Jeep UNIVERSAL CJ-2A - Page 46

'Jeep' UNIVERSAL and 'Jeep' DISPATCHER
D
block. The other core hole expansion plugs in the
cylinder block can be removed by piercing the
center with a sharp tool and prying them out.
Before attempting to install a new plug, clean the
hole thoroughly. Apply a thin coat of sealer on
the new plug and install the plug with a driver.
D-69. Cylinder Head
Be sure that water passages are open and that
all carbon is removed. Inspect all tapped openings.
Repair any damaged threads or broken studs. Run
a tap in the threaded holes to clean up rough or
damaged threads. Before using a tap, squirt
penetrating oil on the threads. Discard or repair
cracked cylinder heads, also those warped ~{2"
[0,793 mm.] or more over the full length of the head.
D-70. ENGINE ASSEMBLY
The engine assembly procedure in the following
paragraphs is given in the sequence to be followed
when the engine is being completely overhauled.
Individual inspection, repair, and fitting operations
previously covered in detail are made throughout
the assembly procedure. The assembly procedure
does not cover accessories. If a new cylinder block
fitted with pistons is used, many of the operations
will not be required.
Mount the cylinder block in an engine repair stand.
If an engine stand is not available, perform the
following assembly operation in a manner designed
to protect personnel against an accident and the
engine and its parts against damage.
D-71. Install Oil Gallery Plug
Coat plug tH~eads with a suitable sealing compound
and install the plugs in the front and rear ends of
the oil gallery in the cylinder block and the rear
end of the cylinder head.
There is also a pipe plug CYs" [3,2 mm.] slotted,
headless) in the opening in the main oil gallery
inside the cylinder block at No. 2 cylinder and
another pipe plug (Ys" square-head) in the opening
in the oil passage directly below the oil pump intake
passage. If these two pipe plugs were removed,
make certain they are reinstalled in the locations
described above or the counterweight of the
crankshaft might strike the projecting head of the
square-head plug.
D-72. Install Tappets
Turn the block upside down. Install the valve
tappets in the ta:P.pet bores in the cylinder block
in their original positions. Check the tappet-to-
bore fit of each tappet as it is installed in the block.
If the stem-to-block clearance of .0005" to .002"
[.0013
a .0051 mm.] is exceeded, install a new tappet
to fit within this tolerance or ream the bore to ac-
comodate an oversize tappet (available in .004"
[.009
mm.] oversize).
D-73. Install Camshaft and Thrust Plate
Lubricate all camshaft bearings and cam surfaces
generously with clean, light engine oil. Carefully,
so not to damage or score the camshaft front bear-
ing, install the camshaft, locating it properly in
the bearings. Do not allow the rear end of the cam-
shaft to strike sharply against the expansion plug
installed in the rear end of the bore.
Install the camshaft thrust plate. Slide the thrust
plate spacer onto the end of the camshaft with the
beveled inner edge of the spacer facing the cam-
shaft. If the same camshaft is being reinstalled
install any shims previously removed. These shim~
are placed between the camshaft shoulder and the
spacer. Torque the thrust plate attaching bolts 20
to 26 lb-ft. [2,8 a 3,6 kg-m.].
End play of the camshaft is determined by running
clearance between the rear face of the camshaft
gear and the thrust plate. The standard clearance
is .004" to .007" [0,102 a 0,178 mm.] as measured
by a dial indicator. Should a check show too little
end play, place a shim of suitable thickness between
the camshaft shoulder and the spacer. Too much
end play may be corrected by removing shims or
dressing off the spacer a slight amount.
D-74. Install Crankshaft and Bearings
Fit the three upper main bearings into theh
respective locations in the cylinder block. Fit the
three lower main bearings into their respective
bearing caps.
NOTE: It is possible to incorrectly install the front
main bearing. The bearing is properly installed in
the cap with the narrower of the two radial oil
grooves
toward the front edge of the cap. If this
bearing is not properly installed, the oil grooves in
the two halves of the bearing will not match at the
parting line and premature failure of the bearing
will result.
Lubricate all bearing surfaces generously with
clean, light engine oil. Place the crankshaft in
position in the cylinder block and install the main
bearing caps. Torque the bolts 65 to 75 lb-ft.
[9,0 a 10,4 kg-m.]
rotating the crankshaft after
each bearing cap is tightened.
Early model L4-134 crankshafts had counter-
weights forged as an integral part of the crankshaft.
Later production crankshafts that have separately
forged counterweights can be installed in place of
the former crankshaft when the following points of
possible interference are checked:
a. After installation, turn the crankshaft slowly
to determine if it clears the pipe plug in the crank-
case main oil line at the rear of the oil pump.
Should there be insufficient clearance, either install
a new slotted headless plug or grind off and slot
the present plug.
b. After installation of the :floating oil intake,
check to determine that the crankshaft clears the
float when the float is in the up position.
c. On gear-driven-camshaft engines, check the
clearance of the connecting rod bolt head with, the
camshaft intake cam for No. 2 cylinder when that
cam is pointed toward the crankshaft. If there is
interference or very little clearance, grind the bolt
head to give about .OS" [1,2 mm.] clearance with
the cam.
d. Before installing the oil pan, it may be neces-
sary to bend the rear main bearing oil return pipe
slightly toward the flywheel to clear the rear
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