1991 MITSUBISHI ECLIPSE check engine

ENGINE <2.0L DOHC Engine>- Crankshaft, Flywheel and Drive Plate,91133
INSPECTIONNOSUHAD
CRANKSHAFT(1) Check the crankshaft journals and pins for streaks and
seizure. Replace if necessary.
6EN0’228
\3EN056
Plastic
6EN043
. .
I1 EN067-(2) Measure the journal O.D. and main bearing I.D. to obtain
the clearance between the two (oil clearance). If the
clearance exceeds the limit, replace the main bearing and,if necessary, the crankshaft.
Standard value:
0.02-0.05 mm (.OOOS-.0020 in.)
Limit: 0.1 mm
(.0040 in.)
Caution
A special
surface treatment has been applied to
crankshaft. Do not machine it to undersize.
CRANKSHAFT OIL CLEARANCE (PLASTIC GAUGE
METHOD)
The crankshaft oil clearance can be measured easily by using aplastic gauge, as follows:
(1) Remove oil and grease and any other foreign matters from
crankshaft journal and bearing inner surface.
(2) Install the crankshaft.
(3) Cut the plastic gauge to the same length as the width of
bearing and place it on journal in parallel with its axis.
(4) Gently place the crankshaft bearing cap over it and tighten
the bolts to the specified torque.
(5) Remove the bolts and gently remove the crankshaft
bearing cap.(6) Measure the width of the smashed plastic gauge at its
widest section by using a scale printed on the plastic gauge
bag.

g-134 ENGINE <2.0L DOHC Engine>- Crankshaft, Flywheel and Drive Plate
3EN301CRANKSHAFT REAR OIL SEAL
(1) Check oil seal lip for wear and damage.
(2) Check rubber for deterioration or hardening.
(3) Check oil seal case for cracks and damage.
RING GEAR (Engine with a manual transaxle)
Check teeth of ring gear for wear and damage. If necessary,
replace the ring gear.
If the ring gear teeth are worn or damaged, also check the
starter motor pinion.
To remove the ring gear, strike the ring gear at several points
on its outer circumference. The ring gear cannot be removed ifit is heated.
To install the ring gear, heat the ring gear to
300°C (572°F) for
shrink fit.
FLYWHEEL (Engine with a manual transaxle)
(1) Check the clutch disc friction surface for ridge wear,
streaks, and seizure. If necessary, replace flywheel.
(2) If the
runout of flywheel exceeds the limit, replace.++.Limit: 0.13 mm
(.0051 in.)
DRIVE PLATE (Engine with an automatic transaxle)
Replace deformed, damaged, or cracked drive plates.
SERVICE POINTS OF REASSEMBLYNWUGAB
14. INSTALLATION OF CRANKSHAFT BEARING (UPPER)
Install the upper crankshaft bearing to the cylinder block.
There is an oil groove in the upper crankshaft bearing.
There is no difference between upper and lower bearings
for the center (with flange).
12. INSTALLATION OF CRANKSHAFT BEARING (LOWER)
Install the lower crankshaft bearing (with no oil groove;
there is no difference for center) to each bearing cap and
apply engine oil to bearing surfaces.

9-136ENGINE <2.0L DOHC Engine> - Cylinder Block
CYLINDER BLOCK
DISASSEMBLY AND REASSEMBLY,+Ymaw-030-42 Nm22-30 ft.lbs.
/50-75 Nm40-54 ft.lbs.
4a
/
r.‘?’
’ cRoll stopper
bracket, front/.50-76 Nm
36-51
ftlbs.
’ Engine support
bracket, left
Roll stopper
bracket, rear-Cylinder block32-42 Nm22-30
ftlbs.
110-130 Nm60-64 ft.lbs.6EN0374
INSPECTION
NOTE
1.Clean parts to remove dust, oil, carbon deposits, and scale
before starting the inspection and ‘repair procedure.
2. Check cylinder block for water leaks and damage
b&fore
cleaning.3. Remove deposits from oil holes and make sure that they
are not clogged.
4. Keep parts neatly arranged according to a matched pair.
CYLINDER BLOCK(1) Visually check for scratches, rust, and corrosion.
Use also a flaw detecting agent for the check. If defects areevident, correct, or replace.~
(2) Using a straightedge and feeler gauge, check the block top-surface for
warpage. Make sure that the surface is free
from gasket chips and other foreign matter.
Standard value: 0.05 mm
(4020 in.) or less
Limit: 0.1 mm
(AM40 in.)

ENGINE <2.0L DOHC Engine> - Cylinder Block9437
Thrustdirection
6EN054-(3) If the distortion is excessive, correct within the allowable
limit or replace.
Grinding limit: 0.2 mm
(008 in.)
The total thickness of the stock allowed to be
removed from cylinder block and mating cylinder
head is 0.2 mm
(008 in.) at maximum.
Cylinder block height (when new): 284 mm (11.18 in.)
(4) Check cylinder walls for scratches and seizure. If defects
are evident, correct (bored to oversize) or replace.
(5) Using cylinder gauge, measure the cylinder bore and
cylindricity. If worn badly, correct cylinder to an oversize
and replace piston and piston rings. Measure at the points
shown in illustration.
Standard value:
Cylinder I.D.:
85.00-85.03 mm (3.3485-3.3476 in.)
Out-of-roundness and taper of cylinder bore:
0.01 mm
(6064 in.) or less
CYLINDER REBORINGNO9VEDCa(1) Oversize pistons to be used should be determined on the
basis of the largest bore cylinder.
Piston size identification
Size0.25 mm
(.Ol in.) O.S.
0.50 mm
(.02 in.) O.S.
0.75 mm
(.03 in.) OS.
1.00 mm LO4 in.) O.S.
Identification mark0.25
0.50
0.75
1 .oo
NOTESize mark is stamped on piston top.
(2) Measure outside diameter of piston to be used. Measure it
in thrust direction as shown.
(3) Based on measure piston O.D. calculate boring finish
dimension.Boring finish dimension
= Piston O.D. + (clearance
between piston O.D. and cylinder)
- 0.02 mm (.OOOSin.) (honing margin)
(4) Bore all cylinders to calculated boring finish dimension.
CautionTo prevent distortion that may result from temperature
rise during honing, bore cylinders, working from
No.2to No.4 to No. 1 to No. 3.
(5) Hone to final finish dimension (piston O.D. + clearance
between piston O.D. and cylinder).
(6) Check clearance between piston and cylinder.
Clearance between piston and cylinder:
:
0.02-064 mm (AMOS-,001~ in.)
:
0.03-0.05 mm (.OOW-.O020 in.)
NOTEWhen boring cylinders, finish all of four cylinders to same
oversize. Do not bore only one cylinder to an oversize.

INTAKE AND EXHAUST - Service Adjustment Procedures11-5
SERVICE ADJUSTMENT PROCEDURES
AIR CLEANER ELEMENT INSPECTION AND RE-PLACEMENTNllQBAF
< 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.
CautionCare must be taken when removing the air cleaner
cover, because the air-flow sensor is attached.
(5) Take out the air cleaner element.
(6) Check the air cleaner element for dirt or clogging.
(7) Replace the air cleaner element if the dirt or clogging is
serious.
(8) Insert the element into the air cleaner body and install the
air cleaner cover.
(9) Install the air intake hose.
(10)Connect the air intake hose and the air-flow sensor
connector.
<2.0L DOHC Engine (Turbo)>(I
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.
(9) Check the air cleaner element for dirt or clogging.
(10)Replace the air cleaner element if the dirt or clogging is
serious.
(11) Insert the element into the air cleaner body.
(12)Clamp the air cleaner cover.
(13)lnstall and tighten the air cleaner retaining bolts to the
specified torque.
(14)Connect the air intake hose and the solenoid valve.
(15)Connect the vaccum hose and the air-flow sensor
connector.

11-6INTAKE AND EXHAUST - Service Adjustment Procedwes
Wasie gate actuator05AOlSO
TURBOCHARGER SUPERCHARGING PRESSURE
INSPECTIONN1mAAB!PTCautionPerform running inspection with two passengers in the
-’vehicle and where full throttle acceleration can be safely
made.The pressure gauge reading is taken by a front seat
passenger.
(1) Disconnect the supercharging pressure control hose at the
solenoid valve (fixed to the air cleaner) and plug the nipple.Attach the pressure gauge to the hose.
(2) Drive the vehicle with full throttle and accelerate the engineto a speed of more than 3,500 rpm at
2nd gear. Measure
the supercharging pressure when the pointer is stabilized.Standard value:
M/T41-75
kPa (6.0-10.8 psi)
A/T37-68
kPa (5.4-9.9 psi)
Caution
If the supercharging pressure deviates from the standard
value, check the following items for possible causes.
When pressure is high:Waste gate actuator malfunction
When pressure is low:
Waste gate actuator malfunction
Supercharging pressure leaks
Faulty turbocharger
+-
SUPERCHARGING PRESSURE CONTRtd $YSTEM
INSPECTIONNllGFAA
(1) After the self-diagnosis content of ECI-MULTI system is
completely read, turn off the ignition switch.
(2) Disconnect the vacuum hose (white-striped) from the wastegate actuator, and connect the hand vacuum pump to the
vacuum hose.
(3) Disconnect the vacuum hose (black) from the intake port (Ain the figure) of the boost which controls the waste gate
actuator, and insert the blind plug into the nipple from whichthe vacuum hose was disconnected.
(4) Keep the (- ) terminal of the battery disconnected for 10seconds or longer, and then reconnect the terminal.
(5) Apply the negative pressure in the following state, and check
the air tightness.
IEngine stateHose (black)Normal stateI
stop ;“““*I
NOTEIf negative pressure is not normal, it can be assumed that there is a
malfunction in the waste gate solenoid valve or vacuum hose.

INTAKE AND EXHAUST - Service Adjustment ProceduresII-7
w05A0155
h61
NO06061
NO0616 I
NO056(6) With the vacuum hose (black) closed when idling, apply
negative pressure and inspect the condition of the negative
pressure.
Engine stateDetonation sensor
connectorNormal state
,
ConnectionNegative pressureleaks.
Idling
DisconnectionNegative pressure
is maintained.
NOTEIf negative pressure is not normal, it can be assumed that there is amalfunction in the knock sensor circuit.(7) Turn off the ignition switch, and connect the connector of
the detonation sensor.
(8)Disconnect the (-) terminal of the battery for 10 seconds or
more.
NOTE
This erases the diagnosis memory of the detonation sensortrouble by disconnecting the detonation sensor connector.
SUPERCHARGING PRESSURE RELIEF SOLENOID
VALVE INSPECTIONNllGGAA
(1) Operation check
Using a hand
vaccum pump, apply a negative pressure to
the solenoid valve nipple on which the white vacuum hose
is connected, and check air-tightness when the voltage is
applied to the solenoid valve terminal and when it i‘s releasedfrom the terminal.
I
Other nipple ofBattery voile solenoid valveNormal state
OpenedNegative pressureleaks.IWhen applied
Closed by fingerNegative pressure
is maintained.
IWhen released OpenedNegative pressure
is maintained.
I
(2) Continuity check of coil
Measure the solenoid valve terminal resistance.Standard value: 36-44
fl [at 20°C (68OF)l
AIR BYPASS VALVE INSPECTIONNllGHAA
(1) Remove the air bypass valve.
(2) Connect the hand vacuum pump to the nipple of the air
bypass valve.
(3) Apply a negative pressure of approx. 53.3 kPa (7.7 psi), andcheck operation of the valve. Also check that air tightness
is maintained.
Negative pressure
About 53.3 kPa (7.7 psi)
Valve operation
It starts opening.

INTAKE AND EXHAUST - Intake Manifold < 1.8L Engine>1145
SERVICE POINTS OF REMOVALNllMBAI
3. DISCONNECTION OF RADIATOR UPPER HOSE
Make mating marks on the radiator hose and the hose
clamp, and then remove the radiator hose.
r
04A0088 19. DISCONNECTION OF FUEL HIGH PRESSURE HOSE
Relieve pressure in the fuel pipe line to prevent fueloutflow.
(Refer to GROUP 14 - Service Adjustment Procedures.)
Caution
Cover fuel pipe line with rag after relieving pressure ascertain pressure may still remain.16.REMOVAL OF DELIVERY PIPE, FUEL INJECTOR AND
PRESSURE REGULATOR
Remove delivery pipe with fuel injector and pressure
regulator.
CautionDo not drop injector when removing delivery pipe.
INSPECTIONNllMCAl
Check the following points; replace the part if a problem isfound.
AIR INTAKE PLENUM
(1) Check air intake plenum for defect or cracks. Replace ifdefective
or cracked.
(2) Check load (negative pressure) of drain port. Check
cooling water and jet air passages for clogging. Clean if
required.
(3) Check deflection of installation surface with straight edge
and feeler gauge.Standard value: 0.15 mm
(.006 in.) or less
Limit:0.3 mm (.012 in.)05AOOB4