rod Cap Bolt

27. Oil Float Support

28. Oil Float Assembly

29. Crankshaft Bearing Centre -Lower

30. Connecting Rod Assembly -- No. 2

31. Connecting Rod Bolt Nut Lock

32. Crankshaft Bearing -- Front Lower

33. Crankshaft Oil Passages

34. Crankshaft Thrust Washer

35. Crankshaft Gear

36. Crankshaft Gear Spacer

37. Timing Gear Cover Assembly

38. Fan and Generator Drive Belt

39. Crankshaft Oil Seal

40. Starting Crank Nut Assembly

41. Crankshaft Gear Key

42. Fan and Governor Drive Pulley Key

43. Timing Gear Oil Jet

44. Fan, Generator and Governor Drive Pulley

45. Camshaft Thrust Plate

46. Camshaft gear Retaining Washer

47. Camshaft Gear Retaining Screw

48. Camshaft Gear Thrust Plate Retaining Screw

49. Camshaft Gear

TO START VEHICLE.

• Release hand brake, if set.

• Depress clutch pedal.

• Move transmission gearshift leer to first speed position – see Fig. 3

(Note that the front axle and transfer case shift levers are not used when the vehicle is driven on the highway in rear wheel drive.)

• Depress the foot accelerator pedal gradually and at the same time,

slowly release the clutch pedal.

• Allow the vehicle to gain momentum (two or three vehicle lengths), then

release the accelerator and depress the clutch at the same moment.

• Move the shift lever promptly to the second speed position.

• Depress the foot accelerator pedal gradually and at the same time,

slowly release the clutch pedal.

• Shift to third or "high" speed in the same way at approximately 18 to 20

mph, releasing the accelerator and depressing the clutch before moving the shift lever.

• The synchronizing mechanism in the transmission makes gear shifting

silent and easy. This device adjusts the speeds of the two gears to be engaged and prevents "clashin

TO CHANGE TO LOWER SPEED.

• Depress the clutch pedal.

• Move the gearshift lever quickly to the next lower speed, increasing the engine speed slightly, if traveling on level

road and release the clutch pedal.

• It will be found advisable to make this change when the engine is placed under heavy pull, or when dropping down to

a very low speed, as when travelling up a steep grade, in sand or in congested traffic.

• Never attempt to make the change with the vehicle traveling at a high rate of speed.

TO STOP THE VEHICLE.

• Release the foot accelerator.

• Depress the clutch pedal and apply foot brake.

• When stopped, move gearshift lever into neutral.

• Set the hand brake and release the clutch and brake pedals.

TO REVERSE VEHICLE.

• With the vehicle at a standstill, depress the clutch pedal.

• Shift the lever into the reverse position, slowly release the clutch pedal and regulate the car speed with the foot

accelerator.

TO USE THE ENGINE AS A BRAKE. The most effective brake for holding the vehicle back on a steep grade is the engine. To use the engine as a brake, shift into one of the lower speeds before starting to descend. Keep the clutch engaged, the throttle closed, and the ignition “ON”. Low gear will hold any vehicle effectively on any hill it can climb. Never engage the clutch suddenly when the vehicle is coasting with the clutch released and the transmission gears in mesh, as damage to the driving mechanism may result.

FIG. 4 -- END SECTIONAL VIEW OF ENGINE

1. Ignition Distributor

2. Cylinder Head Gasket

3. Eshaust Valve Guide

4. Intake Manifold Assembly

5. Valve Spring Cover Assembly

6. Heat Control Valve

7. Crankcase Ventilator Baffle

8. Exhaust Manifold Assembly

9. Crankcase Ventilator Assembly

10. Distributor Shaft Friction Spring

11. Oil Pump Driven Gear

12. Oil Pump Gasket

13. Oil Pump Assembly

14. Oil Pump Pinion

15. Oil Pump Cover aft

16. Oil Pump Relief Plunger

17. Oil Pump Relief Plunger Spring

18. Oil Pump Relief Plunger Shim

19. Oil Pump Relief Plunger Spring Retainer

20. Oil Pump Sh21. Oil Pan Assembly

22. Oil Pan Drain Plug

23. Oil Float Support

24. Crankshaft Bearing Dowel

25. Crankshaft Bearing Cap to Crankcase Screw

26. Oil Float Assembly

27. Oil Filler Tube

28. Oil Filler Cap and Level Indicator

29. Distributor Oiler

STARTING VEHICLE ON UPGRADE. In starting on an upgrade, hold the vehicle with the hand brake, disengage the clutch and shift the transmission into low speed, then accelerate the engine with the foot accelerator in the regular way while simultaneously releasing the hand brake and engaging the clutch SHIFTING GEAR IN TRANSFER CASE. The transfer case is essentially a two speed transmission, which provides a low and a direct gear and also a means of connecting the engine power to the front axle. It is an auxiliary unit attached to the rear of the standard transmission. Control of the transfer case is through the two shift levers, Fig. 1 No. 19 and No. 20. The left lever, No. 20, is used to connect and disconnect the power to the front axle. The right lever, No. 19 is used to shift the transfer case gears to secure either “High” (direct drive) or a very low gear ratio for heavy pulling requirements. Instructions for shifting gears in the transfer case are as follows: See Fig. 3.

1. To engage front axle drive, depress the clutch pedal, release accelerator and move the left hand shift lever (No. 20) to rear position

2. With the front axle drive engaged, the right hand lever (No. 19) may be shifted to the rear into “High” (direct) or forward into “Low”. The “Neutral” position midway between “High” and “Low” is for use when the power take-off belt drive is used. The vehicle cannot be driven when this lever is in “Neutral”.

3. To disengage the front axle drive, depress the clutch pedal, release the accelerator and shift the left lever to the forward position. The transfer case can be operated only in “High” (direct drive) when the front axle drive is disengaged.

4. Shifting from high to low transfer case gear should not be attempted except when the vehicle is practically at a standstill. The front axle drive must be engaged for this shift. Release the accelerator and depress the clutch pedal – move the left hand shift lever to the rear position to engage the front wheel drive, then move the right hand shift lever to forward position (low transfer case gear).

5. Shifting from low to high transfer case gear may be accomplished at any time, regardless of vehicle speed. Release accelerator and depress clutch pedal and shift right hand lever into rear position.

USE OF FOUR WHEEL DRIVE. The “Universal Jeep” is equipped with four-wheel drive and transfer case to provide additional traction and a low gear ratio for use on difficult terrain and to provide low speed pulling power for industrial and agricultural use. Four-wheel drive should be used only when greater traction and power are required than provided by the standard transmission and low gear. Avoid the use of four-wheel drive on hard surfaced highways as it will result in rapid tire wear and hard shifting of the transfer case gears. Should hard shifting occur, disengage the clutch, start engine, shift the transmission into reverse gear, back the vehicle a few feet, and disengage the clutch. If transfer case is in low range, shift into high, then disengage front axle drive (left lever forward).

STEERING KNUCKLE OIL SEAL.

When parking during cold, wet weather, swing the front wheels from right to left to wipe away moisture adhering to the front axle universal joint housings and oil seals, Fig. 5. This will prevent freezing with resulting damage to the oil seal felts. When the vehicle is stored for any period, the front axle universal joint housings should be coated with light grease to prevent rusting.

How to Save Gasoline

1. In cold weather economical starting of the engine is easily obtained by pressing down on the accelerator pedal once or twice, then push down on the clutch pedal and start engine using the choke sparingly. Do not use the choke when starting a warm engine.

2. Do not use the choke excessively while engine is warming up and never leave it out longer than absolutely necessary.

3. Accelerate gently. Tramping on the accelerator pumps more gasoline into the cylenders than can be effectively used.

4. Holding the car in second gear until you get up to high speeds may easily double the gasoline you should use in getting under way. Shift into high gear at about 20 miles per hour.

5. Fast driving uses up more gasoline. Travel at moderate speeds if you want gasoline economy.

6. Decelerate to a gradual stop. Sudden stops, like sudden starts, are wasteful of gasoline.

7. Park your car in the shade if possible, hot sun evaporates gasoline.

8. Don't drive your tires with less than the proper amount of air pressure. Under-inflated tires mean more road friction, more work for the engine to do -- and therefore more gasoline consumed. See "Tire Pressure".

9. Keep the battery charged up in good condition. It helps starting and provides good ignition thereby reducing loss of gasoline.

10. Letting the engine idle for long periods wastes gasoline.

11. Be sure that the carburetor is in proper condition for maximum mileage and power.

12. One faulty or dirty spark plug may waste as much as 10 percent of your gasoline. Have the spark plugs tested occasionally.

13. Keep your car well lubricated at all times, and be very careful to follow the instructions on "Lubrication".

14. Keep the radiator filled to the proper level; your engine will remain at a more constant temperature. An overheated engine uses more gasoline.

15. Check the operation of the automatic heat control on the exhaust manifold. The purpose of this heater is to warm the mixture of air and gasoline as it leaves the carburetor, in order to give better vaporization. (See Manifold Heat Control).

16. It is a good idea to have a complete engine tune-up every 5,000 miles, or at least twice a year -- in the Fall when preparing for Winter driving and again in the Spring. The Owner Service Policy entitles you to an adjustment and complete inspection without charge at the end of the first 1000 miles.

CJ2A Operation and Care Manual -- General Lubrication

General Lubrication

The use of high grade lubricants and regular application is specially essential when operating the “Jeep” because of the diversified service it performs. The amount of trouble free service received will be in proportion to the care given. Lubricate the vehicle in accordance with the type of service performed. The following pages should be referred to for instructions covering grade and quality of lubricant for all parts of the vehicle. The mileage instructions should be followed when the vehicle is used for road work. It is impossible to give accurate hourly instructions because of the diversified service and conditions under which the vehicle may be operated. The hours indicated are approximate. To obtain maximum service, good judgment must be used to lubricate the vehicle according to the type of work being done. As an example – when used as a farm tractor under dusty conditions the chassis should be lubricated daily as the new lubrication forces grit and dirt, which has accumulated during the day, from the bearing surfaces. Under these conditions, the air cleaner should also be cleaned and refilled daily or under extreme conditions twice daily. Because of the importance of correct lubrication, detailed recommendations, unit capacities and specifications are given in the following paragraphs.

Lubrication Specifications

Type Lube. Chassis Lube. Mineral Gear Oil Hypoid Oil Steering Gear Lube. Wheel Bearing Lube. Universal Joint Lube. Chassis Lube. Mineral Gear Oil Engine Oil Engine Oil Engine Oil

Winter No. 0 SAE 80 SAE 90 SAE 140 No. 2 No. 0 No. 0 SAE 80 Same Grade as used in engine Same Grade as used in engine See Below

Summer No. 1 SAE 90 SAE 90 SAE 140 No. 2 No. 1 No. 1 SAE 90 Same Grade as used in engine Same Grade as used in engine

See Below

Above 90º F.................SAE 30

Not Lower than 32º F...SAE 20 or 30

As Low as +10º F........SAE 20 W

As Low as -10º F.........SAE 10 W

To temperatures below -10º F, use SAE 10 W plus 10% kerosene.

ENGINE LUBRICATION.

Lubrication of the engine is accomplished by means of a force-feed continuous circulating system. This is effected by means of a gear type pump, located externally on the left side of the engine, and driven by a spiral gear on the camshaft. The oil is drawn into the circulating system through a floating oil intake. The floating intake does not permit water or dirt to circulate, which may have accumulated in the bottom of the oil pan, because the oil is drawn horizontally from near the top surface. An oil pressure gauge is mounted in the instrument panel, which indicates the pressure being supplied to the circulating system. Failure of the gauge to register may indicate absence of oil, leakage or a fault in the lubrication system and the engine should be stopped immediately. If there is plenty of oil in the reservoir the mechanical fault must be corrected before starting the engine. Standard gauge reading is approximately 35 at 30 miles per hour and 10 at idle speed. The quantity of the oil in the crankcase is measured by the bayonet type oil level indicator which is combined with the oil filler cap located in the oil filler pipe at the right side of the engine. When the oil level is below the “Full” mark, pour sufficient new oil into the reservoir to bring the level to the “Full” mark. When the vehicle leaves the factory the crankcase is filled to the correct level with oil of the proper viscosity for the “break-in” period. When the vehicle is used on the highway, completely drain the engine oil at 500 miles and at 1000 miles, then every 2000 miles thereafter, by removing the drain plug in the lower left side of the oil pan. Replace the drain plug and refill with 4 qts (5 qts. when the engine oil filter has been drained) of fresh oil. For heavy industrial or dusty field work, change the oil at the first 10 hours, and each 50 hours thereafter. To secure maximum engine life, watch the condition of the oil closely and should it become contaminated, due to conditions under which the vehicle has been operated, change it immediately. Always drain the oil when the engine is warm. The benefit of draining is, to a large extent, lost if the crankcase is drained when the engine is cold, as some of the foreign matter will remain in the bottom of the oil pan. At least once a year, preferably in the Spring, remove the oil pan and floating oil intake and wash thoroughly with cleaning solution.

CHASSIS LUBRICATION.

When lubricating the chassis refer to the Lubrication Chart. For highway travel, clean and lubricate points 2, 3, 4, 5, 6, 7, 8, 9, 10, and 11 each 1000 miles. When used in industrial or agricultural work the period for lubrication depends entirely upon the type of work being done. When doing dusty field work, lubricate these points daily as grit and dirt will work into the bearing surfaces and cause rapid wear unless forced out by new lubricant. The importance of using a good grade of chassis lubricant can not be exaggerated, for the cost will be more than repaid by longer wear and good service.

OIL FILTER.

The oil filter should be dismantled, cleaned and the filter element replaced at the end of the first 2000 miles of highway travel, or 100 hours

of industrial or field use. Drain the filter at each oil change to prevent the old oil contained in the filter from mixing with and contaminating the new oil. Replace the element at each 8000 miles of highway use or 200 hours of industrial or field use.

AIR CLEANER.

Care of the air cleaner is EXTREMELY IMPORTANT – especially when the vehicle is used under dusty conditions. Clean and refill the air cleaner reservoir to the level mark, with oil of the same grade used in the engine, at etch engine oil change. When the vehicle is used for field work, clean and change the oil in the cleaner DAILY and under dusty conditions TWICE DAILY. When cleaning, use a long screw driver or other suitable tool to dislodge dirt sticking to the bottom and sides of the intake passage in the body of the cleaner.

STEERING GEAR.

Check the level of the lubricant in the steering gear housing every 1000 miles. Avoid the use of cup grease, graphite, white lead or heavy solidified oil. Remove the plug in the steering gear housing and use a hand gun to fill the housing slowly.

WATER PUMP – CLUTCH.

The water pump and clutch release bearings are prelubricated at assembly and the lubricant lasts for the life of the bearings.

GENERATOR.

Two oilers are provided, one at each end; three to five drops of engine oil is recommended every 1000 miles. Be sure to slip the commutator end hole cover back in place.

STARTING MOTOR.

The oil hole cover on the commutator (front) end slips to one side; put three to five drops of engine oil in this hole every 1000 miles. Be sure to slip cover back in place.

IGNITION DISTIBUTOR.

The oiler on the distributor should be lubricated every 1000 miles with several drops of engine oil, Fig. 7, No. 6. Also place one drop of light engine oil on the wick, No. 2 located in the top of the shaft, which is accessible by removing the rotor arm and sparingly apply soft grease on the breaker arm cam No. 4, and a drop of oil on the breaker arm pivot, No. 3. See PROPOER MAINTENANCE for Fig. 7.

SPEEDOMETER AND DRIVE.

Some of the speedometers supplied are equipped with a wick type oiler located on the drive shaft boss directly above the tube and shaft connection to the speedometer head. Lubricate this oiler with a few drops of light oil twice each year. Remove the drive shaft from the tube once each year, clean it thoroughly and lubricate with a good quality light graphite grease.

UNIVERSAL JOINTS (PROPELLER SHAFT).

Every 1000 miles lubricate the propeller shaft universal joints and the slip joints with a good quality lubricant. Lubricate daily for field work.

UNIVERSAL JOINTS (FRONT AXLE SHAFT).

The front axle universal joints are enclosed in the steering knuckle housings, which are filled with lubricant so require no attention other than checking each 1000 miles to be sure the housings are filled to plug level. Once each year or every 300 hours of field work the axle shafts and universal joint assemblies should be removed, thoroughly cleaned and the housings filled with new lubricant.

WHEEL BEARINGS.

Front wheel bearings should be removed, thoroughly cleaned, checked and replaced twice yearly or every 6000 miles. The rear wheel bearings are equipped with hydraulic lubricators. Lubricate them sparingly to guard against surplus oil saturating the brake lining. An oil relief hole at the top of housing, Fig. 32, No. 1, indicates when the bearing is filled with oil.

TRANMISSION AND TRANSFER CASE.

Drilled passages are provided between the transmission and transfer case housings for circulation of the lubricating oil to provide unit lubrication of the two assemblies. The oil level should be checked each 1000 miles or at each lubrication. Drain and refill at each 6000 miles or 300 hours of field work.

Note: The requirements of these housings are small for economy, therefore, it is very important that the lubrication be changed every 300 hours when the vehicle is used for dusty field work.

FRONT AND REAR DIFFERENTIALS.

The differential gears require extreme pressure lubricant, which is suitable for hypoid gear type axles. The level of the lubricant in these units should be checked every 1000 miles. Do not mix different types of hypoid lubricants. Drain and refill the housings each 6000 miles or twice yearly. Use a light engine or flushing oil to clean out the housings.

Note: Do not use water, steam, kerosene, or gasoline for flushing. If the oil is decomposed, dismantling is necessary.

GOVERNOR.

At each lubrication, check the oil level in the governor housing. Use oil of the same grade used in the engine to maintain the lubricant at filler plug level. Drain and refill the housing at each 300 hours of operation.

POWER TAKE-OFF SHAFT AND PULLEY DRIVE HOUSINGS.

Check the lubricant level at each lubrication job, maintaining the lubricant at filler plug level. Should the power take-off be used frequently, change the lubricant each 300 hours.

CJ2A Operation and Care Manual -- Proper Maintenance

NEVER RUN ENGINE IN CLOSED GARAGE Due to the presence of carbon monoxide (a poisonous gas in the exhaust of the engine) never rub the engine for any length of time while the vehicle is in a small closed garage. Opening the doors and windows will lessen the danger considerably, but it is safest if adjustments are being made that require the operation of the engine, to run the vehicle out-of-doors.

INSPECTION. The old adage "An ounce of prevention is worth a pound of cure" was never more true than when applied to any motor vehicle. The importance of regular systematic inspection cannot be over-emphasized. Small and seemingly unimportant faults, if neglected, may grow into expensive major repairs. Regular inspections and prompt correction of small faults will go far toward holding down maintenance expense, eliminating delays in productive operations and upholding the high standard of reliability and performance built into your "Jeep" at the factory. ENGINE TUNE-UP. For best performance and dependability the engine should have a periodic tune-up twice yearly, preferably in the Spring and Fall.

• Remove the spark plugs, clean them thoroughly and space the electrodes to .030" (0.76 mm.) gap.

• Clean and tighten the battery cable terminals, the battery ground connection and the ground strap on the right side of

the engine at the front engine support (See Fig. 10).

• Remove the distributor cap and inspect the contact points. Adjust the points to .020" (0.51 mm.) gap. See Fig.7 No.5.

• Check the ignition timing.

• Check the valve tappet clearance. Adjust to .014" (0.356 mm.) clearance with engine hot or cold.

• Clean the fuel pump filter screen and check fuel line connections.

• Remove ventilator valve Fig. 12 and clean.

• Start the engine and allow it to run until thoroughly warm then set the carburetor idle screw so the engine will idle at

600 rpm. (vehicle speed of approximately 6 mph).

• Adjust the carburetor low speed idle screw so that the engine will idle smoothly.

NOTE: Should the engine fail to perform satisfactorily and the trouble is definitely traced to the carburetor, consult your Willys-Overland Dealer. Carburetor service is specialized and should not be undertaken unless the unit is thoroughly understood.

VALVE AND IGNITION TIMING

Inlet opens 9 degrees before top centre Inlet closes 50 degrees after bottom centre Exhaust opens 47 degrees before bottom centre Exhaust closes 12 degrees after top centre Spark Setting Spark set top centre with automatic spark controls at rest, when using low octane fuel. Firing Order Tappet setting for valve timing Number of flywheel teeth

Piston Measurements from Top Centre

039" (9.91 mm.)

3.772" (95.81 mm.)

3.799" (96.49 mm.) .054" (0.14 mm.) "IGN" 5º BTC 1-3-4-2 .020" (0.51 mm.) 97

CHECKING VALVE TIMING

To check the valve timing, adjust the inlet valve tappet No. 1 cylinder to .020" (0.51 mm.). Use care in making this adjustment that the measurement is accurate with feeler gauges and that the tappet is resting against the lowest surface of the camshaft cam. Rotate the crankshaft clockwise until piston in No. 1 cylinder is ready for the intake stroke. (Mark "I-O" -- intake open -- on the flywheel is in the centre of the engine.) With the crankshaft in this position, valve timing is correct if No. 1 intake valve tappet is jut tight against the end of the valve stem. After checking, adjust all of the tappets .014" (0.356 mm.). Should the timing be incorrect it is advisable to consult your Willys-Overland Dealer

IGNITION TIMING

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