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Mitsubishi Jeep User Manual

Mitsubishi Jeep
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MITSUBISHI
"Jeep"
Full
Mechanical Service Manual
English
Version
Military
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Civilian
Models
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Mitsubishi Jeep Specifications

General IconGeneral
BrandMitsubishi
ModelJeep
CategoryAutomobile
LanguageEnglish

Summary

General Vehicle Data

Jeep VIN Decoding

Information to decode Mitsubishi Jeep vehicle VINs, including body type, wheelbase, and engine codes.

Vehicle Inspection Points

Key locations on the vehicle for performing inspections.

Lubrication Points: Chassis & Steering

Identifies grease points for the chassis and steering components.

Oil: Transmission-Transfer-Differential-Steering

Specifications and procedures for transmission, transfer case, differential, and steering oils.

Jacking Lift Point Locations

Designated points for safely lifting the vehicle.

Jack Stand Location Points

Recommended positions for placing jack stands for support.

Complete Vehicle Dimensions J55-56-57-58-59 Series Civilian

Detailed physical dimensions for civilian J55-59 series models.

Complete Vehicle Dimensions J25 A-A2-A3- (A) Series Military

Detailed physical dimensions for military J25 A-A2-A3-(A) series models.

General Maintenance & Settings

Engine Overview Specification

General specifications and overview of the vehicle's engine.

Tools Required

List of tools necessary for maintenance and adjustments.

Valve Clearance Settings

Correct valve clearance specifications and adjustment procedures.

Injection Pump Timing

Procedures for setting and verifying the fuel injection pump timing.

Engine Idle Setting

How to adjust the engine's idle speed.

Engine Compression Test

Method for testing engine cylinder compression.

Crankcase Timing Gear Front Oil Seal Replacement

Step-by-step guide for replacing the front oil seal on the timing gear.

Oil Pan Gasket Replacement

Instructions for replacing the oil pan gasket.

Oil Pressure Testing & Filter Replacement

Procedures for testing oil pressure and changing the oil filter.

Engine Oil Cooler (Option)

Information regarding the optional engine oil cooler system.

Fuel System

Fuel Filter Water Drain

Procedure for draining water from the fuel filter.

Fuel Line Air Purging

Steps to remove air from the fuel lines.

Fuel Cutoff Solenoid Testing

Methods for testing the fuel cutoff solenoid.

Injection Pump Inspection

Guidelines for inspecting the fuel injection pump.

Boost Compensator Valve Testing (Turbo Engine)

Testing the boost compensator valve on turbo engines.

Injection Nozzle Testing

Procedures for testing fuel injection nozzles.

Injection Nozzle Line System

Details on the fuel injection nozzle line system.

Injection Nozzle Overhaul

Instructions for overhauling fuel injection nozzles.

Fuel Injection Pump Assembly Non-Turbocharged

Information on the fuel injection pump assembly for non-turbocharged models.

Injection Pump Removal

Procedure for removing the fuel injection pump.

Fuel Injection Pump Assembly: Turbocharged

Information on the fuel injection pump assembly for turbocharged models.

Fuel Gage Sending Unit

Details on the fuel gauge sending unit.

Fuel Tank System: Civilian Models

Description of the fuel tank system for civilian models.

Fuel Tank System: Military Models

Description of the fuel tank system for military models.

Accelerator & Throttle Cable Assemblies

Information on accelerator and throttle cable systems.

Fuel Filter Cartridge Replacement

Procedure for replacing the fuel filter cartridge.

Coolant System

General Specifications & Capacities

Overall specifications and fluid capacities for the coolant system.

Coolant System Flushing

Instructions on how to flush the coolant system.

Thermostat Replacement & Testing

Procedures for replacing and testing the thermostat.

Clutch Fan & Drive Belt

Maintenance and replacement of the clutch fan and drive belt.

Water Pump Replacement

Steps for replacing the water pump.

Radiator Replacement

Instructions for replacing the radiator.

Water Pump Overhaul

Details on overhauling the water pump.

Intake-Exhaust-Turbocharger

Air Cleaner Components

Details on the components of the air cleaner system.

Intercooler (Turbocharged Engines)

Information on the intercooler for turbocharged engines.

Turbocharger Removal & Replacement

Procedure for removing and replacing the turbocharger.

Intake & Exhaust Manifolds

Information on intake and exhaust manifold systems.

Exhaust System Diagram & Components

Diagrams and details of the exhaust system components.

Turbocharger Overhaul (Turbocharged Engines)

Instructions for overhauling the turbocharger on turbocharged engines.

Engine Electrical Components & Circuit Diagrams

Alternator Output & Core Line Voltage

Testing alternator output and core line voltage.

Alternator Replacement

Procedure for replacing the alternator.

Starter Motor & Solenoid

Details and service for the starter motor and solenoid.

Glow Plug Circuits Diagram & Test Procedure

Diagrams and testing procedures for glow plug circuits.

Water Temperature Sensor Testing Procedure

How to test the water temperature sensor.

EGR & Glow Plug Control Unit Troubleshooting

Troubleshooting the EGR and glow plug control units.

Glow Relay & Glow Plug Removal

Procedure for removing the glow relay and glow plugs.

Emission Control & EGR System

Information on emission control systems and the EGR system.

Engine & Related Parts Overhaul

Required Tools

List of essential tools for engine overhaul.

Detailed Engine & Parts Specifications

Comprehensive specifications for engine and its components.

Torque Specification

Torque values for various engine fasteners and components.

Engine Removal

Step-by-step guide for removing the engine from the vehicle.

Cylinder Head & Valve Train Overhaul

Detailed procedure for overhauling the cylinder head and valve train.

Flywheel & Components

Information on the flywheel and its related components.

Oil System & Oil Pump Overhaul

Overhaul procedures for the engine oil system and oil pump.

Timing Gears & Camshaft

Service and overhaul for timing gears and camshaft.

Engine Block- Piston-Crankshaft Overhaul

Instructions for overhauling the engine block, pistons, and crankshaft.

Cylinder Sleeve Replacement

Procedure for replacing cylinder sleeves.

Engine Assembly

Guidance on reassembling the engine after overhaul.

Starter Overhaul

Instructions for overhauling the starter motor.

Alternator Components

Details on the components of the alternator.

Vacuum Pump

Information and service for the vacuum pump.

Clutch & Transmission

Pedal Height

Adjustment procedure for clutch pedal height.

System Air Bleeding

Procedure for bleeding air from the clutch system.

Pedal & Linkage System

Information on the clutch pedal and linkage system.

Clutch Hydraulic System

Details and service for the clutch hydraulic system.

Clutch Master Cylinder

Service and overhaul for the clutch master cylinder.

Transmission Specifications

General specifications for the transmission.

Oil Servicing: Transmission & Transfer Case

Procedures for servicing the transmission and transfer case oil.

Transmission Shift Control System

Information on the transmission shift control system.

Transmission Removal

Step-by-step guide for removing the transmission.

Clutch System

Overview and service of the clutch system.

Clutch Disk & Pressure Plate Replacement

Procedure for replacing the clutch disk and pressure plate.

Transmission Major Components

Details on major components within the transmission.

Driveshaft System

Removal & Installation

Instructions for removing and installing the driveshaft.

Driveshaft Warpage Inspection

Procedure for inspecting the driveshaft for warpage.

Front & Rear U-Joint Replacement

Steps for replacing front and rear universal joints.

Front Axle & Differential

Front Axle Specifications

General specifications for the front axle.

Tools

List of tools required for front axle service.

Wheel Alignment

Procedure for performing wheel alignment on the front axle.

Front Axle Backlash & Axel Inspection

Inspection and adjustment of front axle backlash.

Oil Level

Checking and maintaining the oil level in the front axle.

Front Hub Assembly

Service and inspection of the front hub assembly.

Knuckle Assembly

Details on the front axle knuckle assembly.

Front Axel Shafts

Information on front axle shafts.

Front Differential Carrier

Details on the front differential carrier.

Front Differential Carrier Overhaul

Procedure for overhauling the front differential carrier.

Rear Axle & Differential

Front Axle Specifications

Specifications for the front axle (likely a typo, should be rear).

Tools

List of tools required for rear axle service.

Inspection & Oil Level

Checking and maintaining oil level and performing inspection.

Axel Shafts Overhaul

Instructions for overhauling rear axle shafts.

Differential Carrier Inspection

Inspection of the rear differential carrier.

Differential Overhaul

Procedure for overhauling the rear differential.

Front & Rear Suspension

Front Suspension Specification

General specifications for the front suspension system.

Front Suspension Assembly & Components

Details on the front suspension assembly and its parts.

Front Leaf Spring Overhaul

Instructions for overhauling the front leaf springs.

Rear Suspension Specifications

General specifications for the rear suspension system.

Rear Suspension Assembly

Details on the rear suspension assembly.

Rear Leaf Spring Overhaul

Instructions for overhauling the rear leaf springs.

Rear Stabilizer bar

Information and service for the rear stabilizer bar.

Brake System

Brake Pedal Height Adjustment

Procedure for adjusting the brake pedal height.

System Air Bleeding & Brake Shoe Adjustment

Steps for bleeding the brake system and adjusting brake shoes.

Brake Lining & Drum Specification

Specifications for brake linings and drums.

Brake Pedal System Components

Details on the components of the brake pedal system.

Brake Master Cylinder 7 Brake Booster Components

Information on brake master cylinder and brake booster components.

Master Cylinder Rebuild

Procedure for rebuilding the master cylinder.

Brake Vacuum Pump

Service and information for the brake vacuum pump.

Front Drum Brakes

Details on front drum brake systems.

Front Wheel Cylinder

Service and information for the front wheel cylinder.

Rear Drum Brake: Civilian

Information on rear drum brakes for civilian models.

Rear Wheel Cylinder: Civilian

Service for the rear wheel cylinder on civilian models.

Rear Drum Brake: Military

Information on rear drum brakes for military models.

Rear Wheel Cylinder: Military

Service for the rear wheel cylinder on military models.

Parking Brake Inspection

Procedure for inspecting the parking brake system.

Parking Brake Cable System

Details on the parking brake cable system.

Parking Drum Brake System

Information on the parking drum brake system.

Steering System

Specifications

General specifications for the steering system.

Tools

List of tools required for steering system service.

Inspection & Toe In Settings

Procedure for inspecting steering and setting toe-in.

Backlash Settings

Adjustment procedures for steering system backlash.

Ball Joint Inspection

Procedure for inspecting steering system ball joints.

Steering Gear Oil

Information regarding steering gear oil specifications and levels.

Steering Wheel & Column Assembly

Details on the steering wheel and column assembly.

Gear Box Assembly

Information on the steering gear box assembly.

Gear Box Overhaul

Procedure for overhauling the steering gear box.

Steering Linkage

Details on the steering linkage system.

Bell Crank Assembly

Information on the steering bell crank assembly.

Heater System

Heater Controls: Civilian

Details on heater controls for civilian models.

Heater Controls: Military

Details on heater controls for military models.

Heater Unit: Civilian

Information on the heater unit for civilian models.

Heater Unit: Military

Information on the heater unit for military models.

Water Hose Routing

Diagrams and information on water hose routing for the heater.

Defroster Ducting: Civilian

Information on defroster ducting for civilian models.

Defroster Ducting: Military

Information on defroster ducting for military models.

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