MITSUBISHI ECLIPSE 1991 Service Manual

BACKUPGROUP INDEX &ma
;r Service Manual
LASER
TALON
1991
Volume-l
Engine, Chassis
& Body
FOREWORDThis Service Manual has been prepared with the
latest service information available at the time of
‘* publication.It is subdivided into various group
categories and each section contains diagnosis,
disassembly, repair, and installation procedures
along with complete specifications and tightening
references. Use of this manual will aid in properly
performing any servicing necessary to maintain or
restore the high levels of performance and reliabilitydesigned into these outstanding vehicles.
This BACKUP DSM manual IS to be used ONLY as a BACKUP. Please DO NOT REDISTRIBUTEWHOLE SECTIONS. This BACKUP was sold to you under the fact that you do indeed OWNa GENUINE DSM MANUAL. It CANNOT BE considered a REPLACEMENT (Unless your originalmanual was lost or destroyed.)Please See
README.N or README.HTML for additional information
Thank you. G~mm~emymanual@hotma~l.com
1,
wA
CHRYSLER
CORPORATION
Chrysler Corporation reserves the right to make changes in design 0’: tomake additions to or improvements in its products without lmqoslngd ., . any obligations upon itself to install them on its products previouslymanufactured.
0 1990 Mitsubishi Motors CorporationPrinted in U.S.A.Introduction and
Master
Troubleshooting. . . . . .,. . . . . . . . . r...m,
Lubrication and Maintenance . . . . . . . . ‘-0‘8
; “. i,
.Front Suspension. . . . . . . . . . . . . . ..*............d...Rear Axle
. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..‘.....................
/
ServiceBrakes-Parking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..~......................‘t.
Cooling. . . . . . . . . . . . . . . . . ..i....................................
,., .‘,-,
Engine..i....~....r...............~....~.*,.~.~.~,‘~~...;..~~..Intake and Exhaust
. . . . . . ..L....................Fuel System
. . . . . . . . . . . ..ti.......r................~...Propeller Shaft
.......................................IRear
Suspensiori.............................y.f...
ManualSteering- Power.....................................Manual
I
transaxle-Automatic .............:;i...,;.....;Wheels
and Tires.................................
Body.............................................................Heater & Air Conditioning
..............Emission
Contr6l Systems..............
INOTE: For Electrical, refer toVolume-2 “Electrical”.

2INTRODUCTION AND MASTER TROUBLESHOOTING - How to Use This Manual
HOW TO USE THIS MANUALNOaM
CONTENTSThe preceding page contains GROUP INDEX which
lists the group title and group number.
PAGE NUMBERS
All page numbers consist of two sets of digits
separated by a dash. The digits preceding the dash
identify the
number of the group. The digits follow-
ing the dash represent the consecutive page num-
ber within the group. The page numbers can be
found on the top left or right of each page.
TEXT
Unless otherwise specified, each service procedurecovers all models. Procedures covering specific
models are identified by the model codes, or similar
designation (engine type, transaxle type, etc.). A
description of these designations is covered in this
unit under “VEHICLE IDENTIFICATION”.
TROUBLESHOOTING
Troubleshootings are classified into master trouble-
shooting and group troubleshooting and located as
follows:
The master troubleshooting is prepared when the
trouble symptom relates to two or more groups and
given in MASTER TROUBLESHOOTING.
The group troubleshooting guide is prepared for
causes of problems related to that individual group
only; a troubleshooting guide is prepared for each
appropriate group.LIMIT
-9Shows the standard for judging the quality of a part
-
or assembly on inspection and,means the maximumor minimum value within which the part or assembly
must be kept functionally or in strength.
It is a value
established outside the range of standard value.
Removal steps
: The numbers beforepartname correspond to numbers
in the illustration, and indicate
the order of removal.
Disassembly steps : The numbers before partname correspond to num-bers in the illustration,
and indicate the order of
disassembly.
Installation steps : This is provided if installa-tion cannot’be made in the
reverse order of “Removal
steps
“; omitted if installa-tion in the reverse order of“Removal steps” k possi-ble.Reassembly steps : This is .provided if reas-sembly cannot be made
rL+. .
in the reverse order of
“Disassemblysteps” ;omitted if reassembly inthe reverse order of “Dis-assembly steps” is possi-ble.
SERVICE PROCEDURESThe service steps are arranged in numerical order
and attentions to be paid in performing vehicle
service are described in detail in SERVICE POINTS.
.IVL, -....-ce : Removall 4 : InstallationDEFINITION OF TERMS
STANDARD VALUEIndicates the value used as the standard for judgingthe quality of a part or assembly on inspection or the
value to which the part or assembly is corrected and
adjusted. It is given by tolerance.
MODEL INDICATIONS
The following abbreviations are used in this manual for classification of model types.
M/T : Indicates the manual transaxle, or models equipped with the manual transaxle.
A/T: Indicates the automatic transaxle, or models equipped with the automatic transaxle.
MPI: Indicates the multi-point injection, or engines equipped with the multi-point injection.
SOHC: Indicates an engine with the single overhead camshaft, or a model equipped with such an
engine.DOHC: Indicates an engine with the double overhead camshaft, or a model equipped with such an
engine.Turbo: Indicates an engine with turbocharger, or a model equipped with such an engine.
Non-Turbo: Indicates an engine without turbocharger, or a model equipped with such an engine.
FWD: Indicates the front wheel drive vehicles.
AWD: Indicates the all wheel drive vehicles.
ABS: Indicates the anti-lock braking system or models equipped with the anti-lock braking system.

INTRODUCTION AND MASTER TROUBLESHOOTING - How to Use This Manual3Page number
Group title
IIndicates the incidental operation to be
performed before removal or after
installa-
52444BRAKES-Roar Brake Wlmd Cylinder
REAR BRAKE WHEEL CYLINDER
-
-
-
3ENjOVAL AND lNSTAU.AllONII
Remwal stepa
1. Brake drum
2. Bleeder screw
3. Brake tube connectionl * 4.Wheel cylinder assemblyl e 5.Wheel cylinder bootl + 6.Piston assemblyn** 7. Piston cue
NOTEI1 lReverse the removal procedures to reinstall.12)M : Refer to ‘Service Points of Aemcval”.(3)l * : Refer to ‘Service Points of Installation’.14) q :Nc+-r-reusab(epatts
SERWE POINTS REMOVAL’
-7. REMOVAL OF PISTON CUP
Using a screwdriver, remove the piston cup from the piston.
INSPECTION-
Check the following points. and if there is any abnormality, replacethe entire wheel cylinder assembly.
(1) Check piston and wheel cylinder walls for rust or damage.(2) Check clearance between the cylinder and the piston.
Measure in two perpendicular directions to figure the clear-
ance between the wheel cylinder inner diameter
fmax.value)and the piston outer diameter (minvalue).
Limit : 0.15 mm (4059 in.)
NOTE
If the difference is more than the limit, replace the piston and
wheel cylinder as an assembly.This number corresponds to
the number in “Removal
steps”,“Disassembly
steps”,“Installation steps”
or “Reassembly steps”.

4INTRODUCTION AND MASTER TROUBLESHOOTING - How to use This ManualEXPLANATION OF THE TROUBLESHOOTING GUIDE
3. Checking the passenger compartment-temperature sensor, outside-air sensor, air-thermostat sensor and refrigerant-temperature sensor circuitsrIndicatesthe
circuit diagram
for
checking(including the
interface of the
air conditioner
control unit).
II*
in the opera-
tion
descrip-tions only as
necessary, and
these numbers
correspond to
the
numbers
usedin har-
ness and com-
ponent layout
l 1
I--
Operation descriptionA negative-characterlstlc thermstor 1s employed for each sensor in order 10 convey the amblenttemperature of the sensor pan ,o resistanceThe sensor power-supply I2 5V) of the awcondltww““I,ISappliedtothelermlnals116).(15).(17)(5)dlvldedres~~,ancereSlSta”ceR
Providesthe
scription of cir-
cuit operation
for basic under-
standing.
I
diaarams.Tmublrhooting 4DlagnoslsNo 12 The
ou,s,de-a,, sensor ,nput slgnal IS held to 15°C 159°F)No 13 The air-thermostat tensor ~np”t slgnal IS held 10 4°C 139°F)Provides hints
(including
judgement)when trouble-
cedures are fol-
lowed.
ITerminalI S’g”a’CO”dl,,O”*Terminal voltageNO
I
1
Indicatesthe
diagnosis out-
put code No.
and the system
conditions
dur-
kng output.
theconditions un-
der which the
be made.Indicates the specification to
be used for judgement of
the check results.
If there is no particular men-
tion of conditions in the
“Conditions” column, the
column shows the specifica-
tion under normal condi-
tions.

INTRODUCTION AND MASTER TROUBLESHOOTING - ‘How to use miS .Manual5EXPLANATION OF CIRCUIT
DIAGRAMS
-IThe symbols used in circuit diagrams are used as
described below.NOTEFor detailed information
cqncqning the reading of
circuit diagrams, refer to GROUP
8-Wi@ng Har-
ness.
The input/output (dire%%of current flow) relative to
the electronic control unit
isindicated by symbols
(A.m.The (A) symbol indicates
that current flows in the
upward direction.
OutputIndicates a
connector.
IGNITIONSWITCH(IG1)Input
.A Input/output
reht flow is indicat-:ed by the arrow.
In this instance, the
current flow is in
both directions, up
Theconnector
symbol indicates
the device side
connector (for an
intermediate con-
nector, the male
sideconnector)as seen from the
terminalfront
(the connector’s
connection face).cdevice side con- device side con-
L
I
\
Indicatesthe
branch point of a
harness of a differ-ent line diameter
nr line colour.I Indicates
that the con-
nector is the
direct-inser-tion type.

6INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle Identificetion
VEHICLE IDENTIFICATIONNmx-VEHICLE IDENTIFICATION NUMBER LOCATION
The vehicle identification number
(V.I.N.) is located oh a plate
attached to the left top side of the instrument panel.
VEHICLE IDENTIFICATION CODE CHART
PLA.4
All vehicle identification numbers contain 17 digits. The vehicle
number is a code which tells country, make, vehicle type, etc.
\5thDigit
r8thDigitr9thDigit
11thDigit12th to17thDigits
10thDigitModelyearM-
1991Year
7thDigitBody
4-
3 doorHatch-back
Engine
T-1.8 liter
(107cu.in.)[SOHC-MPI1R-2.0 liters(122
cu.in.)
[DOHC-
MPI]
u-2.0 liters
(122cuin.)[DOHC-MPI-Turbo]6thDigit
Price
class
3-Medium
4-
High5-Premium
6-Special
4thDigit
Others
B-Manual
Seat Beltc-
Auto-matic
Seat Belt
3rdDigitVehicleWe
3-Passen-ger
Car
2ndDigitMake
E-EagleP-Plymouth
1stDigitCountry
4-
USA
Serialnumber*CheckPlantLine
E-DSMS-Laser or
TalonFWDT-Talon
AWD
000001to
999999
I
NOTE* “Check digit” means a single number or letter x used to verify the accuracy of transcription of vehicle identification number.

INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle IdentificationVEHICLE IDENTIFICATION NUMBER LIST
NOOCC--
p, VEHICLES FOR FEDERAL
,.. IV.I.N. (except sequence number)
BrandEngine DisplacementModels Code,,; * /./
4P3CS34aM EPlymouth Laser1.8 liter (107 cuin.)D21AMNJElXP/RJEL4P’
4P3CS44aME[SOHC-MPI]
D21AMNHEL4P/RHEL4P4P3CS44ROME2.0 liter
(122 cuin.)
[DOHC-MPI]D22AMNHML4P/RHML4P4P3CS44UuME2.0 liter (122
cu.in.)
[DOHC-MPI-Turbo]D22AMNHFL4P/RHFL4P
4E3CS44ROM EEap$DTrlon2.0 liter (122 cu.in.)
[DOHC-MPI]D22AMNHML4EIRHML4E4E3CS54UnME4E3CT64UOME
Eagle Talon
2.0 liter (122
cu.in.)
[DOHC-MPI-Turbo]D22AMNPFL4EIRPFL4E
D27AMNGFL4E/kGFL4E.1L *,VEHICLES FOR CALIFORNIA
V.I.N. (except sequence number)
BrandEngine DisplacementModels Code
4P3CS34aMEPlymouth Laser1.8 liter (107 cu.in.)D21AMNJELSP/RJELSP
4P3CS44aME
[SOHC-MPI]D21AMNHELSP/RHELSP
4P3CS44RmME2.0 liter (122 cuin.)
[DOHC-MPI]
D22AMNHMLSP/RHMLSP4P3CS44UOME2.0 liter (122
cu.in.1[DOHC-MPI-Turbo]
D22AMNHFLSP/RHFLSP
‘.4E3CS44RuME
Eagle Talon2.0 liter (122 cu.in.1
[DOHC-MPI]
D22AMNHMLSE/RHMLSE4E3CS54UOME4E3CT64UOME
Eagle Talon
2.0 liter (122
cu.in.1[DOHC-MPI-Turbo]
D22AMNPFLSElRPFLSE
D27AMNGFLSE/RGFLSEVEHICLES FOR CANADA
V.I.N. (except sequence number)
BrandEngine DisplacementModels Code 1’1
4P3BS34aME
4P3BS44aMEPlymouth Laser1.8 liter (107
cu.in.1[SOHC-MPI]D21AMNJEL5P/RJEL5PD21AMNHiL5P/RHEL5P4P3BS44ROME
2.0 liter (122
cuin.)
[DOHC-MPI]D22AMNHML5P/RHML5P4P3BS44UuME
2.0 liter (122
cu.in.)[DOHC-MPI-Turbo]D22AMNHFL5P/RHFL5P4E3BS44ROME
Eagle Talon2.0 liter (122 cu.in.)D22AMNHML5EiRHML5E[DOHC-MPI]II4E3BS54UuME4E3BT64UnME
Eagle Talon
2.0 liter (122
cu.in.1
[DOHC-MPI-Turbo]

8INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle Identification
VEHICLE INFORMATION CODE PLATE
NOOCD-Vehicle information code plate is riveted onto the bulkhead in
rithe engine compartment.
The plate shows model code, engine model, transaxle model,
and body color code.
1. MODEL
2. ENGINE
3. TRANSAXLE
4. COLOR,
TRIM OPTD22AMN
HML4P
2 y$y:/e ‘f$$l
4G63
I Engine modelF5M33
y Transaxle model
B14
I Monotone exterior
color code
VEHICLE SAFETY CERTIFICATION LABELNOOCF-
1.The vehicle safety certification label is attached to the face
2. This label indicates the month and year of manufacture,
;eGross Vehicle Weight Rating (G.V.W.R.), Gross Axle
(G.A.W.R.) front and rear, and Vehicle
Identification Number
(V.I.N.).ENGINE MODEL STAMPING
NOOCG-
1.The engine model number is stamped at the front side on
following:
Engine model4637Engine displacement
1.8 liter (107 cu.in.)
[SOHC-MPI]
4G632.0 liter (122 cuin.)
[DOHC-MPI] or
[DOHC-MPI-Turbo]2. The engine serial number is stamped near the engine
model number, and the serial number cycles, as shown
below.Engine serial numberNumber cycling
AA0201 to w9999AA0201 ------- -*AA99997
I1 LAB0001 ------- +AY9999 : 1
I1 t-BAOOOI ------- +YY9999 ’ 1
‘-w

INTRODUCTlON AND MASTER TROUBLESHOOTING - Vehicle Identification9
Theft protection label
onginal parts
w ,IeIW
B ,w w
OOA0212For replacement parts
OOA0213
LOCATIONS
THEFT PROTECTIONNowlABIn order to protect against theft, a Vehicle Identification
Number
WIN) is stamped in, or attached as a label to, the
following major parts of the engine and transaxle, as
tiell as
main outer panels:
Engine cylinder block, Transaxle housing, Fender, Door, Quar-
ter panel, Hood, Trunk lid, Bumpers
In addition, a theft-protection label is attached to replacement
parts for the body outer panel main components, and the same
data are stamped into replacement parts for the engine and the
transaxle.Cautions regarding panel repairs
1. When repainting original parts, do so after first mask-
ing the theft-protection label, and, after painting, be
sure to peel off the masking tape.
2. The theft-protection label for replacement parts is
covered by masking tape, so such parts can be paintedas is. The masking tape should be removed after
painting is finished.
3.The theft-protection label should not be removed from
original parts or replacement parts.
OOA0057OOA0055

IOINTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle Identification
Part
TransaxleManual transaxleAutomatic transaxle
FenderThe illustration indicates
left hand side,
outer.3lA0259
Door31AO250-.