ESP MITSUBISHI ECLIPSE 1991 Owner's Manual
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 1991, Model line: ECLIPSE, Model: MITSUBISHI ECLIPSE 1991Pages: 1216, PDF Size: 67.42 MB
Page 399 of 1216
ENGINE <2.0L DOHC Engine> - Cylinder Head and Valve9-115
1Ghde I.D.
Guide O.D.
1 EN298
Valve
ispring
*seat
\ Iril
: :
MD998737
Valvestem
seal
SpringVALVE GUIDE
NOSPGCCMeasure the clearance between the valve guide and valve
stem and, if the clearance exceeds the limit, replace the valve
guide or valve, or both.
Standard value:
Intake
0.02-0.047 mm (.OOOS-.0019 in.)
Exhaust0.05-0.085 mm (.002-.0033 in.)
Limit:
Intake0.10 mm
(.0040 in.)
Exhaust0.15 mm (.0059 in.)
SERVICE POINTS OF REASSEMBLYNoaPKDEa15.
/ 13. INSTALLATION OF VALVE STEM SEAL
(1) Install the valve spring seat.
(2) Using the special tool, install a new stem seal to the
valve guide.
Caution
1. Do not reuse the valve stem seal.
2. Use the special tool to install the valve stem
seal. Improper
Jnstallation can be a cause of
leakage of oil down into the cylinder.
9.
/5. INSTALLATION OF RETAINER LOCK
(1) Install the valve spring so that its end with identificationcolor is positioned on the rocker arm end.
(2) Using the valve spring compressor, compress the valvespring and insert the retainer lock into position.
Caution
If the valve spring is compressed excessively, the
lower end of the retainer contacts the ‘stem seal,
damaging the stem seal.
Page 412 of 1216
9-128ENGINE <2.0L DOHC Enaine> - Piston and Connectina Rod
DEN050
6EN185
95EN057
Piston ringring gap6EN037
JSERVICE POINTS OF DISASSEMBLY
NOSTFAC2. REMOVAL OF CONNECTING ROD CAP
Mark the large end of the connecting rod with the cylinder
number for use during reassembly.
7. REMOVAL OF NO. 1 PISTON RING
/8. NO.2 PISTON
RINGRemove the piston rings with a piston expander.
INSPECTION
PISTONNO@lCAFReplace the piston if scratches or seizure is evident on its
surfaces (especially the thrust surface). Replace the piston if it
is cracked.PISTON PIN
(1) Insert the piston pin into the piston pin hole with a thumb.
You should feel a slight resistance. Replace the piston pin ifit can be easily inserted or there is an excessive play.
(2) The piston and piston pin must be replaced as an assembly.PISTON RING
NOSTCBF
(1) Check the piston ring for damage, excessive wear, and
breakage and replace if defects are evident. If the piston
has been replaced with a new one, the piston rings must
also be replaced with new ones.
(2) Check the clearance between the piston ring and ring
groove. If the limit is exceeded, replace the ring or piston,
or both.
Standard value: 0.03-0.07 mm
(.0012-.0028 in.)
Limit: 0.1 mm
(.004 in.)
(3) Install the piston ring into the cylinder bore. Force it down
with a piston, its crown being in contact with the ring, to
correctly position it at right angles to the cylinder wall.
Then, measure the end gap with a feeler gauge.
If the ring gap is excessive, replace the piston ring.
Standard value:
No. 10.25-0.40 mm (.0098-.0157 in.)
No.20.20-0.35 mm (.0079-.0138 in.)
Oil0.20-0.70 mm (.0079-.0276 in.)
Limit:
No. 1,
No.20.8 mm (.031 in.)
Oil1.0 mm (.039 in.)
Page 424 of 1216
11-2INTAKE AND EXHAUST - Specifications
SPECIFICATIONS
GENERAL SPECIFICATIONS.prtNIICA-Items
Air cleaner
ElementExhaust system
Front exhaust pipe
Front exhaust pipe
Muffler
CouplingSuspension system
Turbocharger
TypeIdentification No.
4iT>Supercharging pressure control
Intercooler
TypeSpecifications
Unwoven cloth type
Dual type
Single type
Expansion resonance type
Flat coupling
Rubber hangers and O-rings
Exhaust gas turbine type
TD05H-14B-6
TD04-13G-5Waste gate actuator and valve
Air cooled type
SERVICE SPECIFICATIONSNllCB- spr*
ItemsStandardIntake and exhaust manifolds
Distorsion of cylinder head contacting surfacemm (in.) Less than 0.15
(.0059)Supercharging pressure solenoid valve terminal resistance36-44
[at
20°C (68”F)lQ
TurbochargerSupercharging pressure
kPa (psi)
kPa (psi)
0.3
l.0121
TORQUE SPECIFICATIONSNllCC-
ItemsAir cleaner
Air cleaner to body
ResonatorAir cleaner bracket
Intercooler
Intercooler to body
Air by-pass valve
Air pipe
B
Nmftlbs.
8-106-7
10-137-9
12-15
9-11
12-15
9-11
15-22
11-16
12-15
9-11
Page 455 of 1216
14-IFUEL SYSTEM
CONTENTS
AUTO-CRUISECONTROLSYSTEM...........................................109AUTO-CRUISECONTROL.......................................................140SERVICEADJUSTMENTPROCEDURES..............................135Accelerator Cable, Throttle Cable and Auto-cruise
ControlCableInspectionandAdjustment........................136Auto-cruise
ControlSystemInspection.............................135lndrvrdualPartsInspection..................................................137SPECIFICATIONS.....................................................................109GeneralSpecifications.......................................................109ServiceSpecifications
.........................................................109Torque Specrfications..........................................................109TROUBLESHOOTING...............................................................110Auto-CruiseControlCircurt................................................128Auto-cruise
ControlComponentsLocation........................126Auto-cruise Control Related Harnesses
.............................125Check Chart
........................................................................114Input Check.........................................................................123Self-diagnosis
Check..........................................................121Troubleshootrng
Quick-referenceChart..............................110ENGINECONTROL.......................................................................105ENGINECONTROL..................................................................107--SERVICEADJUSTMENTPROCEDURES..............................106Accelerator Cable Inspection and Adjustment..................106Accelerator Switch Inspectron and Adjustment................106SPECIFICATIONS.....................................................................105Lubricants.............................................................................105Sealant.................................................................................105ServiceSpecifications
..........................................................105TorqueSpecifications..........................................................105TROUBLESHOOTING...............................................................105FUELSYSTEM..............................................................................2FUELFILTER............................................................................104FUELLINEANDVAPORLINE..............................................102FUEL PUMP, FUEL GAUGE UNIT ANDOVERFILL LIMITER(TWO-WAY VALVE)
Switch........................................................64Air Conditioner Power Relay
..............................................67Components
Location......................................................56
ControlRelay
.................................................................66EGRControlSolenoidValve...............................................67EGRTemperatureSensor..................................................64Engine Coolant Temperature Sensor
.................................62IdlePosrtionSwitch
...........................................................63IdleSpeedControlServo
.............................
....................65InhibitorSwitch....................................................................65hjeCtOrS................................................................................65IntakeAirTemperatureSensor..........................................6’2MalfunctionlndtcatorLight
..........................................58MotorPosition
Sensor................................................63OxygenSensor
.................................................................64Power Steering 011 Pressure Swatch...........................65PowerTransistor
................................................................67PurgeControlSolenoidValve.........................................67
Self-Diagnosis.......................................................................
ThrottlePositronSensor.....................................................
Vehicle Speed Sensor.........................................................MPI
SYSTEMINSPECTION<2.0L DOHCEngine>...........Air Conditioner Power Relay..............................................
Arr Conditioner Swatch........................................................
Components Location
.........................................................
Control
Relay.......................................................................
EGR Control Solenoid Valve...............................................
EGR Temperature Sensor
...................................................
Engine Coolant Temperature Sensor
.................................Fuel Pressure Control Valve...............................................
Idle Position Switch
............................................................
Idle
SpeedControlServo...................................................Injectors
................................................................................
Intake Air Temperature Sensor..........................................
Malfunction Indicator Light.................................................
Oxygen Sensor
....................................................................
Power
Steering
OilPressureSwitch.................................Power Transistor
.................................................................
Purge Control Solenoid Valve.............................................
Self-Diaanosis.......................................................................
58
63
2382
79
688182
79
7682
77
79
79
76
727879
82
8273ThrottletiPosition Sensor
.....................................................77Vehicle Speed Sensor
.........................................................79SERVICE ADJUSTMENT PROCEDURES<1.8L Engine>........................................................................41Curb Idle Speed Inspection
................................................41EGR Valve Control Vacuum Check....................................47Fuel Pressure Test
..............................................................44Fuel Pump Operation Check
..............................................44Idle Speed Control and Throttle Position
Sensor Adjustment
..............................................................
41Purge Port Vacuum Check
.................................................47Release of Residual Pressure from
High Pressure Fuel Hose
...................................................
44Throttle
Body(Throttle Valve Area)Cleaning....................43SERVICE ADJUSTMENT PROCEDURES<2.0LDOHCEngine>............................................................48Basic Idle Speed Adjustment
.............................................
48
Curb Idle Speed Inspection
................................................48EGR Valve Control Vacuum Check....................................55Fuel Pressure Test
..............................................................52Fuel Pump Operation Check
..............................................51Idle Position Switch Adjustment........................................52Purge Port Vacuum Check
.................................................55Release of Residual Pressure from
High Pressure Fuel Hose
...................................................51Throttle Body (Throttle Valve Area) Cleaning....................51ThrottlePositionSensorAdjustment.................................50SPECIALTOOLS......................................................................6SPECIFICATIONS.....................................................................2GeneralSpecifications.........................................................2Sealant and Adhesive
.........................................................5Service Specifications
..........................................................4Torque Specifications
..........................................................5THROlTLEBODY<1.8LEngine>........................................85THROlTLE BODY <2.0L DOHC Engine>............................89TROUBLESHOOTING...............................................................6
Page 558 of 1216
FUEL SYSTEM - Fuel Line and VaDor Line/Fuel Filter
High-pressur
hose
f+-----Eye bolt
Gasket
Fuel filter
Flare nut
Fuel main
pipe
\-Apply engine
&ring Oi’
FUEL FILTERREMOVAL AND INSTALLATION3.2.INSTALLATION OF FUEL FILTER
(1) When installing the fuel filter, first temporarily install the
filter to the filter bracket; then insert the main pipe at
‘*the connector part of the filter, and manually screw in
..the main pipe’s flare nut.
(2) Holding the fuel filter nut, tighten the fuel main pipe’s
flare nut and eye bolt at the specified torque. Then
tighten the filter to the bracket.
Pre-removal Operation@Release of Residual Pressure from High
Pressure Hose.
(Refer to P.14-44.)IIFuel filter removal steps
**1. Eye bolt2. Gasket3. Connection for Fuel high-pressure hose
4. Gasket
5. Connection for Fuel main pipe6. Mounting bolt+e l 4 7. Fuel filter
NOTE(1) Reverse the removal procedures to reinstall.(2) +e : Refer to “Service Points of Removal”.(3) l + : Refer to “Service Points of Installation”(4) m : Non-reusable partsINSTALLATION OF HIGH PRESSURE FUEL HOSE
Apply engine oil to the hose union.
Insert the hose, being careful not to damage the O-ring, andtighten securely.
Caution
Because there is high pressure applied between the
fuel pump and the injection mixer, be especially sure
that there is no fuel leakage in this area.
N14VA-25-35 Nm
18-25
ft.lbs.
vd-
7’
1
Y03A0231SERVICE POINTS OF REMOVAL
NlIVBAA1. REMOVAL OF EYE BOLT
Refer to P.14-103.
7. REMOVAL OF FUEL FILTER
Refer to
P.14-103.SERVICE POINTS OF INSTALLATION
7. INSTALLATION OF FUEL FILTER
Refer to P. 14-104.
N14VCAA
Page 593 of 1216
AUTO-CRUISE CONTROL SYSTEM - service Adjustment ~rocehre~
ACTUATOR INSPECTlCfN
(1) Remove the actuator.
(2) Apply negative pressure to the actuator with
the! &c&mpump and check that the holder moves more than 35
,mm(1.38 in.). In addition, check that there is no change
iii the
position of the holder when negative pressure is main-
tained in that condition.
(3) First install the actuator and then inspect and adjust the
cruise control cable (Refer to
P.14-136.).
I,_1I-35 mm (1.38 in.) or more07AOO52
VEHICLE-SPEED SENSOR INSPECTION
Refer to GROUP 8-Meters and Gauges for checking of vehiclespeed sensor.
ACCELERATOR SWITCH INSPECTIONRefer to GROUP 21 -Troubleshooting.
Page 597 of 1216
, d-a:-;._‘PROPELLER
=. ’SHAFT
CONTENTSNlBAA-
PROPELLER SHAFT........................................4Lubricants......................................................3
2
SPECIAL TOOLS3ServiceSpecifications.................................................................................
TorqueSpecifications...................................2
SPECIFICATIONS.............................................2
TROUBLESHOOTING......................................3
General
Specifications..................................21
Page 598 of 1216
16-2PROPELLER SHAFT - Specifications
SPECIFICATIONS
GENERAL SPECIFICATIONSNWCA--
ItemsPropeller shaft
TypeLength
x O.D.
Front
Center
RearUniversal joint
TypeSpecifications
4 joint propeller shaft
mm (in.)
707
x 50.8 (27.8 x 2.00)
647.5
x. 50.8 (25.5 x 2.00)
530.5
x 50.8 (20.9 x 2.00)
No.
1 (front)
No. 2 (center front)
No. 3 (center rear) [Lobro joint]
No. 4 (rear)
Cross type universal joint bearing
Cross type universal joint
Journal O.D.
Equal velocity joint type
Equal velocity joint size O.D.mm (in.)
mm (in.)Cross type
Cross type
Equal velocity type
Cross type
Needle roller bearing
(oilless type)
14.689
(.5783)Lobro joint
(oilless type)
94 (3.7)
NOTEPropeller shaft length indicates the length between the center points of each joint.
SERVICE SPECIFICATIONSNWCB-
ItemsSpecifications
Standard value
Journal axial playmm (in.)
0.02-0.06 (.0008-.0024)
Limit
Propeller shaft
runout(Dial indicator reading)
Frontmm (in.)
0.6 (.024) or less
Centermm (in.)0.6 (.024) or less
Rearmm (in.)0.6 (.024) or less
TORQUE SPECIFICATIONSNlBCC--
ItemsNmCenter bearing self locking nut
30-40Flange yoke to differential companion flange
30-35Center propeller shaft to center yoke
160-220Rear propeller shaft to companion flange
160-220Companion flange to Lobro joint assembly
30-40tft.lbs.
22-29
22-25
116-159
116-159
22-29
Page 599 of 1216
PROPELLER SHAFT - Specifications/Special Tools/Troubleshooting*(g&a
LUBRICANTS‘) wN$ii%.y,
Items
Sleeve yoke surfaceSpecified lubricant
h +Quafqtity ; ’‘I, ‘. ,b:MOPAR Hypoid Gear
Oil/API classification As required
GL-4 or higher, SAE 75W-85WLobro jointOuter and inner races
assemblyball grooves
Rubber packingLobro joint assembly
inner part
Center bearing front and rear grease
grooves and dust seal lip
Shafts and grease sumps of journal,
dust seal lips and needle bearingsRepair kit grease
Repair kit grease
MOPAR Multi-mileage Lubricant
Part No. 2525035 or equivalentAs required
,.. . ‘*
,^45-55
g(1.59-1.94 oz)As required
SPECIAL TOOLSNlBDA--
TROUBLESHOOTINGNWEAAB
SymptomNoise at start
Noise and vibration
at high speedProbable causeWorn journal bearing
Worn sleeve yoke spline
Loose propeller shaft installation
Unbalanced propeller shaft
Worn journal bearing
Improper snap ring selectionRemedy
Replace
Retighten
ReplaceAdjust the clearance
Page 611 of 1216
1 pq
,s I’
:
REAR
SUSPENSION
LATERAL ROD.................................................11
REAR AXLE HUB............................................14
REARSUSPENSIONASSEMBLY..................5
SERVICE ADJUSTMENT PROCEDURES.......3Rear Hub Rotary-Sliding Resistance
(Torque)Adjustment.....................................4Rear Wheel Alignment Inspection
...............3Wheel Bearing End Play Adjustment
..........3
SHOCKABSORBERASSEMBLY...................8
SPECIAL TOOL................................................3
SPECIFICATIONS.............................................2
GeneralSpecifications..................................2
ServiceSpecifications...................................2Torque Specifications
...................................2
TORSION AXLE AND ARM ASSEMBLY......12
TROUBLESHOOTING......................................3
REARSUSPENSIONASSEMBLY . . . . . . . . . . . . . . . . . .21
SHOCK ABSORBER ASSEMBLY...................32
SERVICE ADJUSTMENT PROCEDURES.......20Rear WheelAlignment
Inspection................20
SPECIAL TOOLS.............................................18
SPECIFICATIONS.............................................16
GeneralSpecifications..................................16
ServiceSpecifications...................................16LTorqueSpecifications...................................17
Lubricant.......................................................17
STABILIZER BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
TRAILING ARM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
TROUBLESHOOTING......................................19
UPPER AND LOWER ARM............................25
CONTENTSN17AA-