wheel MITSUBISHI ECLIPSE 1991 Manual PDF

BRAKES - Wheel Speed Sensor 545
14LOl89
Cross-section A-ACross-section B-B
12R015i
5. INSTALLATION OF FRONT SPEED SENSOR BRACKET
Assemble the speed sensor and the speed sensor bracket.
NOTE(1) The shape is different for the left and right speed
sensor brackets. Each bracket has an identification
symbol, so be sure to note these symbols
ahd. install
correctly.
FR: Indicates that the bracket is for the front speed
sensor.R: Indicates that the bracket is for the right wheel.
L: Indicates that the bracket is for the left wheel.
(2) Check to be sure, when installing the speed sensor to
the bracket, that the letters “FR” are visible.
4. INSTALLATION OF FRONT SPEED SENSOR(1) Temporarily install the speed sensor to the knuckle.Caution
Be careful when handling the pole piece at the tip of
the speed sensor and the toothed edge of the rotor
so as not to damage them by striking against other
parts.(2) Note the following points when connecting the speed
sensor cable, and secure the cable by the clip.
@ Secure the cable by the clip so that the white-
painted parts of the blackened parts (in the illustra-
tion) of the speed sensor cable are within the rangeof the angles indicated by cross-section A-A and
cross-section B-B in the illustration.
@ Check to be sure that the white-painted part
(shaded in the illustration) of the speed sensor cableis not twisted.Caution
Because there is the possibility of damage to the
cable during driving if the speed sensor cable is
twisted, care must be taken regarding thispoint.
(3) Insert a feeler gauge into the space between the speed
sensor’s pole piece and the rotor’s toothed surface, and
then tighten the speed sensor at the position where theclearance is the standard value all around.Standard value:
0.3-0.9 mm (.012-.035 in.)
NOTE
If the clearance between the speed sensor’s pole pieceand the rotor’s toothed surface is not within the
standard value range, it is probable that the rotor is
incorrectly installed, recheck installation.

6-4CLUTCH - Troubleshooting
TROUBLESHOOTINGNO6hi.J
SymptomProbable causeRemedy
Clutch slipsInsufficient clutch pedal playAdjust
Excessive wear of clutch disc facingReplace
Hardening of clutch disc facing, or adhesion of oilReplace
Clutch release fork catchingRepair or replace parts
Weak or damaged diaphragm spring
Replace
Clogging of hydraulic systemRepair or replace parts
Gear shift malfunctionExcessive clutch pedal playAdjust
Distorted clutch disc, excessive oscillation
Replace
Clutch cover assembly wornReplace
Clutch disc spline worn or corrodedReplace
Clutch disc facing peelingReplace
Clutch release bearing wornReplace
Damaged pressure plate or flywheelReplace
Leakage, air introduction or clogging of hydraulic systemRepair or replace parts
Clutch noiseInsufficient clutch pedal playAdjust
Improper installation of clutch cover assemblyRepair or replace parts
Excessive wear of clutch disc facing
Replace
Clutch release fork catchingRepair or replace parts
Clutch release bearing worn
Replace
Weak or damaged torsion springReplace
Damaged pilot bushingReplace
Insufficient lubrication of bearing sleeve sliding surfaceRepairClutch pedal feels “heavy”
Insufficient lubrication of clutch pedalRepairInsufficient lubrication of clutch disc spline
Repair
Clutch release fork catchingRepair or replace parts
Insufficient lubrication of bearing sleeve sliding surface
Repair
Clutch chattersWorn or damaged clutch disc facingReplace
Oil adhered to clutch disc facingReplace
Uneven height of diaphragm springRepair or replace parts
Weak or damaged torsion spring
Replace
Damaged pressure plate or flywheelReplace
Loose or damaged mountingReplace or tighten
mounting

CLUTCH - Clutch Pedal6-7
CLUTCH PEDAL
-. REMOVAL AND INSTALLATIONNOSPA-
.“-Pre-removal Operation
*Removal of the Lap Cooler Duct,Shower Duct (L.H.) and Knee Pro-tector (Refer to GROUP 23%lnstru-ment Panel.)*Removal of the Steering ColumnAssembly (Refer to GROUP 19-Steering Wheel and Shaft.)*Removal of the Relay Box (Indoor)
17-26 Nm
12-19 ft.lbs.
11-17 Nm
8-12 ft.lbs.
IO-15 Nm’ tl(i/\:/ Fl/Yv .1-m.---I- I I KIDS.Post-installation Operation
l installation of the Relay Box (Indoor)l installation of the Steering ColumnAssembly (Refer to GROUP 19-Steering Wheel and Shaft.)l installation of the Lap Cooler Duct,Shower Duct (L.H.) and Knee Pro-tector (Refer to GROUP 23 Instru-ment Panel.)l Adjustment of the Brake Pedal (Re-fer to GROUP 5-Service Adjust-ment Procedures.)aAdjustment of the Clutch Pedal (Re-
fer to P.6-5.)
!
:k -16
20-25 Nm
14-f8 ft.lbs.
Removal steps
I, Clutch pedal return spring 2. Brake pedal return spring3. Interlock switch
4. Clutch switch control system>
5. Bolt system>6. Stop light switch
7. Clip
l + 8. Bushing
9. Turn over spring
e+ IO. Bushing11. Cotter pinl + 12. Washerl + 13. Clevis pin14. Pedal support bracket assembly
15. Clutch pedal mounting nut
16. Clutch pedal bracket17. Lever
l + 18. Clutch pedal bushing~~ 19. Clutch pedal bushing
20. Pedal rod
e+ 21. Brake pedal bushings
22. Clutch pedal
23. Brake pedal
24. Pedal pad
NOTE(1) Reverse the removal procedures to reinstall.(2) l + : Refer to “Service Points of (3) m : Non-reusable parts

CLUTCH - Clutch Cover and Disc647
08A0038
6CLOO3SERVICE POINTS OF REMOVAL
NO6OSAH
1. REMOVAL OF CLUTCH COVER ASSEMBLY/P.
CLUTCH DISCDiagonally loosen bolts which attach clutch cover to
flywheel. Back off bolts in succession, one or two turns at atime, to avoid bending cover flange.
Caution
DO NOT clean clutch disc or release bearing with
cleaning solvent.
INSPECTIONNlNGCAB
CLUTCH COVER ASSEMBLYl Check the diaphragm spring end for wear and uneven
height.
Replace
If wear is evident or height difference exceeds the
limit.Limit
: 0.5 mm (.02 in.)l
Check the pressure plate surface for wear, cracks and color
change.lCheck the strap plate rivets for looseness and replace the
clutch cover assembly if loose.
CLUTCH DISCl
Check the facing for loose rivets, uneven contact, deteriora-tion due to seizure,
adhesron of oil or grease and replace
the clutch disc if defective.
l
Measure the rivet sink and replace the clutch disc if it is outof specification.Limit
: 0.3 mm (.012 in.)l
Check for torsion spring play and damage and if defective,replace the clutch disc.
l Combine the clutch disc with the input shaft and check
sliding condition and check for play in the rotating direction.If it does not slide smoothly, check after cleaning and
reassembling. If the play IS excessive, replace the clutch
drsc and/or the input shaft.
CLUTCH RELEASE BEARING
Caution
The release bearing is packed with grease, so don’t use
cleaning oil, etc. to clean it.l Check for
beanng heat damage, other damage, abnormal
noise and/or improper rotation. Also check whether or not
there IS wear at the point of contact with the diaphragm
spring.lIf there is abnormal wear at the pornt of contact with the
release fork, replace the bearing.
RELEASE FORKlIf there is abnormal wear at the
pornt of contact with the
bearing, replace the release fork.

6-18CLUTCH - Clutch Cover and Disc
I6CLO33
Clutch disc
T& assemblyClutch cover
6CLO26
SERVICE POINTS OF INSTALLATIONNWGDAT
5. A,PPLlCATlONOF GREASE TO RELEASE FORKAi&
(1) Apply a coating of the specified grease to the point of
contact with the fulcrum and the point of contact withi(the release bearing.
Specified grease: MOPAR Multi-mileage Lubricant
Part Nq.2525035 or equivalentCautionWhen installing the
clutch, apply grease to each
part, but be careful not to apply excessive grease;
excessive grease will cause clutch slippage and
shudder.
(2) Apply a coating of the specified grease to the end of therelease cylinder’s push rod and to the push rod hole in
the release fork.
Specified grease: MOPAR Multi-mileage Lubricant
Part No.2525035 or equivalent
4. APPLICATION OF GREASE TO CLUTCH RELEASE
BEARING
Pack the inner surface of the clutch release bearing and thegroove with the specified grease.
L4r
Specified grease: MOPAR Multi-mileage Lubricant _
Part No.2525035 or equivalentCaution
For the release bearing of a resin sleeve, grease mustnot
be applied to the sleeve part.
2. APPLICATION OF GREASE TO CLUTCH DISC/ 1.
CLUTCH COVER ASSEMBLY
(1) Apply a coating of the specified grease to the clutch
disc spline, and then use a brush to rub it in.
Specified grease: MOPAR Multi-mileage Lubricant
Part No.2525035 or equivalent
(2) Using the special tool (clutch disc center guide),
position the clutch disc to the flywheel.
(3) Install the clutch cover assembly. Tighten the bolts a
little at a time, working in a diagonal sequence, finally
tightening them to the specified torque.

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

9-12ENGINE - Specifications3msStandard ValueLimit
Undersize rework dimension of pinmm (in.)
0.25
f.010) U.S.44.735-44.750
(1.7612-1.7618)0.50
(.020) U.S.44.485-44.500
(1.7514-1.7520)0.75
(030) U.S.44.235-44.250(1.7415-1.7421)
Undersize rework dimension of journalmm (in.)
0.25
(.OlO) U.S.56.735-56.750(2.2337-2.2342)
0.50
(020) U.S.56.485-56.500(2.2238-2.2244)
0.75
(.030) U.S.56.235-56.250
(2.2140-2.2146)
wheelRunoutmm (in.)Less than 0.13
(0051)I pressure at curb idle speedkPa (psi)80 (11.4) or more
onditions: oil temperature is 75 to
90°C67 to 194”F)l
1 w-wTip clearancemm (in.)
Drive gear
0.06-0.12 (.0024-.0047)0.20 i.0079)Driven gear
0.04-O. 12 (.0016-.0047)0.18 (.0071)Side clearancemm (in.)
Drive gear
0.10-0.16 (.0039-.0063)0.20 (.0079)Driven gear
0.02-0.05 (.0008-.0020)0.15 (.0059)
rlief spring
Free lengthmm (in.)
43.8 (1.724)
Load
[37N at 8.2 Ibs.]mm (in.)
40.1 (1.5787)
ive belt
For alternator
Deflection
mm (in.)
Inspection
9.0- 11.5 (.354-,453)New belt
7.5-9.0 (.295-.354)Used belt
10
i.394)TensionN (Ibs.)
Inspection
250-500 (55- 110)
New belt
500-700 (110-154)Used belt
400 (88)
For air conditioner compressor
Deflectionmm (in.)
Inspection
Approx. 8
(315)New belt
5.0-5.5 (.197-.217)Used belt
6.0-7.0 (.236-.276)

9-16ENGINE - SpecificationsItems
Connecting rod
Bendmm (in.)
Twistmm (in.)
Connecting rod big end to crankshaft
side clearancemm (in.)
Piston pin press-in loadN (Ibs.)Standard Value
0.05 or less per 100
(0020 or less per 3.937)
0.1 or less per 100
(0040 or less per 3.937)
0.10-0.25 (.0040-.0098)
75,000- 175,000
(1,653-3,858)Limit
0.4
(0157)Connectingrod bearing
Oil clearancemm (in.)
Crankshaft main bearing
Oil clearancemm (in.)
Crankshaft
Pin O.D.mm (in.)
Journal
0.D:mm (in.)
Out-of-roundness of journal and pinmm (in.)
Taper of journal and pinmm (in.)
End playmm (in.)
FlywheelRunoutmm (in.)
Oil pressure at curb idle speedkPa (psi)
[Conditions: oil temperature is 75 to
90°C(167 to 194”F)l
0.02-0.05 (.0008-.0020)
0.02-0.05 (.0008-.0020)
44.980-44.995
(1.7709-1.7715)
56.980-56.995
(2.2433-2.2439)Less than
0.015 (.0006)Less than
0.005 (.0002)
0.05-0.18 (.0020-.0070)80
(11.4) or more0.1
(.004)0.1
(004)0.25
LOO981Less than 0.13
(.0051)Oil pump
Tip clearancemm (in.)
Drive gear
0.16-0.21 (.0063-.0083)0.25 f.0098)Driven gear
0.13-0.18 (.0051-.0071)0.25 t.0098)Side clearancemm (in.)
Drive gear
0.08-0.14 (.0031-.0055)0.25 (.0098)Driven gear
0.06-0.12 (.0024-.0047)0.25 i.0098)
qelief spring
Free lengthmm (in.)
46.6 (1.835)
Load
[61N at 13.4 Ibs.]mm (in.)
40.1 (1.579)

9-18ENGINE - Specifications
TORQUE SPECIFICATIONS
NO9CG-Items
Engine mount insulator nut (large)
(small)
Engine mount bracket nut or bolt
Transaxle mount insulator nut
Transaxle mount to body
Front roll stopper insulator nut
Front roll stopper bracket to centermember
Rear roll stopper insulator nut
Rear roll stopper bracket to centermember
Accelerator cable adjusting bolts
Fuel high pressure hose to delivery pipe
Ground cable to air intake manifold
Control wiring harness to air intake plenum
Power steering oil pump to bracket
Air conditioner to bracketcompressor
Exhaust pipe clamp bolt
Exhaust pipe to rubber hanger
Oil drain plug
panOil (bolts)
pan(nuts)VVater pulley
pump
Tensioner pulley bracket (air conditioner compressor)
Timing belt front coverCrankshaft sprocket
Camshaft sprocket
Timing belt “B” tensioner bolt
-eft engine support bracket3il switch
pressure3il unit
pressure gauge
Iii filter bracket
Iii cover
pumpqelief plug
‘lywheel or drive plate
ixhaust pipe bracket
support
‘rant roll stopper bracket
Iear roll stopper bracket‘rant engine bracket
support
:1.8L Engine>
Oil screen
Rocker cover
Camshaft bearing cap bolt (6 x 20)
(8 x 65)
Exhaust pipe to exhaust manifold
Intake manifold bolt
stay
Cylinder head bolt
Crankshaft pulley
Crankshaft damper pulleyNm
ftlbs.
60-8043-58
30-4022-29
50-6536-47
60-8043-58
40-5029-36
50-6536-47
40-5029-36
40-5029-36
40-5029-36
4-63-4
4-6
3-4
4-6
3-4
4-6
3-4
35-45
25-33
23-27
17-20
30-4022-29
10-157-l 135-45
25-33
6-84-6
5-73.5-5
8-106-7
23-27
17-20
10-127-9
110-13080-94
80-10058-72
15-2211-16
30-4222-308-126-9
8-126-9
15-2211-16
15-1811-13
40-5029-36
130-14094-101
30-4222-3055-75
40-54
110-13080-94
50-7036-51
18-2513-18
5-74-5
20-2714-2019-21
14-15
30-4022-29
18-2513-18
70-7551-5415-1811-13
15-1811-13

ENGINE <1.8L Engine>- Service Adjustment Procedures9-25
MANIFOLD VACUUM INSPECTION(1) Before inspection and adjustment, put the vehicle
in=following state.
l Engine coolant temperature:
85-95°C (185-205°F)
l Lights, electric, cooling fan, and accessories: OFF
lTransaxle: Neutral
(N or P for vehicles with an automa-
tic transaxle)
l Steering wheel: Neutral position
(2) Check that the idling revolution speed is normal.
(3) Remove the PCV hose from the PCV valve and attach a
vacuum gauge.
(4) Check that the negative pressure at the intake manifold
during idle revolution is normal.
Standard value: 510 mmHg (20
in.Hg)(5) If outside the standard value, isolate the cause by referring
to the following table and repair the fault.
SymptomCauseRemedy
l The vacuum gauge reading is less thanl Ignition timing is retarded.l Adjust the ignition timing.
standard value, but the pointer is
-stable.
l The vacuum gauge pointer swingsl Air mixture concentration too
slowly.rich.
l Check ECI-MULTI system.l The vacuum gauge pointer drops irre-
gularly.
l The vacuum gauge pointer drops inter-
mittently to 30 to
160 mmHg (1.2 to
6.3 in.Hg).l The vacuum gauge pointer drops sud-
denly from the normal reading to 250rronnrt$,(9.8 rn.Hg), then returns tol Air mixture concentration too
lean.
l Check ECI-MULTI system.0 Incomplete close contact of in-
take exhaust valve seat.l Check and repair the valve.
l Broken cylinder head gasketl Replace cylinder head gasket.