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MITSUBISHI
"Jeep"
Full
Mechanical Service Manual
English
Version
Military &Civilian
Models
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James
L.
Danko
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Page 2
Mitsubishi "Jeep" English Full Mechanical Service Manual
Copyright
© 2009 by James Danko
All rights reserved. All text and graphics
in
this pUblication if the author, unless
otherwise noted
or
credited. It is unlawful to reproduce-or copy in anyway-resell,
or
redistribute this information without the express written permission
of
the
publisher.
This book is an independent publication, and the author and/or publisher thereof
are not
in
anyway associated with, and are not authorized to act on behalf
of
any
of
the manufactures listed in this book. All registered trademarks are the property
of
their respective owners. The publisher reserves the right to revise this
publication or change its content from time to time without obligation to notify any
persons
of
such revision
or
changes.
Artwork: James
L.
Danko© 2009
Layout By: James
L.
Danko
Computer Assistance: Yoshiro (www.yoshiro.com)
Printed
in
U.S.A-United Kingdom-Australia
Publisher LuLu.com
ISBN: 978-0-557-07670-3
1rst Edition 2009
.
".
Mitsubishi Motors and all trademarks relative
of
the Jeep brand (Willys, Kaiser)
are owned by their respective corpQration(s).
"',
-
Page 3
Mitsubishi
Jeep
Series
"J"
Series
3
Page 4
4
I
Page 5
Contents
1. General Vehicle
Data
11
• Jeep VIN Decoding
• Vehicle Inspection Points
• Lubrication Points: Chassis & Steering
• Oil: Transmission-Transfer-Differential-Steering
• Jacking Lift Point Locations
• Jack Stand Location Points
• Complete Vehicle Dimensions J55-56-57-58-59 Series Civilian
• Complete Vehicle Dimensions J25 A-A2-A3- (A) Series Military
2. General Maintenance &
Settings
21
• Engine Overview Specification
• Tools Required
• Valve Clearance Settings
• Injection Pump Timing
• Engine Idle Setting
• Engine Compression Test
• Crankcase Timing Gear Front Oil Seal Replacement
• Oil Pan Gasket Replacement
• Oil Pressure Testing
& Filter Replacement
• Engine Oil Cooler (Option)
t
3.
Fuel System.......................................•....................................35
• Fuel Filter Water Drain
• Fuel Line Air Purging
• Fuel Cutoff Solenoid Testing'
• Injection Pump Inspection
• Boost Compensator Valve
Testing\Turbo
Engine)
• Injection Nozzle Testing
5
Page 6
• Injection Nozzle Line System
• Injection Nozzle Overhaul
• Fuel Injection Pump
Assembly
Non-Turbocharged
• Injection Pump Removal
• Fuel Injection Pump Assembly: Turbocharged
• Fuel
Gage
Sending Unit
• Fuel
Tank
System: Civilian Models
• Fuel
Tank
System: Military Models
• Accelerator & Throttle Cable Assemblies
• Fuel Filter Cartridge Replacement
4. Coolant System
57
• General Specifications & Capacities
• Coolant System Flushing
• Thermostat Replacement & Testing
• Clutch Fan & Drive Belt
•
Water
Pump
Replacement
• Radiator Replacement
•
Water
Pump Overhaul
5. I
ntake-Exhaust-
Turbocharger
71
•
Air
Cleaner Components
• Intercooler (Turbocharged Engines)
• Turbocharger Removal
& Replacement
• Intake & Exhaust Manifolds
• Exhaust System Diagram & Components
• Turbocharger Overhaul (Turbocharged Engines)
6.
Engine
Electrical
Components & Circuit
Diagrams
89
• Alternator Output & Core Line V(1ltage
• Alternator Replacement
6
Page 7
• Starter Motor & Solenoid
•
Glow
Plug Circuits Diagram &Test Procedure
•
Water
Temperature Sensor Testing Procedure
•
EGR & Glow
Plug Control Unit Troubleshooting
•
Glow
Relay &
Glow
Plug Removal
• Emission Control &
EGR
System
7.
Engine & Related Parts Overhaul 1
01
• Required Tools
• Detailed Engine
& Parts Specifications
• Torque Specification '
• Engine Removal
• Cylinder Head & Valve Train Overhaul
• Flywheel
& Components
• Oil System
& Oil Pump Overhaul
• Timing Gears
& Camshaft
• Engine Block- Piston-Crankshaft Overhaul
• Cylinder Sleeve Replacement
• Engine Assembly
• Starter Overhaul
• Alternator Components
•
Vacuum
Pump
8. Clutch &
Transmission
; 187
• Pedal Height
• System
Air
Bleeding
• Pedal
& Linkage System
• Clutch Hydraulic System
• Clutch
Master
Cylinder
• Transmission Specifications
• Oil Servicing: Transmission
& Transfer Case
7
Page 8
• Transmission Shift Control System
• Transmission Removal
• Clutch System
• Clutch Disk
& Pressure Plate Replacement
• Transmission Major Components
9.
Driveshaft System 203
• Removal & Installation
• Driveshaft Warpage Inspection
• Front
& Rear U-Joint Replacement
10. Front Axel & Differential
211
• Front Axel Specifications
• Tools
• Wheel Alignment
• Front Axle Backlash
&Axe/Inspection
• Oil Level
• Front Hub Assembly
• Knuckle Assembly
• Front Axel Shafts
• Front Differential Carrier
• Front Differential Carrier Overhaul
11. Rear Axel & Differential 241
• Front Axel Specifications
• Tools
• Inspection
& Oil Level
• Axel Shafts Overhaul
• Differential Carrier Inspection
• Differential Overhaul
8
Page 9
12. Front & Rear
Suspension
~
263
• Front Suspension Specification
• Front Suspension Assembly
& Components
• Front Leaf Spring Overhaul
• Rear Suspension Specifications
• Rear Suspension Assembly
• Rear Leaf Spring Overhaul
• Rear Stabilizer bar
.13. Brake
System
277
• Brake Pedal Height Adjustment
• System Air Bleeding
& Brake Shoe Adjustment
• Brake Lining & Drum Specification
• Brake Pedal System Components
• Brake Master Cylinder 7 Brake Booster Components
• Master Cylinder Rebuild
• Brake Vacuum Pump
• Front Drum Brakes
• Front Wheel Cylinder
• Rear Drum Brake: Civilian
• Rear Wheel Cylinder: Civilian
• Rear Drum Brake: Military
• Rear Wheel Cylinder: Military
• Parking Brake Inspection
• Parking Brake Cable System
• Parking Drum Brake System
9
Page 10
14.
Steering
System
303
• Specifications
• Tools
• Inspection & Toe In Settings
• Backlash Settings
• Ball Joint Inspection
• Steering
Gear
Oil
• Steering Wheel & Column Assembly
•
Gear
Box Assembly
•
Gear
Box Overhaul
• Steering Linkage
• Bell Crank Assembly
15. Heater System
321
• Heater Controls: Civilian
• Heater Controls: Military
• Heater Unit: Civilian
• Heater Unit: Military
• Water Hose Routing
• Defroster Ducting: Civilian
• Defroster Ducting: Military
10
Page 11
General Vehicle Data
General Vehicle Data
• Jeep VIN Decoding
• Vehicle Inspection Points
• Lubrication Points: Chassis & Steering
• Oil: Transmission-Transfer-Differential-Steering
• Jacking
Lift Point Locations
• Jack Stand Location Points
• Complete Vehicle Dimensions J55-56-57-58-59 Series Civilian
• Complete Vehicle Dimensions J25 A-A2-A3- (A) Series Military
11
Page 12
Jeep Decoding
Following the examples below
will
provide information to decode your
Mitsubishi Jeep Vehicle.
Note: K
or
KB
is
a Japanese Domestic Emissions Code for Exhaust Gas
Regulations.
Not
all
older Jeeps
do
have this code. They simply start from the
Letter
"J"
The
First Letter
'1"
Represents Jeep
The
Second Letter
or
Number
Represents Body Type
or
Wheelbase
•
3=
Long
(Hardtop)
•
4=
Long
(Soft-top)
•
2=
Middle (Hardtop-Soft-top)
•
5=
Short
(Soft-top)
Civilian Use
KBJ
5 5 F F
TT
~
Intercooler
Turbocharger
! I 4M/T, Floor Shift
I I Diesel 2700 (4DR5)
I Short Wheelbase Canvas
Top
'-----Jeep
Series
L.-------Meets
Environmental Regulations 1994
Military Use
J 2 5 A
lL.--
Use 1/2
Ton
Truck Note: See Diagrams For Details
<---
DieseI4DR5
'--- Middle Wheelbase
'---
Jeep
12
Page 13
The
Third
Number
indicates the Engine Type: See Chart
0=2.2L Diesel
or
Gas
2=2.3L Gas (KE47) 4=2.7L Diesel (4DR5)
5=2.7 Diesel (Turbo)
6=
2.4L Diesel (4G53)
7=
2.7 Gas (G54B)
8=2.0 Gas (4G52) 9=2.0 Gas (G52B)
Note: Verifying a
VIN
code can
not
guarantee the original engine
is
in
the
vehicle. Check the engine block for the engine series code.
Not
all
Jeeps have continued (Long) codes. These were option codes
or
shifter
location.
"F"
=Floor
Shift
"C"
Column Shift.
Other
codes equaled
"F"
for
Intercooler
Turbo
and
"A"
Codes for military use.
13
Page 14
Inspection Points
Front Differential Breather
Front A
....
xle Dust Boot
Speedometer Cable
Passenger Side Dust Boot
Clutch Release Cylinder
Rear Ditlerential Breather
14
Page 15
Lubrication Grease Points: Chassis & Steering
15
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