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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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 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). "', ­

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 Mitsubishi Jeep Series

"J" Series

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 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

I •
•
•
•
Crankcase Timing Gear Front Oil Seal Replacement
Oil Pan Gasket Replacement
Oil Pressure Testing & Filter Replacement
Engine Oil Cooler (Option)
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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
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 • 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. Intake-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
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 • 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 101

• 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
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 • 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

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 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

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 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

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 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

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 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

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 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.

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 Inspection Points

Front Differential Breather Front A..xle Dust Boot Speedometer Cable

Passenger Side Dust Boot Clutch Release Cylinder Rear Ditlerential Breather

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 Lubrication Grease Points: Chassis & Steering

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