specifications 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”.

INTRODUCTION AND MASTER TROUBLESHOOTING - :;k%ii::& and25
GENERAL DATA AND SPECIFICATIONSNOOHA-
OOAOl59
GENERAL SPECIFICATIONS
z-
A-l
.8L Engine1.8L Engine2.0L DOHC2.0L DOHCItems“Medium”“High”~%n?urbo):Tz%$
Vehicle dimensions
mm(in.)Overall length
14,330(170.5)4,330(170.5)4,330(I 70.5)4,330(170.5)Overall width
21,690(66.5)1,690(66.5)
1,690
(66.5)
1,690(66.5)Overall height
31,306(51.4)1,306(51.4)1,306(51.4)
1,306(51.4)Wheel base
4
2,470(97.2)2,470(97.2)2,470(97.2)2,470(97.2)Tread Front
5
1,465(57.7)
1,465(57.7)
1,465
(57.7)1,465(57.7)
Rear6
1,450(57.1)1,450(57.1)1,450(57.1)1,450(57:l i
Overhang Front
7950(37.4)950(37.4)950(37.4)
950(37.4)
Rear
8
910(35.8)910(35.8)910(35.8)910(35.8)Minimum running ground
9
160(6.3)160(6.3)
160(6.3)160(6.3)clearancemm (in.)
Angle of approach
degrees10 15.3”15.3”15.3”
15.3”Angle of departure
degrees11 18.1”
18.1” ’18.1“
18.1”Vehicle weight
kg (Ibs.)
Curb weights
M/T
1,145(2,524)
1,165(2,568)
1,215
(2,679)
1,245(2,745)
AIT1 ,I 70(2,579)
1,190(2,623)
1,240
(2,734)
1,280(2,822)Gross vehicle weight rating
1,585(3,494)1,585(3,494)
1,630
(3,594)‘I ,670(3,682)Gross axle weight rating
Front
900(1,984)900(1,984)930(2,050)965(2,127)
Rear
685(1,510)685(1,510)
700
(1,543)705‘(1,554)Seating capacity
4
444
EngineModel No.
4G3746374G634G63
TransaxleModel No.
Manual transaxle
F5M22F5M22F5M22F5M33Automatic transaxle
F4A22F4A22F4A22F4A33
Clutch
TypeDry-single discDry-single discDry-single discDry-single disc& diaphragm& diaphragm& diaphragm& diaphragm
springspringspringspring

INTRODUCTION AND MASTER TROUBLESHOOTING - f~EEaZ% acld27
=r
9..
Items
TransaxleModel No.
Manual transaxle
Automatic transaxle
Clutch
Type
Chassis
TireFront suspension
TypeRear suspension
Type
Brake
Type
SteeringGear type
Gear ratio
Fuel tank
Capacity
2.0L DOHC Engine2.0L DOHC Engine2.0L DOHC Engine
(Non-Turbo)(FWD-Turbo)(AWD-Turbo)
F5M22F5M33W5M33
F4A22F4A33W4A33Dry-single disc
Dry-single discDry-single disc& diaphragm spring& diaphragm spring& diaphragm spring
P205/55R16 89HP205155R16 89VP205/55R16 89Vor 205/55R16 89Vor 205/55R16 88Vor 205/55R16 88Vor 205/55R16 88VIndependent strut
Independent strutIndependent strut
3-Link Torsion axle3-Link Torsion axleDouble wishbone
Front
Disc
DiscDisc
RearDisc
DiscDiscRack and pinion
Rack and pinionRack
,and pinion
03coccliters (gals.) 60 (16)
60 (16)60 (16)
)
ENGINE SPECIFICATIONS
Items4G374G63 Non-Turbo4G63 Turbo
TypeIn-line SOHCIn-line DOHCIn-line DOHC
Number of cylinders
444
Boremm (in.) 80.6 (3.17)
85.0 (3.35)85.0 (3.35)
Strokemm (in.) 86.0 (3.39)
88.0 (3.46)88.0 (3.46)
Piston displacement
cm3 (cu.in.) 1,755 (107)1,997 (122)1,997 (122)Compression ratio
9.09.07.8Firina order
1-3-4-21-3-4-21-3-4-2
TRANSAXLE SPECIFICATIONS
ItemsF5M22F5M33W5M33F4A22F4A33W4A33
TypeGear ratio
1 st
2nd
3rd
4th
5th
Reverse
TransaxlePrimary reduction ratio
Secondary reduction
ratio
Transfer
5-speed M/T5-speed M/T
3.363
3.090
1.947
1.833
1.285
1.217
0.939
0.888
0.756
0.741
3.0833.166
5speed M/T4-speed A/T4-speed AIT
3.083
2.8462.551
1.6841.5811.488
1.115
1.0001 .ooo
0.8330.6850.685
0.666--
3.166
2.1762.176
Qspeed AIT
2.551
1.488
1 .ooo
0.685
-
2.176
1.096
3.9411.2081.275
1.1251.2281.228
3.4373.866
3.5623.222
3.600
-1.090--1.090

LUBRICATION AND MAINTENANCE - Maintenance Service
osFol2ENGINE
OIL FtLTER SELECTtONThis vehicle is equipped with a full-flow, throw-away oil
,~
filter.The same type of replacement filter is recommended as a
replacement filter for this vehicle. It is possible, particularilyin cold weather, that this vehicle may develop high oil
pressure for a short duration. You should be sure that any
replacement filter used on this vehicle is a high-quality filterand is capable of withstanding a pressure of 256 psi
(manufacturer’s specifications) to avoid filter and engine
damage. The following is a high-quality filter and is stronglyrecommended for use on this vehicle
: Mitsubishi Engine
-Oil Filter Part No. MD031805 or MD084693.
Any replacement oil filter should be installed in accordancewith the oil filter manufacturer’s installation instructions.
(1) Remove the engine oil filler cap.
(2) Remove the engine oil drain plug, and drain out the
engine oil.
(3) Remove the engine oil filter by using the oil filter
wrench.(4) Clean the oil filter mounting surface of the oil filter
bracket.(5) Coat engine oil to the O-ring of new oil filter.
(6) Turn the oil filter by hand to install to the block.
NOTEThe oil filter tightening torque is
11-13 Nm (8-10
ftlbs.).A(7) Supply engine oil.
.(8) Start and run engine and check for engine oil leaks.
(9) After stopping engine, check oil level and replenish as
necessary.9. MANUAL TRANSAXLE (Inspect oil level)
NOOSBCEbInspect each component for evidence of leakage, and
check the oil level by remaining the filler plug. If the oil is
contaminated, it is necessary to replace it with new oil.
1. With the vehicle parked at a level place, remove the
filler plug and check to be sure that the oil level is up tothe lower edge of the filler plug hole.
2. Check to be sure that the transmission oil is not
noticeably dirty, and that it has a suitable viscosity.

FRONTSUSPENSION
’
CONTENTSNOZAA-CENTERMEMBER AND
CROSSMEMBER..............................................44
DRIVESHAFT..................................................15HUB AND KNUCKLE
......................................9
LOWERARM
...................................................33
~SERVICE ADJUSTMENT PROCEDURES.......8
FrontWheelAlignment................................8Hub End Play Inspection
.............................8
WheelBearingAdjustment..........................9
SPECIALTOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
SPECIFICATIONS.............................................2General Specifications
..................................2
Lubricants......................................................5Service Specifications
...................................4
TorqueSpecifications...................................4STABILIZER BAR
.............................................37
STRUTASSEMBLY.........................................29

2-2FRONT SUSPENSION - Specifications
SPECIFICATIONS
GENERAL SPECIFICATIONSNOZCA-

ItemsVehicles with 1.8L EngineVehicles with 2.0L DOHCVehicles with 2.0L DOHC
Engine Engine MIT
MM/TAITMITNTSuspension systemMcPherson strut with’ coil spring and compression’ rod type
Coil spring
Wire dia.
x0.D. x13.4x173.4x 13.6x173.6x 13.7x173.7x 13.9x173.9x 13.9x173.9x 14.1 x174.1xfree length326.5 (.53x334.5 (.54x314 (.54x321.5 (.55x321.5 (.55x329 (.55x
mm (in.) 6.83x12.9)6.83x
13.2)6.84x 12.4)6.85x 12.7)6.85x 12.7)6.85x 12.9)Coil springGreen
x 1Green x 2Light blue x 1 Light blue x 2 Light blue x 2 Orange x 1
identification
colorSpring constant
N/mm
(IbsAn.) 22 (123)22 (123)24 (134)24 (134)24 (134)24 (134)Shock absorber
TypeHydraulic, cylindrical double acting type
Maximum length
mm (in.) 483 (19.02)
Compressed length
mm (in.) 330 (12.99)
Strokemm (in.) 153 (6.02)
Damping force
[at 0.3
m/set.
(0.984 ft./sec.)l
Expansion
N (Ibs.) 1,000 (220)
ContractionN (Ibs.) 300 (66)
Wheel bearing
TypeDouble-row angular-contact ball bearing
0.D.xl.D. mm (in.) 80x40 (3.15x1.57)
Drive shaft
Joint type
OuterB.J.“l
InnerT.J.“’Drive shaft
Lengthmm (in.)
L.H. shaft708 (27.9)706 (27.8)
R.H. shaft368 (14.5)366 (14.4)
NOTE*1: B.J.: Birfield joint*2: T.J.: Tripod joint706 (27.8)
702 (27.6)366 (14.4)
370 (14.5)

FRONT SUSPENSION - SpecificationsItemsMiT
Al-rSuspension system
McPherson strut with coil spring and compression rod type
Coil spring
Wire
dia.xO.D.xfree length
mm (in.) 14.0x174.0x326.514.2x174.2x333.5(.55x6.85x 12.9)(.56x6.86x13.1)
Coil spring identification color
Pink
x 1
Pink x 2
Spring constant
N/mm
(Ibs./in.) 26 (146)26 (146)Shock absorber
TypeHydraulic, cylindrical double acting type
Maximum length
mm (in.) 489 (19.25)
Compressed length
mm (in.) 340 (13.39)
Strokemm (in.) 149 (5.87)
Damping force [at 0.3 m/set.
(0.984 ft./set.)]
ExpansionN (Ibs.) 1,000 (220)
ContractionN (Ibs.) 300 (66)
Wheel bearing
TypeDouble-row angular-contact ball bearing
0.D.xl.D.mm (in.) 80x40 (3.15x1.57)
Drive shaft
Joint type
Outer
B.J.“’
InnerT.J.“’Drive shaft
Lengthmm (in.)
L.H. shaft368 (14.5)365 (14.4)
R.H. shaft368 (14.5)371 (14.6)
NOTE
*I: B.J.: Birfield joint**: T.J.: Tripod joint

2-4FRONT SUSPENSION - Specifications
SERVICE SPECIFICATIONS;02CB-
ItemsVehicles with
1.8L Engine
Vehicles with
2.0L DOHC Engine
Standard value
Camber14’230’5’+30’10’+30’
Caster2”20’ -t 30’2”24’ 3130’2”18’ f 30’
Toe-inmm (in.) Of3 (Ok.12)Of3 (Ok .12)Of3 (Ok.12)
Protruding length of stabilizer bar
mounting boltmm (in.) 16-18
(.63-.70)--Setting of T.J. boot lengthmm (in.)
L.H.75+3 (2.95f.12)80-+3 (3.15f.12)85_+3 (3.35k.12)
R.H.85f3 (3.35k.12)80+3 (3.15k.12)85f3 (3.35f.12)Lower arm ball joint starting
torqueNm (in.lbs.) 3-10 (26-87)3- 10 (26-87)3- 10 (26-87)
Stabilizer link ball joint starting
torqueNm (inlbs.) -1.7-3.2 (15-28)1.7-3.2 (15-28)
Crossmember bushings projection
mm (in.)
Bushing A
7.2-10.2 (.28-.40)7.2-10.2 (.28-.40)7.2-10.2 (.28-.40)
Bushing
B6.5-9.5 (.26-.37)6.5-9.5 (.26-.37)6.5-9.5 (.26-.37)
LimitHub end playmm (in.) 0.2
(.008) or less
Wheel bearing starting torque
(Hub starting torque)Nm
(in.lbs.) 1.8 (16) or less
TORQUE SPECIFICATIONSNO2CG.
ItemsDrive shaft nut
Tie rod end ball joint
Knuckle to ball joint
Knuckle to strut assembly
Strut top end nut
Strut mounting nut
upperCaliper assembly mounting bolt
Center bearing bracket
Front speed sensor bracket
Front toothed rotor
Stabilizer bar bracket to crossmember
Stabilizer link
Lower arm clamp to crossmember (nut)
Lower arm clamp to crossmember (bolt)
Lower arm to crossmember
Stay to crossmember
Front exhaust pipe to exhaust manifold
Turbo
Non-TurboFront exhaust pipe clamp
Crossmember to body
Front roll stopper bracket to centermember
Nmftlbs.
200-260144-188
24-3417-25
60-7243-52
1 IO-14080-101
60-7043-51
40-5029-39
80-10058-72
36-4626-33
9-14
7-109-14
7-10
30-4222-3035-4525-33
35-4725-34
80-I 0058-72
100-12072-87
70-8051-58
40-6029-43
30-4022-29
30-4022-29
100-12072-87
40-5029-36

FRONT SUSPENSION - Specifications2-5Items
Rear roll stopper bracket to centermember
Centermember installation bolts (front)
Centermember installation bolts (rear)
Joint assembly and gear box connecting bolt
Steering gear box assembly to return tube
Steering gear box assembly to pressure hose
Steering gear box assembly to crossmember
Pressure hose bracket to crossmember
Transfer installation bolt
Nmftlbs. I’, ‘,
40-5029-36
80-10058-72
80-I 0058-72
15-20II-1412-18
9-13
12-189-13
60-8043-58
9-14
7-10
55-6040-43
60-8043-58
Gusset installation bolt
70-8051-58Left member installation bolt (front)
80-10058-72
Left member installation bolt (rear)
70-8051-58
Vo. 1 crossmember installation nut80-10058-72qight member installation bolt (front)
80-10058-72?ight member installation bolt (rear)
70-8051-58
+ont roll stopper to No. 1 crossmember40-5029-36
?ont roll stopper installation nut50-6536-47
Iront exhaust pipe to catalytic converter40-6029-43
‘rant exhaust pipe to hangerIO-157-11
‘-. LUBRICANTSNO2CD--
ItemsSpecified lubricantsQuantity
Outer surface of wheel bearing outer race
MOPAR Multi-mileage LubricantAs required
Wheel bearing inner racePart No. 2525035 or equivalent
Oil seal lip
Strut insulator bearing
Lower arm ball joint
Stabilizer link
Inner dust coverMOPAR Multi-mileage Lubricant
Part No. 2525035 or equivalent
7-10 g (.25-.35 oz.)
Outer dust cover
MOPAR Multi-mileage Lubricant
Part
No.2525035 or equivalent4-6
g (.14-.21 oz.)
B.J. boot grease
Repair kit grease
Vehicles with
1.8L engine
95 g (3.4 oz.)
Vehicles with
2.0L DOHC engine110 g (3.9 oz.)
95 g (3.4 oz.)
T.J. boot grease
Repair kit grease
Vehicles with
1.8L engine105 g (3.7 oz.)
Vehicles with
2.0L DOHC engine120 g (4.2 oz.)
105 g (3.7 oz.)
Spider assemblyRepair kit greaseAs required
NOTEThe grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot.

2-8FRONT SUSPENSION - Service Adjustment Procedures
SERVICE ADJUSTMENT PROCEDURES
HUB END PLAY INSPECTIONNO2FAAB --- ’
1. Jack up the vehicle and remove the front wheels.
2.Remove the disc brake caliper and suspend it with a wire.
(Refer to GROUP
5-Service Adjustment Procedures.)
3.Attach a dial indicator as shown in the illustration, and thenmeasure the axial play while moving the hub back and
forth.Limit
: 0.2 mm (.008 in.) or less
NOTE
Secure the brake disc and hub by the wheel nut so that thebrake disc won’t come off the hub.
4.If axial play exceeds the limit, disassemble and check parts.
FRONT WHEEL ALIGNMENTNOZFBAQ
NOTEThe front suspension assembly must be free of worn, loose or
damaged parts prior to measurement of front wheel align-
A
ments.--l
Measure wheel alignment by using the special tool.
CAMBER AND CASTER
Standard value
:
<1.8L><2.0L>
FWDAWD
Camber
14’+ 30’5’k3010’f 30
Caster250 + 30’2”24’ + 30’29 8’ f 30Camber and caster are pre-set at the factory and cannot be
adjusted.
NOTE
If camber and caster are not within specifications, replace bentor damaged parts.
TOE-INStandard value
:Of3 mm (Of.12 in.)
1. Adjust the toe-in by undoing the clips and turning the left
and right tie rod turnbuckles by the same amount (in
-opposite directions).
2. The toe will move out as the left turnbuckle is turned
- ,’toward the front of the vehicle and the right turnbuckle is
turned toward the rear of the vehicle.