service 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”.

INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions befdre Service‘1 S
OOV663OOY192
FOOO 1.
FOOO18
0
OOD511
J7
PRECAUTIONS BEFORE SERVICE wxww
PROTECTING THE VEHICLEIf there is a likelihood of damaging painted or interior parts
during service operations, protect them with suitable covers
(such as seat covers, fender covers, etc.).
REMOVAL AND DISASSEMBLY
When checking a malfunction, find the cause of the problem. If
it is determined that removal and/or disassembly is necessary,
perform the work by following the procedures contained in thisService Manual.
If punch marks or mating marks are made to avoid error in
assembly and to facilitate the assembly work, be sure’to makethem in locations which will have no detrimental effect on
performance and/or appearances.
If an area having many parts, similar parts, and/or parts whichare symmetrical right and left is disassembled; be sure to
arrange the parts so that they do not become mixed during theassembly process.
1. Arrange the parts removed in the proper order.
2.Determine which parts are to be reused and which are to
be replaced.
3.If bolts, nuts, etc., are to be replaced, be sure to use only
the exact size specified.
i:c ” -,.> ‘..“i,. i” ,,‘. 5,
SPECIAL TOOLSIf other tools are substituted for the special tools to do service
or repair work, there is the danger that vehicle parts might be
damaged, or the technician might be injured; therefore, be sureto use the special tool whenever doing any work for which the
use of one is specified.
PARTS TO BE REPLACEDIf any of the following parts are removed, they must be
replaced with new parts.
1. Oil seals
2. Gaskets (except rocker cover gasket)
3. Packings
4. O-rings
5. Lock washers
6. Cotter pins
7. Self-locking nuts

I4INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions before Service
mm (In.1smo59
PARTSWhen replacing parts, use MOPAR genuine parts.
VEHICLE WASHING
If high-pressure car-washing equipment or steam car-washing
equipment is used to wash the vehicle, be sure to maintain the
spray nozzle at a distance of at least 300 mm (12 in.) from anyplastic parts and all opening parts (doors, luggage compart-
ment, etc.).
SERVICING ELECTRICAL SYSTEM
1. Note the following before proceeding with work on the
electrical system.
Note that the following must never be done:
Unauthorized modifications of any electrical device or
wiring, because such modifications might lead to a vehicle
malfunction, over-capacity or short-circuit that could result
in a fire in the vehicle.
2. When servicing the electrical system, disconnect the
negative cable terminal from the batten/.
Caution1. Before connecting or disconnecting the negative
cable, be sure to turn off the ignition switch and thelighting switch.
(If this is not done, there is the possibility of
semiconductor parts being damaged.)
2. For MPI-equipped models, after completion of the
work steps [when the battery’s negative
(-) termi-
nal is connected], warm up the engine and allow it
to idle for approximately five minutes under the
conditions described below, in order to stabilize
engine control conditions, and then check to be
sure that the idling is satisfactory.
Engine coolant temperature:
85-95°C (185-203°F)
Lights, electric fans, accessories: OFF
Transaxle: neutral position
(A/T models: “N” or “P”)
Steering wheel: neutral (center) position

16INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions before Service
Cl6362
OOYSssOOV833
10A15A
COY5695. Connect connectors which have catches by inserting the
connectors until they snap.
9%
ELECTRICAL COMPONENTS1. When installing any of the vehicle parts, be careful not to
pinch or damage any of the wiring harnesses.
2. Sensors, relays, etc.,are sensitive to strong impacts.
Handle them with care so that they are not dropped or
mishandled.
,**3. The electronic parts used for relays, etc., are sensitive to
heat. If any service which causes a temperature of
80°C
(176°F) or more is performed, remove the part or parts in
question before carrying out the service.
FUSES AND FUSIBLE LINKS
1.If a blown-out fuse is to be replaced, be sure to use only a
fuse of the specified capacity. If a fuse of a capacity larger
than that specified is used, parts may be damaged and thecircuit may not be protected adequately.
Caution
1.If a fuse is blown-out, be sure to eliminate the causeof the problem before installing a new fuse.
;i2.Check the condition of fuse holders. If rust or dirt isfound, clean metal parts with a fine-grained sand-
paper until proper metal-to-metal contact is
made.Poor contact of any fuse holder will
often lead tovoltage drop or heating in the circuit
and colildresult in improper circuit operation.

INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions before Sew&e‘37
Nominal
sizeSAE
gi:ePermissible current
In engine
Othercompart-areasment
0.3mm2AWG22-5A
0.5
mm2AWG207A13A
0.85
mm’AWG189A17A
1.25
mm2AWG1612A22A
2.0mm2AWG1416A30A
3.0mm’AWG1221A40A
5.0mm2AWG1031A54A
r ‘.
oorsas
2. If additional optional equipment is to be installed, in ttievehicle, follow the procedure listed in the
ap@@priateinstruction manual; however, be sure to pay “careful
attention to the following points:
“9:(1) In order to avoid overloading the
wiring;’ take the
electrical current load of the optional
,equipment into
consideration, and determine the appropriate .wire size:(2) Where possible, route the wiring through the existing
harnesses.(3) If an ammeter or similar instrument is to be
connectedto a live-wire circuit, use tape to protect the wire, use a
clamp to secure the wire, and make sure that there is
no contact with any other parts.
(4) Be sure to provide a fuse for the load circuit of the
optional equipment.
TUBES AND OTHER RUBBER PARTS
Be careful to avoid spilling any gasoline, oil, etc., or rubber
parts, they might be adversely affected.
LUBRICANTSIn accordance with the instructions in this Service Manual,
apply the specified lubricants in the specified locations during
assembly and installation.
!’IV/ :>,I
BRAKE FLUID
Be careful to avoid spilling any brake fluid on painted surfaces,because the paint coat might be discolored or damaged.

18INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions b&ire Service
DOING SERVICE WORK IN GROUPS OF VO’bRMORE TECHNICIANS
.-I-7.IIf the service work is to be done by two or more technicians
working together, extra caution must be taken.
VoltagedistributionMaximum
voltage
NOTE ON INSTALLATION OF RADIO EQIJIPMEATeThe computers of the electronic control system has been
designed so that external radio waves will not interfere with
their operation.
However, if antenna or cable of amateur transceiver etc. is
routed near the computers, it may affect the operation of the
computers, even if the output of the transceiver is no more
than
25W.To protect each of the computers from interference by
transmitter (hum, transceiver, etc.), the following should be
observed.1. Install the antenna on the roof or rear bumper.
2.Because radio waves are emitted from the coaxial cable of
the antenna, keep it 200 mm (8 in.) away from the
computers and the wiring harness. If the cable must cross
hthe wiring harness, route it so that it runs at right angles to
the wiring harness.
3.The antenna and the cable should be well matched, and thestanding-wave ratio* should be kept low.
4.A transmitter having a large output should not be installed
in the vehicle.
5.After installation of transmitter, run the engine at idle, emit
radio waves from the transmitter and make sure that the
engine is not affected.
“STANDING-WAVE RATIO
If an antenna and a cable having different impedances are
connected, the input impedance Zi will vary in accordance with
the length of the cable and the frequency of the transmitter,
and the voltage distribution will also vary in accordance with
the location.
The ratio between this maximum voltage and minimum voltage
is called the standing-wave ratio. It can also be represented bythe ratio between the impedances of the antenna and the
cable.The amount of radio waves emitted from the cable increases
as the standing-wave ratio increases, and this increases the
possibility of the electronic components being adversely
affected.

c
--INTRODUCTION AND MASTER
TROUBLESHOOTtNG - Towing and Hoi&gT9
I-
Sling type
Wheel lift type
Flat bed type
iling type
Vheel lift type
lat bed type
TOWING AND HOISTINGNOOGA-
llJ/RE;~R TOWING RECOMMENDATION
FRONT TOWING PICKUP
Caution
This vehicle cannot be towed by a wrecker using sling-typeequipment to prevent the bumper from deformation.
If this vehicle is towed, use wheel lift or flat bed
equipment.
The vehicle may be towed on its rear wheels for extended
distances provided the parking brake is released. It is recom-
mended that vehicles be towed using the front pickup
whenever possible.
REAR TOWING PICKUP
Caution
This vehicle cannot be towed by a wrecker using sling-typeequipment to prevent the axle beam from deformation.lf this vehicle is towed, use wheel lift or flat bed
equipment.
Manual transaxle vehicles may be towed on the front wheels,
provided the transaxle is in neutral and the drive-line has not
been damaged. The steering wheel must be
clam,ped in the
straight-ahead position with a steering wheel clamping device
designed for towing service use.
Caution
Do not use steering column lock to secure front wheel
position for towing.
3,“’Automatic transaxle vehicle may be towed on the
frontwheelsat speeds not to exceed 50 km/h (30 mph) for a distances hot
to exceed 30 km (18 miles).
Caution
If these limits cannot be met, the front wheels must ‘be
placed on a tow dolly.
TOWING WHEN KEYS ARE NOT AVAILABLE
When a locked vehicle must be towed and keys are not
available, the vehicle may be lifted and towed from the front,,
provided the parking brake is released: If not released, the rearwheels should be placed on a tow dolly.
I

20INTRODUCTION AND MASTER TROUBLESHOOTING - Towing and Hoisting
Frame contact support location
OOAOI 71
: 928mm (36.5 in.)
: 998mm (39.3 in.)
IRearISAFETY PRECAUTIONS
The following precautions should be taken when
towin the
vehicle.
1.DO NOT LIFT OR TOW THE VEHICLE BY ATTACHING TOOR WRAPPING AROUND THE BUMPER.
2. Any loose or protruding parts of damaged vehicle such as
hoods, doors, fenders, trim, etc., should be secured prior tomoving the vehicle.
3.Operator should refrain from going under a vehicle while it
is lifted by the towing equipment, unless the vehicle in
adequately supported by satefy stands.
4. Never allow passengers to ride in a towed vehicle.
5. State and local rules and regulations must be followed
when towing a vehicle.
Refer to the section “Special Handling Instructions for AWD
Models”.
HOISTING
POST TYPESpecial care should be taken when raising the vehicle on a
frame contact type hoist. The hoist must be equipped with the
proper adapters in order to support the vehicle at the proper
locations.Caution
When service procedures require removing rear sutpen-
sion, fuel tank, spare tire and lift gate, place addmonal
weight on rear end of vehicle or anchor vehicle to hoist to
prevent tipping of center of gravity changes.
FLOOR JACK
The usual type of floor jack is used at the following locations.
Front:
Under the mid point of centermember
Under the mid point of crossmember
Rear:
Under the jack up bracket of rear floor pan
Under the rear differential
Cautions
1. Never use a jack at the lateral rod or rear suspension
assembly.

2.In order to prevent scarring the centermember or crossmember
, place a piece of cloth on the
jack’s contact surface (to prevent corrosion caused by
damage to the coating).
3. A floor jack must never be used on any part of the
underbody.
4.Do not attempt to raise one entire side of the vehicle byplacing a jack midway between front and rear wheels.
This practice may result in permanent damage to the
body.