Mitsubishi Jeep Manuel utilisateur

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MITSUBISHI

"Jeep"

Full

Mechanical Service Manual

English

Version

Military

Civilian

Models

;

'l'.

",;

James

Danko

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Mitsubishi "Jeep" English Full Mechanical Service Manual

this pUblication ifthe author, unless

otherwise noted

credited. It is unlawful to reproduce-or copy in anyway-resell,

redistribute this information without the express written permission

the

publisher.

This book is an independent publication, and the author and/or publisher thereof

are not

anyway associated with, and are not authorized to act on behalf

any

the manufactures listed in this book. All registered trademarks are the property

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

such revision

changes.

Artwork: James

Layout By: James

Danko

ComputerAssistance: Yoshiro (www.yoshiro.com)

Printed

U.S.A-United Kingdom-Australia

Publisher LuLu.com

ISBN: 978-0-557-07670-3

1rst Edition 2009 .

Mitsubishi Motors and all trademarks relative

the Jeep brand (Willys, Kaiser)

are owned by their respective corpQration(s).

"',

Mitsubishi

Jeep

Series

"J"

Series

4 I

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

• Engine Overview Specification

• Tools Required

• Valve Clearance Settings

• Injection Pump Timing

• Engine Idle Setting

I • Engine Compression Test

• Crankcase Timing Gear Front Oil Seal Replacement

• Oil Pan Gasket Replacement

• Oil Pressure Testing &Filter Replacement

• Engine Oil Cooler (Option)

Fuel System.......................................•....................................35

• Fuel Filter Water Drain

• Fuel Line Air Purging

• Fuel CutoffSolenoid Testing'

• Injection Pump Inspection

• Boost Compensator Valve

Testing\Turbo

Engine)

• Injection Nozzle Testing

• 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. I

ntake-Exhaust-

Turbocharger

•

Air

Cleaner Components

• Intercooler (Turbocharged Engines)

• Turbocharger Removal & Replacement

• Intake & Exhaust Manifolds

• Exhaust System Diagram & Components

• Turbocharger Overhaul (Turbocharged Engines)

Engine

Electrical

Components

Circuit

Diagrams

• Alternator Output & Core Line V(1ltage

• Alternator Replacement

• Starter Motor &Solenoid

•

Glow

Plug Circuits Diagram &Test Procedure

•

Water

Temperature Sensor Testing Procedure

•

EGR

Glow

Plug Control UnitTroubleshooting

•

Glow

Relay &

Glow

Plug Removal

• Emission Control &

EGR

System

Engine &Related Parts Overhaul 1

• 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

• Transmission Shift Control System

• Transmission Removal

• Clutch System

• Clutch Disk &Pressure Plate Replacement

• Transmission Major Components

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

12. Front &Rear

Suspension

263

• Front Suspension Specification

• Front Suspension Assembly & Components

• Front LeafSpring 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

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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