maintenance MITSUBISHI ECLIPSE 1991 Service Manual
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 1991, Model line: ECLIPSE, Model: MITSUBISHI ECLIPSE 1991Pages: 1216, PDF Size: 67.42 MB
Page 1 of 1216

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”.
Page 35 of 1216

LUBRICATION AND’ I
MAINTENANCE
CONTENTSGENERAL INFORMATION
..............................2MAINTENANCE SERVICE
...............................7Air
CleanerElement.....................................7Automatic Transaxle....................................
11Ball Joint and Steering Linkage Seals
........13Brake Hoses
.................................................12
DiscBrakePads...........................................12-lbDrive Belt (For Water Pump and
Alternator).....................................................8
DriveShaftBoots.........................................13
EngineCoolant.............................................12
EngineOil.....................................................9
EngineOilFilter...........................................9Exhaust System
............................................13
FuelHose.....................................................7
FuelSystem.................................................7
ManualTransaxle..........................................10
RearAxle......................................................13
SparkPlugs...................................................8
TimingBelt......................................................8RECOMMENDED LUBRICANTS AND
LUBRICANT CAPACITIES TABLE
..................4SCHEDULED MAINTENANCE TABLE
............3
Page 36 of 1216

o-2LUBRICATION AND MAINTENANCE - General Information
GENERAL INFORMATIONNGQPA--Maintenance and lubrication service recommenda-
tions have been compiled to provide maximum
protection for the vehicle owner’s investment
against all reasonable types of driving conditions.
Since these conditions vary with the individual
vehicle owner’s driving habits, the area in which the
vehicle is operated and the type of driving to which
the vehicle is subjected, it is necessary to prescribe
lubrication and maintenance service on a time
frequency as well as mileage interval basis.
Oils, lubricants and greases are classified and
graded according to standards recommended by theSociety of Automotive Engineers (SAE), the Amer-
ican Petroleum Institute (API) and the National
Lubricating Grease Institute
(NLGI).MAINTENANCE SCHEDULES
Information for service maintenance is provided
under “SCHEDULED MAINTENANCE TABLE”.
Three schedules are provided; one for “Required
Maintenance”, one for “General Maintenance” and
one for “Severe Usage Service”.
Item numbers in the “SCHEDULED MAINTE-
NANCE TABLE” correspond to the item numbers in
the “MAINTENANCE SERVICE” section.
SEVERE SERVICEVehicles operating under severe service conditions
will require more frequent service.
Component service information is included in
appropriate units for vehicles operating under one ormore of the following conditions:
1.Trailer towing or police, taxi, or commercial type
operation2. Operation of Vehicle
(1) Short-trip operation at freezing temperature
(engine not thoroughly warmed up)
(2) More than 50% operation in heavy city
traffic during hot weather above
32°C (90°F)(3) Extensive idling
(4) Driving in sandy areas
(5) Driving in salty areas
(6) Driving in dusty conditions
ENGINE OIL
The SAE grade number indicates the viscosity of
engine oils, for example, SAE 30, which is a single
grade oil. Engine oils are also identified by a dual
number, for example, SAE
lOW-30, which indicates
a multigrade oil.
The API classification system defines oil perform-
ance in terms of engine usage. Only engine oil
designed “For Service SG” or “For Service
SGKD”,when available, should be used. These oils contain
sufficient chemical additives to provide maximum
engine protection. Both the SAE grade and the API
designation can be found on the container.Caution
Test results submitted to EPA have shown thatlaboratory animals develop skin cancer after
prolonged contact with used engine oil. Accor-
dingly, the potential exists for humans
to de-
velop a number of skin disorders, including
cancer, from such exposure to used engine oil.
Care should be’ taken, therefore, when changingengine oil, to minimize the amount and length of
exposure time to used engine
pi! on your skin.
Protective clothing and gloves, that cannot be
penetrated by oil, should be worn. The skin
should be thoroughly washed with soap and
water, or use waterless hand cleaner, to removeany used engine oil. Do not use gasoline,
thinners, or solvents.
GEAR LUBRICANTSThe SAE grade number also indicates the viscosity
of Multi-Purpose Gear Lubricants.
The API classfication system defines gear lubricants
in terms of usage. Typically gear lubricants conform-ing to API
GL-4 or GL-5 with a viscosity of SAE
75W-85W are recommended for manual transaxle.
LUBRICANTS
- GREASES
Semi-solid lubricants, bear the NLGI designation andare further classified as grades 0, 1, 2, 3 etc.
Whenever “Chassis Lubricant” is specified, Multi-
Purpose Grease,
NLGI grade 2 should be used.
MOPAR Multi-Mileage Lubricant, P&t Number
2525035 or equivalent, meets these requirement
and is recommended.
FUEL USAGE STATEMENT
Use gasolines having a minimum anti-knock index
(Octane Value) of 87,
(R + M)/2. This designation is
comparable to a Research Octane Number of 91.
Unleaded gasolines only must be used in vehicles
equipped with catalyst emission control systems.
All vehicles, so equipped, have labels located on the
instrument panel and on the back of fuel filler lid that
state, “UNLEADED GASOLINE ONLY”. These vehi-
cles also have fuel filler tubes especially designed toaccept the smaller diameter unleaded gasoline
dispensing nozzles only.
MATERIALS ADDED
TO FUELIndiscriminate use of fuel system cleanng agents
should be avoided. Many of these materials in-
tended for gum and varnish removal may contain
highly active solvents or similar ingredients that can
be harmful to gasket and diaphragm materials usedin fuel system component parts.
Page 37 of 1216

LUBRICATION AND MAINTENANCE - Scheduled MaintenanCe Table. &3
SCHEDULED MAINTENANCE TABLE1
- SCHEDULED MAINTENANCE SERVICES FOR EMISSION CONTROL AND PRO;;
VEHICLE PERFORMANCEInspection and Services should be performed any time a malfunction is observed or suspected. Retain
receipts for all vehicle emission services to protect your emission warranty.
Kilometers in Thousands 24 48 72 80 96
No.Emission Control System Maintenance
Service IntervalsMileage in Thousands 15 30 45 50 60
1Check Fuel System (Tank, Line and Connections and Fuel Filler Cap) for Leaks
Every 5 YearsorX
2Check Fuel Every 2 Years for Leaks or DamageorXX
3Replace Air Cleaner Element
atXX
4Replace Spark Plugs
atXXGENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE PERFORMANCE
Yo. General Maintenance
Service IntervalsKilometers in Thousands 24 48 72 80 9cMileage in Thousands 15 30 45 50
6C
5Timing Belt (Including theBalancer Belt)ReplaceatX
6Drive Belt (for Water Pump
and Alternator)Inspect for tensionatXX.’
Non-TurboChange Every YearEvery 12 000 kmOr (7,500 miles).
7Engine Oil
TurboChange Every 6 MonthsEvery 8,000 km
(5,000 miles)
Non-TurboChange Every Yearor X X XX
8Engine Oil
Filter
TurboChange Every YearEvery 16,000 km
(10,000 miles)
9Manual Transaxle OilInspect Oil LevelatX.X
Inspect Fluid Level Every Yearor X X XX
10Automatic Transaxle Fluid
Change FluidatXX11 Engine Coolant
Replace Every 2 YearsorXX
12Disc Brake PadsInspect for Wear Every Yearor X X XX13 Brake Hoses
Check for Deterioration or Leaks Every YearX X XX
l 4Beiloint and Steering Linkageinspect for Grease Leaks and Damage Every
2 YearsorXX
15Drive Shaft BootsInspect for Grease Leaks and Damage Every Yearor XXXX
Rear Axle
With LSDChange OilXX1 6
Exhaust System (Connection17Portion of Muffler, Pipings andCheck and Service as Required Every 2 Yearsorx -xConverter Heat Shields)
NOTELSD: Limited-slip differential
Page 38 of 1216

0-4 LUBRICATION AND MAINTENANCEScheduled Maintenance Table/Recommended Lubricants- and Lubricant Capacities TableSCHEDULED MAINTENANCE UNDER SEVERE USAGE CONDITIONS
The maintenance items should be performed according to the following table:
F.Mileage Intervals Kilometers in ThousandsSevere Usage
Service to be(Miles in Thousands)ConditionsMaintenance
Item
Performed24 36 48 60 72 80 84 96
(:,:) (15) (22.5) (30) (37.5) (45) (50) (52.5) (60) * B ’ D E F G
Air CleanerReplaceElementMore FrequentlyXX
Spark PlugsReplace
XXXx xx
Engine Oil$$~~~h~vev orEvery 4,800 km (3,000 miles)xxxx x
Engine Oil FilterReplace Every or6 MonthsEvery 9,600 km (6,000 miles)xxxx x
Disc Brake PadsInspect for WearMore FrequentlyXX
Severe usage conditionsA-Driving in dusty conditionsE-Driving in sandy areas
B-Trailer towing or police, taxi, or commercial typeF-Driving in salty areas
operationG-More than 50% operation in heavy city trafic during
C-Extensive idlinghot weather above 32°C (90°F)D-Short trip operation at freezing temperatures
(engine not thoroughly warmed up)
RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLENOONA- --z.
RECOMMENDED LUBRICANTS
Items
Engine Oil
Manual Transaxle
TransferRecommended lubricantskF&cesisification
SG or SG/CD (For further details, refer to SAE viscosity
MOPAR Hypoid Gear
Oil/API classification GL4 or higher, SAE 75W-85W
Automatic TransaxleMOPAR ATF PLUS (Automatic Transmission Fluid Type 7176) or Dia
ATF SP or Equivalent
Power SteeringMOPAR ATF PLUS (Automatic Transmission Fluid Type 7176VAutomatictransmission fluid or “DEXRON” or “DEXRON II”
Rear Axle
Brake and Clutch
Rear Wheel BearingsRefer to
P.O-6.
MOPAR Brake Fluid/Conforming to DOT 3
MOPAR Front Wheel Bearing Grease, or MOPAR Multi-MileageLubricant/Multipurpose grease NLGI Grade 2EP
Hood Lock Latch,, Door Lock Strikers,
Seat Adjusters, Lrftgate Lock, Parking
Brake Cable MechanismMOPAR Lubriplate/Multipurpose grease NLGI Grade 2
Engine CoolantMOPAR Antifreeze Permanent-Type Coolant/High quality
ethylene-glycolantifreeze coolant
Door Hinges, Liftgate Hinges
Engine oil
/
N
Page 39 of 1216

LUBRICATION AND MAINTENANCE - Recommended Lubrie’ntsand Lubrtcant Capacttles Table
LUBRICANT CAPACITIES TABLE
Description
Engine Oil Engine Oil
Crankcase (including oil filter) Crankcase (including oil filter)
<1.8L Engine><1.8L Engine><2.0L DOHC Engine><2.0L DOHC Enaine>Oil filter Oil filter
Oil cooler (Turbo) Oil cooler (Turbo)
Metric measureU.S. measure
3.9 liters’.4.4 liters
0.4 liter
0.3 liter
4.‘1 qts.4.6 qts.
‘h qt.Y2 qt.
Cooling System (including heater and coolant reserve system)
<2.0L DOHC Engine>6.2 liters
7.2 liters6.6
qts.
7.6 qts.
Manual Transaxle
1.8liters1.9qts.2.2liters2.3qts.
2.3liters
2.4qts.
Transfer
I0.6 literI.63 qt.
Au:oFmqaAtF2pnsaxle
Rear Axle
Power Steering
Fuel Tank
"C“F4912040
104
27
80
1660
1050
032-10
14-15
5-20-4
-23-10
-29-20
6.1 liters6.4 qts.
7.0 liters7.4 qts.
0.7 liter.74 qt.
0.9 liter.95 sf.60 liters
15.9 gal?.
’ ~ “.SELECTION OF LUBRICANTS
ENGINE OIL
Engine oil should be used which conform to the requirements
of the API classification “For Service SG” or “For Service
SGKD”, and have the proper SAE grade number for the
expected temperature range.
Caution
Nondetergent or straight mineral oil must never be used.
Energy Conserving Oil
In order to improve fuel economy and conserve energy new,
lower friction engine oils have been developed. These oils are
readily available and can be identified by such labels as “EnergyConserving”,“Energy Saving”,“Improved Fuel Economy”,
etc.
/”SAE
5W-20 Not recommended for sustained
high speed vehicle operation.**SAE
5W-30 may be used for operation in very
cold weather areas where the lowest atmos-
pheric temperature is below
-23°C (-10°F).
Page 40 of 1216

O-6LUBRICATION AND MAINTENANCE - Capacities TableRecommended Lubricants and Lubricant
72A0044Oil Identification Symbol
A standard symbol appears on the top of oil containers and hasthree district areas for identifying various aspects of the oil.
The top portion will indicate the quality of the oil. The center
portion will show the SAE viscosity grade, such as SAE
IOW-30. “Energy Conserving” shown in the lower portion,
indicates that the oil has fuel-saving capabilities.
REAR AXLE
LubricantAPI classification
GL-5 or higher
Anticipated temperature rangeViscosity rangeAbove -23°C
(-10°F)SAE 90SAE 85W-90SAE 8OW-90
-23°C to -34°C (-10°F to -30°F)SAE 8OW, SAE 8OW-90Below -34°C
(-30°F)SAE 75WSELECTION OF COOLANT
COOLANTRelation between Antifreeze Concentration and Specific Gravity
concentration
ExampleThe safe operating temperature is
- 15°C (5°F) when the measured specific gravity is 1.058 at the coolant
temperature of
20°C (68°F).
Cautions1. If the concentration of the coolant is below 30%, the anti-corrosion property will be adversely
affected. In addition, if the concentration is above 60%, both the anti-freeze and engine cooling
properties will decrease, affecting the engine adversely. For these reasons, be sure to maintain theconcentration level within the specified range.
2. Do not use a mixture of different brands of anti-freeze.
Page 41 of 1216

LUBRICATION AND MAINTENANCE - Maintenance Service
MAINTENANCE SERVICE1. FUEL SYSTEM (Tank, Lines,
Connect%ms and
Fuel Filler Cap) (Check for
leaks)/2. FUEL
HOSE (Check for leaks or
damage)1 NSOSAGtib1. Check for damage or leakage in the fuet
lines and
connections and looseness of the fuel
fi!:ler cap.
2.Inspect the surface of fuel hoses for heat and mecha-
nical damage. Hard and brittle rubber, cracking, check-
ing, tears, cuts, abrasions and excessive swelling
indicate deterioration of the rubber.
3. If the fabric casing of the rubber hose is exposed by
cracks and abrasions in the fuel system, the hoses
should be changed.
3. AIR CLEANER ELEMENT (Replace)
NOOSAKBbThe air cleaner element will become dirty and loaded with
dust during use, and the filtering effect will be substantially
reduced. Replace it with a new one.
<1.8L Engine, 2.0L DOHC Engine (Non-Turbo)>
(1) Disconnect the air-flow sensor connector.
(2) Remove the air intake hose.
(3) Unclamp the air cleaner cover.
(4) Push the air intake hose backward, and remove the air
cleaner cover.
Caution
Care must be taken when removing the air cleaner
cover, because the air-flow sensor is ‘attached.
(5) Take out the air cleaner element.
<2.0L DOHC Engine (Turbo)>
(1) Disconnect the air-flow sensor connector.
(2) Disconnect the boost hose.
(3) Disconnect the solenoid valve with hoses.
(4) Disconnect the air intake hose.
(5) Remove the air cleaner retaining bolts.
(6) Remove the air cleaner assembly.
(7) Unclamp the air cleaner cover.
Caution
Care must be taken when removing the air cleaner
cover, because the air-flow sensor is attached.
(8) Take out the air cleaner element.
Page 42 of 1216

O-8LUBRICATION AND MAINTENANCE - Maintenance Service
0-L
I-TOlLO182
-
, ,6COOO9
u6COO394. SPARK PLUGS (Replace)
NOOSAOFa1. Spark plugs must spark properly to assure proper
~engine performance and reduce exhaust emission
level.Therefore, they should be replaced periodically with
new ones.
2. The new plugs should be checked for the proper gap.
Spark plug gap
1.0-1.1 mm (.039-.043 in.)
0.7-0.8 mm (.028-.031 in.)
3.Install the spark plug and tighten to 20-30 Nm (15-21
ft.lbs.).5. TIMING BELT (Replace)
NOOSBACaReplace the belt with a new one periodically to assure
proper engine performance.
For removal and installation procedures, refer to GROUP
g-Timing Belt.
6. DRIVE BELT (For Water
Pump and Alternator)
(Inspect for tension)
NOOSSBN(1) Place straight edge as shown in the illustration.
(2) Measure the deflection with a force of
100 N (22 Ibs.)rzapplied to belt mid-point between water pump pulley
-and alternator pulley. If the standard value is not
obtained, make adjustment.
Standard value:
<1.8L Engine>8.0-11.0 mm (.315-A33 in.)
<2.0L DOHC Engine>
9.0-11.5 mm (.354-.453 in.)
(3) Use a tension gauge to check the belt tension. If the
standard value is not obtained, make adjustment.
When tension gauge is used, the tension may be
measured between any two pulleys.
Standard value:
250-500 N (55-110 Ibs.)
Page 43 of 1216

LUBRICATION AND MAINTENANCE - Maintenance ServiceO-9
01R03407. ENGINE OIL (Change)
NWSAAFAlways use lubricants which conform to the requirements
of the API classification “For Service SG” or “For Service
SGKD” .when available, and have the proper SAE grade
number for the expected temperature range.
Never use nondetergent or straight mineral oil.
(1) After warming up the engine, remove the oil filler cap.
(2) Remove the drain plug to allow the engine oil to drain.
(3) Replace the drain plug gasket with a new one and
tighten the drain plug.
(4) Supply new engine oil through the oil filler.
Engine oil total capacity:
< 1.8L Engine>3.9 liters (4.1 qts.)
<2.0L DOHC-Non-Turbo>4.4 liters (4.8 qts.)
<2.0L DOHC-Turbo>4.7 liters (5.0 qts.1[including oil filter 0.4 liter
(l/2 qt.)]
(5) Start and run the engine a few minutes.
(6) Stop the engine and check the engine oil level.
8. ENGINE OIL FILTER (Change)
NOO!SABGaThe quality of replacement filters varies considerably. Only
high quality filters should be used to assure most efficient
service.Genuine oil filters require that the filter is capable of
withstanding a pressure of 256 psi
.are high quality filters
and are recommended as follows:
Oil Filter Part No.
Mitsubishi Genuine Parts: MD031805 or equivalent
NOTEFactory installed Mitsubishi Engine Oil Filter PartNo.MD084693 or MD031805.
’