1991 MITSUBISHI ECLIPSE Oxy

11-4INTAKE AND EXHAUST- Specifications/Special Tool/Troubleshooting
ItemsEngine oil level gauge guide mounting bolt
Engine hanger to engine
Exhaust manifold to engine
Exhaust manifold to turbocharger
Oil pipe to engine
Water pipe
(B) to water inlet pipe
Waste gate actuator
Oxygen sensor
Water pipe
(B) to turbocharger
Air outlet fitting
Oil pipe to turbocharger
Water pipe (A) to turbocharger
Water pipe (A) mounting bolt
Exhaust fitting
Oil return pipe
Exhaust pipe and main muffler
Front exhaust pipe to exhaust manifold
Front exhaust pipe to exhaust fitting
Front exhaust pipe clamp
Rubber hangerFront exhaust pipe to catalytic converter
Catalytic converter to center exhaust pipe
Hanger bracket to body
Hook to center exhaust pipe
Center exhaust pipe to main muffler
Moulding to main muffler
Nmft.lbs.
12-15
9-l 112-159-11
25-3018-?255-65
40-4714-19
IO-l+
40-5029-36
IO-137-9
40-5029-36
35-5025-36
9-14
7-1028-34
20-25
35-5025-36
IO-127-9
55-65
40-47
8-106-7
30-4022-29
40-6029-43
30-4022-29
IO-157-11
40-6029-43
30-4022-29
10-157-11
10-157-11
30-4022-29
4-63-4
TROUBLESHOOTINGNllEAAB
Symptom
Exhaust gas leakage
Abnormal noiseProbable cause
Loose joints
Broken pipe or muffler
Broken separator in muffler
Broken rubber hangersInterference of pipe or muffler with vehicle body
Broken pipe or mufflerRemedy
Retighten
Repair or replace
Replace
Correct
Repair or replace
.-*
SPECIAL TOOLNllDA-
I ToolNumberNameI UseIRemoval/Installation of oxygen sensor
Removal/Installation of oxygen sensor
Fs\

II-20INTAKE AND EXHAUST - Turbocharger
TURBOCHARGER
REMOVAL AND INSTALLATION
II
NHLA-
Pre-removal Operation*Draining Engine Coolant
(Refer to GROUP
0-Maintenance Service.)
*Draining Engine Oil
(Refer to GROUP g-Engine
Adjustment.)1
Po+installation Operationl Flllrng Engine Oil(Refer to GROUP O-Main@
nance Service.)l Filling Engine Coolant(Refer to GROUP O-Mainte-
nance Service.)
12-15 Nm12-15 Nm
9- 11ft.lbs.3
12-15 Nm
9-l 1 ftlbs
moval steps
1. Condenser fan motor assembly< Vehicles with air conditioner >) *4 2. Oxygen sensor3. Engine oil level gauge guide4. O-ring
5. Connection for air intake hose6. Connection for vacuum hose7. Connection for vacuum hose8. Connection for air hose A9. Air outlet fitting
10.Gasket1 1.Heat protector A12. Heat protector B13. Power steering oil pump14. Oil pump bracket15.Self-locking nut16.Engine hanger17.Eye bolt
h-50 Nm29-36 ft.lbs.
19. Connection for water hosel * 20. Connection for water pipe f321. Self-locking nut22. Gasket23. Exhaust manifold24. Exhaust manifold gasket25. Ring26. Gasket
05M1149

INTAKE AND EXHAUST - Turbocharger11-21
35-50 Nm25-Qg
ft-lbs*26-34 Nm
20-25 ftlbs.
\/3655-65 Nm
4o-4: ft*lbs-
35-50 Nm25-36 ftlbs.
05A0136
NOTE(1) Reverse the removal procedures to reinstall.(2) l * : Refer to “Service Points of Removal”.(3) l + : Refer to “Service Points of Installation”.(4) q : Non-reusable parts
27. Oil return pipe28.
Gasketl * l a 29. Turbocharger30. Eye bolt
31. Gasket
32. Water pipe B33. Eye bolt
34. Gasket35. Water pipe A36. Eye bolt37. Gasketw l c 38. Oil pipe39. Exhaust fitting40. GasketMD998748
1SERVICE POINTS OF REMOVALNllL9AD
2. REMOVAL OF OXYGEN SENSORDisconnect the
connector of the oxygen sensor, and install
the special tool to the oxygen sensor.
Then, using an offset (box-end) wrench, remove the oxygen
sensor.

INTAKE AND EXHAUST - TurbochargerII-23
05K557
’ MD998748
05A0023
DISASSEMBLY AND REASSEMBLY20.lNSTALLATlON OF WATER PIPE
(B)
Before installing to the water inlet pipe, apply machine oil to
the inner surface of the pipe flare.2. INSTALLATION OF OXYGEN SENSOR
Use the special tool to install the oxygen sensor.NllLE-.
lo-13 Nm7-9 Mbs.
Disassembly steps
1. Snap pin2. Waste gate actuator
3. Couplingl 4. Turbine housingl *l C 5. Snap ring+e *a 6. Cartridge assemblyl * 7. O-ring8. Compressor cover
NOTE(I) Reverse the disassembly procedures to reassemble.(2) 4~ : Refer to “Service Points of Disassembly”.
(3) ++ : Refer to “Service Points of Reassembly”.
(4) q : Non-reusable parts6 1 NO084

1 I-26INTAKE AND EXHAUST -Exhaust Manifold c 1.8L Engine>
EXHAUST MANIFOLD
< 1.8L Engine>
REMOVAL AND INSTALLATION
20-24 ft.lbs.
05A0135Removal steps’
1. Engine oil level gauge guide
2. O-ring3. Self locking nut4. Gasket5. Oxygen sensor6. Exhaust manifold cover (A)
7. Engine hanger8. Exhaust manifold9. Exhaust manifold gasket10. Exhaust manifold cover (B)
NOTE(1) Reverse the removal procedures to reinstall.(2) 4, : Refer to “Service Points of Removal”.(3) q : Non-reusable parts
SERVICE POINTS OF REMOVALNHNBAG5. REMOVAL OF OXYGEN SENSOR
Disconnect the connector of the oxygen sensor, and install
the special tool to the oxygen sensor.
Then, using an offset (box-end) wrench, remove the oxygen
sensor.
INSPECTIONNllNCALO
Check the following points; replace the part if a problem is
found.-y=.EXHAUST MANIFOLD
Check for damage or cracking of any part.EXHAUST MANIFOLD GASKET
Check for flaking or damage of the gasket.
O-ring
3EN239
or blockage.
5. Clean the inlet section of the compressor cover with a rag.
Inspect it for signs of contact with the compressor turbine.
If worn, replace it.WASTE GATE ACTUATOR
1.Leak-test the waste gate valve actuator with a hand vacuum
pump.
Replace the actuator if it does not hold vacuum.
2. Check the rod to see that it is not bent or binding.
SERVICE POINTS OF REASSEMBLYNllLHAB
7. INSTALLATION OF O-RING
Coat the inner surface of a new O-ring with a thin film of
engine oil, and set it in the groove of the cartridge assembly.
Caution+%
Be careful not to damage the O-ring while installing it as__
oil leakage could result.

INTAKE AND EXHAUST- Exhaust Manifold <2.0L DOHC Engine (Non-Turbo) >11-27
EXHAUST MANIFOLD < 2.0L DOHC Engine (Non-Turbo) >
REMOVAL AND INSTALLATION,lcIii3\
I-**1
steps
1.Condenserfanmotor
2. Self locking nut3.Gasket
4. Exhaust manifold cover (A)12-15
Nm9- 11 ft.lbs.
06AOl56
5. Oxygen sensor6. Self locking nut
7. Engine hanger
8. Exhaust manifold9. Exhaust manifold gasket
0. Exhaust manifold cover
(B)
NOTE(I) Reverse the removal procedures to reinstall.(2) +* : Refer to “Service Points of Removal”(3) 0 : Non-reusable parts
NllNA6
SERVICE POINTS OF REMOVALNllNSAH
5. REMOVAL OF OXYGEN SENSOR
Disconnect the connector of the oxygen sensor, and installthe special tool
to the oxygen sensor.
Then, using an offset (box-end) wrench, remove the oxygen
sensor.
INSPECTIONNllNCALl
Check the following points; replace the part if a problem is
found.EXHAUST MANIFOLD
Check for damage or cracking of any part.EXHAUST MANIFOLD GASKET
Check for flaking or damage of the gasket.

11-28INTAKE AND EXHAUST - Exhaust Manifold ~2.0~ DOHC Enoine (Turbo)>
EXHAUST MANIFOLD <2.0L DOHC Engine (Turbo)>
REMOVAL AND INSTALLATION
Pre-removal Operation*Draining Engine Coolant(Refer to GROUP O-Mainte-nance Service.)*Draining Engine Oil(Refer to GROUP O-Mainte-nance Service.)
Rennova1 steps
1.Condenser fan motor assemblyOxygen sensor connectorEngine oil level gauge guideO-ring
\30-40 Nm22-29 ft.lty3. & (
EJ\\=a-50 N
4 .ri29-38 ftk.
,
Post-installation Operation@Filling Engine Oil(Refer to GROUP O-Mainte-nance Service.)@Filling Engine Coolant(Refer to GROUP O-Mainte-nance Service.)NllNA-C
130 25-30 Nmd/18-22 ft.lbs.
;:4.
s5:7.
::10.Ii.12.13.14.15.
Connection for air intake hose
Connection for vacuum hoseConnection for vacuum hoseConnection for air hose AHeat protector AHeat protector 6Power steering oil pumpOil pump bracketSelf-locking nut
Engine hangerEve bolt
16. Gasket17. Connection for water hose
19IBWI 18. Connection for water pipe B19. Self-locking nut20.
Gasket
05Ao15421.
Exhaust manifold22. Exhaust manifold gasket23.
Ring24. Gasket
NOTE(1) Reverse the removal procedures to reinstall.(2) +, : Refer to “Service Points of Removal”.(3) l * : Refer to “Service Points of Installation”(4) m : Non-reusable parts

14-IFUEL SYSTEM
CONTENTS
AUTO-CRUISECONTROLSYSTEM...........................................109AUTO-CRUISECONTROL.......................................................140SERVICEADJUSTMENTPROCEDURES..............................135Accelerator Cable, Throttle Cable and Auto-cruise
ControlCableInspectionandAdjustment........................136Auto-cruise
ControlSystemInspection.............................135lndrvrdualPartsInspection..................................................137SPECIFICATIONS.....................................................................109GeneralSpecifications.......................................................109ServiceSpecifications
.........................................................109Torque Specrfications..........................................................109TROUBLESHOOTING...............................................................110Auto-CruiseControlCircurt................................................128Auto-cruise
ControlComponentsLocation........................126Auto-cruise Control Related Harnesses
.............................125Check Chart
........................................................................114Input Check.........................................................................123Self-diagnosis
Check..........................................................121Troubleshootrng
Quick-referenceChart..............................110ENGINECONTROL.......................................................................105ENGINECONTROL..................................................................107--SERVICEADJUSTMENTPROCEDURES..............................106Accelerator Cable Inspection and Adjustment..................106Accelerator Switch Inspectron and Adjustment................106SPECIFICATIONS.....................................................................105Lubricants.............................................................................105Sealant.................................................................................105ServiceSpecifications
..........................................................105TorqueSpecifications..........................................................105TROUBLESHOOTING...............................................................105FUELSYSTEM..............................................................................2FUELFILTER............................................................................104FUELLINEANDVAPORLINE..............................................102FUEL PUMP, FUEL GAUGE UNIT ANDOVERFILL LIMITER(TWO-WAY VALVE).............101FUEL PUMP, FUEL GAUGE UNIT ANDOVERFILL LIMITER (TWO-WAY VALVE).............99FUELTANK.............................................................97FUELTANK..............................................................93INJECTOR.................................................................................83MPISYSTEMINSPECTION<1.8LEngine>.......................56AirConditioner
Switch........................................................64Air Conditioner Power Relay
..............................................67Components
Location......................................................56
ControlRelay
.................................................................66EGRControlSolenoidValve...............................................67EGRTemperatureSensor..................................................64Engine Coolant Temperature Sensor
.................................62IdlePosrtionSwitch
...........................................................63IdleSpeedControlServo
.............................
....................65InhibitorSwitch....................................................................65hjeCtOrS................................................................................65IntakeAirTemperatureSensor..........................................6’2MalfunctionlndtcatorLight
..........................................58MotorPosition
Sensor................................................63OxygenSensor
.................................................................64Power Steering 011 Pressure Swatch...........................65PowerTransistor
................................................................67PurgeControlSolenoidValve.........................................67
Self-Diagnosis.......................................................................
ThrottlePositronSensor.....................................................
Vehicle Speed Sensor.........................................................MPI
SYSTEMINSPECTION<2.0L DOHCEngine>...........Air Conditioner Power Relay..............................................
Arr Conditioner Swatch........................................................
Components Location
.........................................................
Control
Relay.......................................................................
EGR Control Solenoid Valve...............................................
EGR Temperature Sensor
...................................................
Engine Coolant Temperature Sensor
.................................Fuel Pressure Control Valve...............................................
Idle Position Switch
............................................................
Idle
SpeedControlServo...................................................Injectors
................................................................................
Intake Air Temperature Sensor..........................................
Malfunction Indicator Light.................................................
Oxygen Sensor
....................................................................
Power
Steering
OilPressureSwitch.................................Power Transistor
.................................................................
Purge Control Solenoid Valve.............................................
Self-Diaanosis.......................................................................
58
63
2382
79
688182
79
7682
77
79
79
76
727879
82
8273ThrottletiPosition Sensor
.....................................................77Vehicle Speed Sensor
.........................................................79SERVICE ADJUSTMENT PROCEDURES<1.8L Engine>........................................................................41Curb Idle Speed Inspection
................................................41EGR Valve Control Vacuum Check....................................47Fuel Pressure Test
..............................................................44Fuel Pump Operation Check
..............................................44Idle Speed Control and Throttle Position
Sensor Adjustment
..............................................................
41Purge Port Vacuum Check
.................................................47Release of Residual Pressure from
High Pressure Fuel Hose
...................................................
44Throttle
Body(Throttle Valve Area)Cleaning....................43SERVICE ADJUSTMENT PROCEDURES<2.0LDOHCEngine>............................................................48Basic Idle Speed Adjustment
.............................................
48
Curb Idle Speed Inspection
................................................48EGR Valve Control Vacuum Check....................................55Fuel Pressure Test
..............................................................52Fuel Pump Operation Check
..............................................51Idle Position Switch Adjustment........................................52Purge Port Vacuum Check
.................................................55Release of Residual Pressure from
High Pressure Fuel Hose
...................................................51Throttle Body (Throttle Valve Area) Cleaning....................51ThrottlePositionSensorAdjustment.................................50SPECIALTOOLS......................................................................6SPECIFICATIONS.....................................................................2GeneralSpecifications.........................................................2Sealant and Adhesive
.........................................................5Service Specifications
..........................................................4Torque Specifications
..........................................................5THROlTLEBODY<1.8LEngine>........................................85THROlTLE BODY <2.0L DOHC Engine>............................89TROUBLESHOOTING...............................................................6