service MITSUBISHI ECLIPSE 1991 Service Manual

7-30COOLING - waterHose and Water Piue <2.0L DOHC Ermine (Non-Turbo)>
04ROO24
04AOO98SERVICE POINTS OF INSTALLATION
N071DAJZ
17. INSTALLATION OF O-RING/ 16. WATER INLET PIPE“4Insert the O-ring to the water inlet pipe, and coat the outer
circumference of the O-ring with water.
By coating with water, the insertion to the water pump will
become easier.Caution
Care must be taken not to permit engine oil or other
greases to adhere to the O-ring
15. CONNECTION OF RADIATOR LOWER HOSEAlign the mating marks on the radiator hose and hose
clamp and then connect them; then, applying force in the
direction indicated by the arrow in the illustration, seat the
clamp to the trace marks of the previous connection.Caution
Be sure to install the hose clamps at the trace marks ofthe
previous connection.

COOLING -Water Hose and Water Pipe <2.0L DOHC Engine (Turbo)>7-31WATER HOSE AND WATER PIPE
7--<2.0L DOHC Engine (Turbo)>
REMOVAL AND INSTALLATION
N071A-C
. .
ation OperationPost-installi@Filling of the Engine Oil(Refer to GROUP g-EngineaFilling of the
Engine Coolant(Refer to GROUP 7-ServiceAdjustment Procedures.)
Pre-removal OperationeDraining of the Engine Coolant(Refer to GROUP 7-ServiceAdjustment Procedures.)*Draining of the Engine Oil(Refer to GROUP g-Engine
25-30 Nm
18-22 ftlbs.4n-47 ft.lbs.
w35-45 N/m12-15 Nm25-33 ft.lbs.
9- 11ft.lbs.----Q&Removal steps
1. Condenser fan motor assembly2. Oxygen sensor harness connector3. Engine oil level gauge guide4. O-ring5. Connection for air intake hose6. Connection for vacuum hose7. Connection for air hose A8. Connection for vacuum hose9. Heat protector A10. Heat protector B
4*11. Power steering oil pump
12. Oil pump bracket
13. Self-locking nut
14. Engine hanger22-29
ft.lbs. 29-43 ft.lbs.
15. Eye bolt16. Gasket17. Connection for water hose
I)+ 18. Connection for water pipe B19. Self-locking nut20. Gasket21. Exhaust manifold22. Exhaust manifold gasket
23. Ring
24. Gasket
05m154

7-32COOLING -Water Hose and Water Pipe <2.0L DOHC Engine (Turbo)>
35-50 Nm/ 25-36 ft.lbs.
35-50 Nm-- - _ . __._25-36 ft.lbs.25. Oil return pipe
26.Gasket
++ l 27. Turbocharger
28.Eye bolt29.Gasket
30.Water pipe631.Eye bolt32.Gasket33. Water pipe A
++ 34. Water hose (to turbocharger)35. Water hose
36. Water by-pass hose37. Connection for heater hose
+e l 38. Connection for radiator lower hose39. Water hose
40. Water hose
41. Water hose
22-30 ft.lbs.30-40 Nm
22-29 ft.lbs.04A011642. Exhaust pipe support bracket
43. Water pipe
l * 44. Water inlet pipe
l * 45. O-ring
FFTkeverse the removal procedures to reinstall.(2) a+ : Refer to “Service Points of Removal”.(3) l + : Refer to “Service Points of Installation”(4) m : Non-reusable parts

COOLING- Water Hose and Water Pipe <2.0L DOHC Engine (Turbo)>7-330140552
Mating marks
04A0090
rMating marks
04A0090
SERVICE POINTS OF REMOVALNO7lBAC311. DISCONNECTION OF POWER STEERING OIL PUMP
Disconnect the oil pump with hoses from the bracket.
NOTEThe removed power steering oil pump should be fastened
(by using rope, etc.) in a position that will not interfere with
the removal/installation of the engine assembly.
27. REMOVAL OF TURBOCHARGER ASSEMBLY
Remove the turbocharger assembly with the exhaust
fitting, water pipe A, water pipe
B and the oil pipe attached
to it.
38. DISCONNECTION OF RADIATOR LOWER HOSE
After making mating marks on the radiator hose and the
hose clamp, disconnect the radiator hose.
INSPECTIONN07lCAAa3WATER PIPE AND HOSE INSPECTION
Check the water pipe and hose for cracks, damage, clog and
replace them if necessary.
SERVICE POINTS OF INSTALLATION
N071DAJ345. INSTALLATION OF
0-RING/44. WATER INLET PIPE
Insert the O-ring to the water inlet pipe, and coat the outer
circumference of the O-ring with water.
By coating with water, the insertion to the water pump will
become easier.
Caution
Care must be taken not to permit engine oil or other
greases to adhere to the O-ring.
38. CONNECTION OF RADIATOR LOWER HOSE
Align the mating marks on the radiator hose and hose
clamp and then connect them; then, applying force in the
direction indicated by the arrow in the illustration, seat the
clamp to the trace marks of the previous connection.
Caution
Be sure to install the hose clamps at the trace marks ofthe previous connection.

7-34 COOLINGWater Hose and Water Pipe <2.0L DOHC Engine (Turbo)>/Engine Coolant Temperature- Gauge Unit. Engine Coolant Temoerature Sensor and Enoine Coolant Temoerature Switch
05A0026
05K55734. INSTALLATION OF WATER HOSE
Install the water hose with the longer straight area
positioned on the turbo side.
27. INSTALLATION OF TURBOCHAGER ASSEMBLY
Clean the alignment surfaces shown in the illustration.
Caution
When cleaning, care must be taken so that a piece of
the gasket does not enter the oil passage hole.
18. INSTALLATION OF WATER PIPE
(B)Before installing to the water inlet pipe, apply machine oil to
the inner surface of the pipe flare.
ENGINE COOLANT TEMPERATURE GAUGE UNIT, ENGINE COOLANT
TEMPERATURE SENSOR AND ENGINE COOLANT TEMPERATURE
SWITCHREMOVAL AND INSTALLATION
N070%-
Pre-removal Operation
*Draining of the Engine Coolant
(Refer to GROUP O-Maintenance
Service.)@Supplying of the Engine Coolant
(Refer to GROUP O-Maintenance
< 1.8L Engine>
20-4014-291
’lo-12 Nm7-9 ft.lbs.04AOO99<2.0L DOHC Engine>10112 Nm
7-9 ft.lbs.
Removal
l +1. Engine coolant temperature gauge unit
++ 2. Engine coolant temperature sensor
(Engine control)
*4 3. Engine coolant temperature switch(Air conditioner)
NOTEl a : Refer to “Service Points of Installation”.

COOLINGEngine Coolant Temperature Gauge Unit, Engine Coolant- TemDerature Sensor and Enaine Coolant Temperature Switch7-35
.---
Sensor04GO033
0400032
1c0010
INSPECTIONNomDM3ENGINE COOLANT TEMPERATURE GAUGE UNIT
Raise the water temperature and measure the resistance if
within the standard value.
Standard value:
104213.5 52 [at 70°C (158OF)lENGINE COOLANT TEMPERATURE SENSOR
(Engine control)
Raise the water temperature and measure the resistance if
within the standard value.
Standard value:
At
20°C (68°F)2.45 + 0.24 k&
At
80°C (176°F)296f32 8ENGINE COOLANT TEMPERATURE SWITCH
(Air conditioner)
(1) Immerse the engine coolant temperature switch in oil and
then heat (by using a gas stove flame or similar method) soas to increase the oil temperature.
(2) Check to be sure that the engine coolant temperature
switch is switched OFF when the oil temperature reaches
the standard value.
Standard value:
112-l 18°C (234-244°F)Caution
The oil used above should be engine oil and should be
stirred well while being heated; do not heat more than
necessary.SERVICE POINTS OF INSTALLATION
NO7OEAU3. ENGINE COOLANT TEMPERATURE
SWITCHI2.ENGINE COOLANT TEMPERATURE SENSOR/l. EN-
GINE COOLANT TEMPERATURE GAUGE UNIT
Apply sealant to threaded portion and tighten.
Specified sealant: MOPAR Part No.4318034 or equiva-
lent

9-1
ENGINE
CONTENTSNOSAA-
ENGINE<1.8L
Engine>..................
24CRANKSHAFT, FLYWHEEL AND
DRIVE PLATE................................................
69
CYLINDER
BLOCK.........................................72
CYLINDERHEADANDVALVE
...................
53CYLINDER HEAD GASKET
...........................
36ENGINE ASSEMBLY
.....................................31ENGINE MOUNTING
....................................
28ENGINE ROLL STOPPER
.............................
30FRONT CASE, OIL PUMP AND
SILENT SHAFT
..............................................
58
OILPANANDOILSCREEN........................34
PISTON AND CONNECTING ROD
..............
65ROCKER ARMS AND ROCKER SHAFTS..
..51ROCKER ARMS, ROCKER ARM SHAFTS
AND CAMSHAFT
..........................................48
SERVICE ADJUSTMENT PROCEDURES..
...24TIMING BELT
................................................41TRANSAXLE MOUNTING
............................
29
ENGINE <2.0L DOHC Engine> . . . . . .
74CAMSHAFTS AND CAMSHAFT
OIL SEALS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84CAMSHAFTAND
ROCKERARM. . . . . . . . . . . . . . . .109CRANKSHAFT, FLYWHEEL AND
DRIVE PLATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
CYLINDERBLOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
CYLINDERHEADANDVALVE
. . . . . . . . . . . . . . . . . . .112CYLINDER HEAD GASKET
...........................90ENGINE ASSEMBLY
.......................................81ENGINE MOUNTING
......................................77ENGINE ROLL STOPPER
...............................
79FRONT CASE, OIL PUMP AND
SILENT SHAFT
..............................................117OIL PAN AND OIL SCREEN
..........................
87
PISTONANDCONNECTING
ROD..............127SERVICE ADJUSTMENT PROCEDURES..
.....76TIMING BELT
................................................
85TRANSAXLE MOUNTING
............................78
GENERALINFORMATION................2
SPECIAL TOOLS...............................20
SPECIFICATIONS...............................8General Specifications
................................8Sealants and Adhesives
.............................19Service Specifications
.................................8Torque Specifications
.................................18
TROUBLESHOOTING........................23Compression Too Low
Connecting Rod Noise/Main Bearing Noise
Excessive Engine Rolling and Vibration
Noisy Valves
Oil Pressure Drop
Oil Pressure Too High
Timing Belt Noise

9-8ENGINE - Specifications
SPECIFICATIONS
GENERAL SPECIFICATIONSBNDBCA-
Items
TypeNumber of cylinders
Boremm (in.)
Strokemm (in.)
Compression ratio
Firing order
Silent shaft
Valve timing
Intake valve
Opens (BTDC)
Closes
(ATDC)Exhaust valve
Opens (BBDC)
Closes (ATDC)
LubricationSpecifications
1.8L Engine2.0L Engine
In-line Single Over Head CamshaftIn-line Double Over Head
Camshafi44
80.6 (3.17)85 (3.35)
86 (3.39)88 (3.46)
9.09.0 (Non-Turbo)
7.8 (Turbo)
l-3-4-21-3-4-2EquippedEquipped
20”
.26” (Non-Turbo)
21’ (Turbo)
52”46” (Non-Turbo)
51’ (Turbo)
55”
55”
17”9”Pressure feed-full flow filtrationPressure feed-full flow filtration
SERVICE SPECIFICATIONSNOSCB-
-4.8L Engine>
Items
Standard Value
Engine adjustments
Engine compression pressurekPa (psi)
-Engine compression pressure difference
-between each cylinder
kPa (psi)
Intake manifold vacuum at idle
mmHg (in.Hg)510 (20)
Timing belt “B” tension
mm (in.)
5-7
(.20-.28)Cylinder head
Overall height
mm (in.)
88.5 (3.484)
Flatness of gasket surface
mm (in.)
Less than 0.05
(0019)Flatness of manifold mounting
surfacemm (in.) Less than 0.15 (.0059)Limit
Min. 920 (131)
Max. 100 (14)
-0.2
(-.008)**Limit must be -0.2
(-.008) combined
with amount of
grinding of cylinder
block gasket surface.
0.2
(008)0.3
(.012)

ENGINE - SpecificationsItems
Valve stem to valve guide clearance
Intake
Exhaust
Valve guide
Lengthmm (in.)
Intake
Exhaust
Service size
mm (in.)mm (in.)Standard Value
0.03-0.06 (.0012-.0024)
0.05-0.09 (.0020-.0035)44 (1.73)
48 (1.89)
0.05
(.002), 0.25 (.OlO),
0.50
i.020) oversizeLimit
0.10
f.004)0.15
i.006)Valve seat
Width of seat contactmm (in.)
Seat angle
Valve spring
Free lengthmm (in.)
Load
N (Ibs.)
Out of squarness
Cylinder block
Cylinder boremm (in.)
ZIut-of;yundness and taper of cylinder bore
Cylinder block heightmm (in.)
Flatness of gasket surfacemm (in.)qight silent shaft
Front journal diametermm (in.)
Rear journal diametermm (in.)
Oil clearancemm (in.)
Front journal
Rear journal
-eft silent shaft
Front journal diametermm (in.)
Rear journal diametermm (in.)
Oil clearancemm (in.)
Front journal
Rear journal
‘istonO.D.mm (in.)
Clearance (Piston to cylinder)mm (in.)
0.9-l .3 (.0354-.0512)
44”-44.549.2
(1.937)48.2 (1.898)
274.6 (62) at installed height
Less than 2”4”
80.6 (3.173)
Less than 0.01
(.0004)285.2
(11.228)Less than 0.05
(.0020)0.1 (.0039)38.959-38.975
(1.5338- 1.5344)
35.951-35.967
(1.4154- 1.4160)
0.030-0.061(.0012-.0024)
0.050-0.091(.0020- .0036)
18.467- 18.480(.7270- .7276)
35.951-35.967(1.4154-1.4160)
0.020-0.054 (.0008-.0021)
0.050-0.091 (.0020-.0036)80.6
(3.173)
0.01-0.03 (.0004-.0012)

ENGINE - SDecifications9-11
.-ems
Ring groove widthmm (in.)
No. 1No. 2
Oil
Service sizemm (in.)Standard ValueLimit1.52- 1.54 (.0598-.0606)
1.51-l .53 (.0594-.0602)
4.015-4.045 (.1581-.1593)0.25
(.OlO), 0.50 (.020),0.75 (.030), 1.00 (.039)oversize
ston ring
Side clearancemm (in.)
No. 1No. 2
End gapmm (in.)
No. 1No. 2
Oil ring side railmm (in.)
Service sizemm (in.)
0.045-0.085 (.0018-.0033)0.12 (.005)
0.02-0.06 (.0008-.0024)0.1 (.004)
0.30-0.45 LO1 188.0177)0.8 (.031)
0.20-0.35 (.0079-0.138)0.8 i.031)
0.20-0.70 (.0079-.0276)1.0 (.039)0.25
(.OlO), 0.50 (.020).0.75 (.030), 1.00 LO391oversize
lnnecting rod
Bendmm (in.)
Twistmm (in.)
Connecting rod
bigmKdi,;; crankshaft
side clearance
Piston pin press-in loadN (Ibs.)
xrnecting rod bearing
Oil clearancemm (in.)
Service sizemm (in.)0.05 or less per 100
(.0020 or less per 3.937)
0.1 or less per 100
LOO39 or less per 3.937)
0.10-0.25 (.0039-.0098)0.4 (.016)
5,000- 15,500 (l ,l OO-3,300)
0.02-0.05 (.0008-.0020)0.1 (.004)0.25
(.OlO), 0.50 (.020),0.75 (.030) undersize.ankshaft main bearing
Oil clearancemm (in.)
Service sizemm (in.)
0.02-0.05 (.0008-.0020)0.25
(.OlO), 0.50 i.0201,
0.75 l.030) undersize
ankshaft
Pin O.D.mm (in.)45 (1.77)
Journal O.D.mm (in.)57 (2.24)
Out-of-roundness of journal and pinmm (in.)Less than
0.015 (.OOOS)Taper of journal and pinmm (in.)Less than
0.005 (.0002)tnd playmm (in.)
0.05-0.18 (.0020-.0070)0.4 (.016)