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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

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

11

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)

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

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

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

Alternator Output & Core Line V(1ltage

Alternator Replacement

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57

71

89

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

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

Pedal Height

System Air Bleeding

Pedal & Linkage System

Clutch Hydraulic System

Clutch Master Cylinder

Transmission Specifications

Oil Servicing: Transmission & Transfer Case

101

187

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Transmission Shift Control System

Transmission Removal

Clutch System

Clutch Disk & Pressure Plate Replacement

Transmission Major Components

9. Driveshaft System

Removal & Installation

Driveshaft Warpage Inspection

Front & Rear U-Joint Replacement

10. Front Axel & Differential

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

Front Axel Specifications

Tools

Inspection & Oil Level

Axel Shafts Overhaul

Differential Carrier Inspection

Differential Overhaul

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203

211

241

12. Front & Rear Suspension

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

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

263

277

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14. Steering System

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

Heater Controls: Civilian

Heater Controls: Military

Heater Unit: Civilian

Heater Unit: Military

Water Hose Routing

Defroster Ducting: Civilian

Defroster Ducting: Military

10

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303

321

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

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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)

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

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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
vehicle. Check the engine block for the engine series code.

the

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

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Inspection Points

Front Differential Breather

Passenger Side Dust Boot

14

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Front A..xle Dust Boot

Clutch Release Cylinder

Speedometer Cable

Rear Ditlerential Breather

Lubrication Grease Points: Chassis & Steering

15

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