steering 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”.

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

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

26INTRODUCTION AND MASTER TROUBLESHOOTING - :;:%:a=and
Items
Chassis
TireFront suspension
TypeRear suspension
We
Brake
Type
SteeringGear typeFront
RearGear ratio
Fuel tank
Capacityliters (gals.)

1.8L Engine
“Medium”Pl85/70R14
PI 85/70Rl4
Independent
strut
Independentstrut
3l\Fk Torsion&k-k Torsion
Disc
DiscDisc
Disc
Rack and
pinion
03
Rack and
pinion
cn60 (16)
60
(16)
ItemsVehicle dimensions
mm(in.)Overall length
1Overall width
2Overall height
3Wheel base
4
TreadFront5
Rear6
OverhangFront7
Rear8Minimum running ground
9
clearancemm (in.)
Angle of approachdegrees
10Angle of departure
degrees 11
Vehicle weight
kg (Ibs.)Curb weightsMiT
Al-rGross vehicle weight rating
Gross axle weight rating
Front
RearSeating capacity
EngineModel No.
1.8L Engine
“Medium”2.0L DOHC
Kr%n?u rbo)
P205/55Rl6 89H
;;5/55R16 89V%55R16
88V
Independentstrut
zx;;k Torsion
Disc
Disc
Rack and
pinion
co60 (16)
2.0L DOHC
#b”;
P205/55Rl6 89
or
205155R16 88V
Independentstrut
3Lnk Torsion
Disc
Disc
Rack and
pinion
co
60 (16)
2.0L DOHC Engine(Non-Turbo)
4,330(I 70.5)
1,690(66.5)
1,306(51.4)
2,470(97.2)
1,465(57.7)
1,450(57.1)
950(37.4)
910(35.8)
160(6.3)
15.3
18.1”
1,230 (2,712)
1,255 (2,767)
1,630 (3,594)930 (2,050)
700 (1,543)
4
4G63
2.0L DOHC Engine
(FWD-Turbo)
4,350(171.3)
1,700(66.9)
1,306(51.4)
2,470(97.2)
1,465(57.7)
1,450(57.1)
960(37.8)
920(36.2)
160(6.3)
13.2”
18.1”
1,260 (2,778)
1,295 (2,855)
1,670 (3,682)965 (2,127)
705 (1,554)
1
4G63
2.0L DOHC Engine
(AWD-Turbo)
4,380(I 72.4)
1,700(66.9)
1,321(52.0)
2,470(97.2)
1,465(57.7)
1,455(57.3)
960(37.8)
950(37.4)
158(6.2)
14.0”
17.6”
1,405 (3,097)
1,440 (3,175)
I,81 0 (3,990)
1,005 (2,216)
805 (1,775)
4
4G63

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

INTRODUCTION AND MASTER TROUBLESH’OOTING .- Master ~pAi&oOti~31POOR FUEL MILEAGE
../, *,, /S./..‘, _I, #_.a,‘.rr?
Symptom
Poor fuel mileageProbable cause
Fuel leak
Air cleaner clogged.Ignition system problems
Reference page or remedy”Repair as necessary.
-8-169
IFuel injection system problems.I-ICompression too low.9-23
Tires improperly inflated.22-3
Clutch slips.6-4
Brakes drag.5-7I
NOISE
Symptom
NoiseProbable cause
Loose bolts and nuts.
Engine noiseReference page or remedy
Retighten as necessary
9-23
’
HARD STEERING
Symptom
Hard steeringProbable causeLoose power steering oil pump belt
Low fluid levelAir in power steering system
Low tire pressure
Reference page or remedy19-12
Replenish19-13
22-3
Excessive turning resistance of lower arm ballExcessively tightened of steering gear box
IImproper front wheel alignment2-8
Excessive turning resistance of tie-rod ballioint2-35
1 i-23.30
19-8.10Sticky flow control valve
Bent rack in steering gear box‘.19-4119-23.30
POOR RETURN OF STEERING WHEEL TO CENTERSymptom
1Probable causeIReference pageI
Poor return of steering wheel tocenterImproper front wheel alignment
2-8
Improper tire pressure22-3
Excessive tightened rack support cover19-23.30
I-- ~~~Damaged front wheel bearingI2-12I

32INTRODUCTION AND MASTER TROUBLESHOOTING - Master Troubleshooting
POOR RIDING
Symptom
Poor ridingProbable causeReference page or remedy
Improper tire pressure22-3
lmbalanced wheels
Improper front or rear wheel alignment
Malfunctioning shock absorberRepair
2-8,2917-3.20
Broken or worn stabilizer
Broken or worn coil spring2-29,37,42_ 17-8,32,35
Loose suspension securing bolt(s)Retighten
Worn lower arm bushing2-33
Worn suspension arm bushing2-33Y,’ ,>’
1 17-3.20I
ABNORMAL TIRE WEAR
Symptom
Abnormal tire wearProbable causeReference page
Improper front or rear wheel alignment2-8
Improper tire pressure22-3
Ilmbalanced wheelsIILoose wheel bearingsMalfunctioning shock absorber17-3
2-29
17-8,32
ROAD WANDER
Symptom
Road wanderProbable cause
Improper front or rear wheel alignmentReference page2-8
17-3.20Excessive play of steering wheel
19-7.10
Poor turning resistance of lower arm ball joint1 2-35I
Improper tire pressure22-3
Loose or worn lower arm bushing2-33
Loose or worn wheel bearings
Loose rack support cover in steering gear box
19-23,30
/-=..\

INTRODUCTION AND MASTER TROUBLESHOOTING - Master Troubleshooting
VEHICLE PULLS TO ONE SIDE
Symptom
Vehicle pulls to one sideProbable causeReference pageI
Improper front or rear wheel alignment
lmbalanced or worn tires
Uneven tire pressure2-817-3,2022-3
Excessive turning resistance of lower arm ball2-35
joint
Wheel bearing seizureReplace
Broken or weak coil spring2-29
Bent front axle drive shaft
2-15,3-13
Deformed lower arm2-35
STEERING WHEEL SHIMMY
SymptomSteering wheel shimmy
L
Probable cause
Improper front or rear wheel alignmentReference page or remedy2-8
17-3,20
Improper tire pressure22-3
lmbalanced wheelsReplace
Poor turning resistance of lower arm ball joint2-35
Excessive play of steering wheel
19-7,lO
Broken or weak front stabilizer2-33
Worn lower arm bushing2-33
Malfunctioning shock absorber2-29
17-8,32
Broken or weak coil spring
Wear, play, or seizure of wheel bearing
Wear, play, or seizure of drive shaft ball joint
Replace
2-15.3-13
BOTTOMING
I-SvmotomProbable cause1 Reference page or remedy[Bottoming
Overloaded vehicle
Broken or weak coil springMalfunctioning shock absorberCorrect2-29
l7-8,32

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

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 6Inspect Oil LevelXX
Exhaust System (Connection17Portion of Muffler, Pipings andCheck and Service as Required Every 2 Yearsorx -xConverter Heat Shields)
NOTELSD: Limited-slip differential