1991 MITSUBISHI ECLIPSE brake

INTRODUCTION AND MASTER TROUBLESHOOTING - f~EEaZ% acld27
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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
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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

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

0-4 LUBRICATION AND MAINTENANCEScheduled Maintenance Table/Recommended Lubricants- and Lubricant Capacities TableSCHEDULED MAINTENANCE UNDER SEVERE USAGE CONDITIONS
The maintenance items should be performed according to the following table:
F.Mileage Intervals Kilometers in ThousandsSevere Usage
Service to be(Miles in Thousands)ConditionsMaintenance
Item
Performed24 36 48 60 72 80 84 96
(:,:) (15) (22.5) (30) (37.5) (45) (50) (52.5) (60) * B ’ D E F G
Air CleanerReplaceElementMore FrequentlyXX
Spark PlugsReplace
XXXx xx
Engine Oil$$~~~h~vev orEvery 4,800 km (3,000 miles)xxxx x
Engine Oil FilterReplace Every or6 MonthsEvery 9,600 km (6,000 miles)xxxx x
Disc Brake PadsInspect for WearMore FrequentlyXX
Severe usage conditionsA-Driving in dusty conditionsE-Driving in sandy areas
B-Trailer towing or police, taxi, or commercial typeF-Driving in salty areas
operationG-More than 50% operation in heavy city trafic during
C-Extensive idlinghot weather above 32°C (90°F)D-Short trip operation at freezing temperatures
(engine not thoroughly warmed up)
RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLENOONA- --z.
RECOMMENDED LUBRICANTS
Items
Engine Oil
Manual Transaxle
TransferRecommended lubricantskF&cesisification
SG or SG/CD (For further details, refer to SAE viscosity
MOPAR Hypoid Gear
Oil/API classification GL4 or higher, SAE 75W-85W
Automatic TransaxleMOPAR ATF PLUS (Automatic Transmission Fluid Type 7176) or Dia
ATF SP or Equivalent
Power SteeringMOPAR ATF PLUS (Automatic Transmission Fluid Type 7176VAutomatictransmission fluid or “DEXRON” or “DEXRON II”
Rear Axle
Brake and Clutch
Rear Wheel BearingsRefer to
P.O-6.
MOPAR Brake Fluid/Conforming to DOT 3
MOPAR Front Wheel Bearing Grease, or MOPAR Multi-MileageLubricant/Multipurpose grease NLGI Grade 2EP
Hood Lock Latch,, Door Lock Strikers,
Seat Adjusters, Lrftgate Lock, Parking
Brake Cable MechanismMOPAR Lubriplate/Multipurpose grease NLGI Grade 2
Engine CoolantMOPAR Antifreeze Permanent-Type Coolant/High quality
ethylene-glycolantifreeze coolant
Door Hinges, Liftgate Hinges
Engine oil
/
N

LUBRICATION AND MAINTENANCE - Maintenance Service
L-4GoodOOA0051C9FW1014K512(9) Supply 4 liters (8.5 pints) of specified ATF into case
through dipstick hole. [Total quantity of ATF required is
6.1 liters (12.9 pints).
Actually however, approx. 4.5 liters (9.5 pints) of fluid
can be replaced because rest of fluid remains in torque
converter.]Specified fluid: MOPAR ATF PLUS (Automatic
Transmission Fluid Type 7176) or
Dia ATF SP or Equivalent
(10)Start engine and allow to idle for at least two minutes.
Then, with parking brake on, move selector lever
momentarily to each position, ending in “N” Neutral
position.
(1 l)Add sufficient ATF to bring fluid level to lower mark.
Recheck fluid level after transaxle is at normal operating
temperature.
Fluid level should be between upper and lower marks of“HOT” range. Insert dipstick fully to prevent dirt from
entering transaxle.
11 .ENGINE COOLANT (Change)NOOSBEAcCheck the cooling system parts, such as radiator, heater,
and oil cooler hoses, thermostat and connections for
leakage and damage.
CHANGE COOLANT
1. Remove the radiator cap.
2. Loosen the drain plug to drain the coolant.
3. Drain the coolant from the reserve tank.
4. After draining the coolant, tighten the drain plug
securely.
5.Supply the coolant into the radiator until it is filled up to
its filler neck.
6. Supply the coolant into the reserve tank.
7. After warming the engine until the thermostat opens,
remove the radiator cap and check the coolant level.
8.Supply the coolant into the radiator until it is filled up to
its filler neck, and install the
.radiator, cap securely.
9.Fill the reserve tank with coolant up to the “FULL” line.12DISC BRAKE PADS (Inspect for wear)
NOOSBFA~Check for fluid contamination and wear. Replace complete
set of pads if defective.
Caution
The pads for the right and left wheels should be
replaced at the same time. Never “split” or intermix
brake pad sets.
All four pads must be replace as a complete set.
Thickness of lining (A)
Limit
:2.0 mm (.08 in.)

LUBRICATION AND MAINTENANCE - Maintenance Serviceo-13
OOAOlB6
13.BRAKE HOSES (Check for deteriorati.on or
leaks)NwBBnAs
Inspection of brake hoses and tubing should be included inall brake service operations.
The hoses should be checked for:
1. Correct length, severe surface cracking, pulling, scuf-
fing or worn spots. (If the fabric casing of the hoses is
exposed by cracks of abrasion in the rubber hose cover,
the hoses should be replaced. Eventual deterioration ofhose may occur with possible bursting failure.)
2. Faulty installation, casing twisting or interference with
wheel, tire of chassis.
14.BALL JOINT AND STEERING LINKAGE SEALS
(Inspect for grease leaks and damage)
NWSBJAb1. These components, which are permanently lubricated
at the factory, do not require periodic lubrication.
Damaged seals and boots should be replaced to
prevent leakage or contamination of the grease.
2. Inspect the dust cover and boots for proper sealing,
leakage and damage. Replace them if defective.
15.DRIVE SHAFT BOOTS (Inspect for grease leaksand damage)
NWSBJAc1. These components, which are permanently lubricated
at the factory, do not require periodic lubrication.
Damaged boots should be replaced to prevent leakage
or contamination of the grease.
2. Inspect the boots for proper sealing, leakage and
damage. Replace it if defective.
16.REAR AXLE (CONVENTIONAL DIFFERENTIAL)(Inspect oil level)-AWD
NWSBFCa
Remove the filler plug and inspect the oil level at bottom offiller hole. If the oil level is slightly below the filler hole, it is
in satisfactory condition.
16.REAR AXLE (LIMITED-SLIP DIFFERENTIAL)
(Oil change)-AWD
N66SBFCcBefore changing the rear axle oil, check to make sure that
there is no oil leakage from the rear axle housing.
Remove the drain plug and drain out of the oil.
Put the oil plug back in place, and then pour new oil in
through the filler hole.
17.EXHAUST SYSTEM (CONNECTION PORTION
OF MUFFLER, PIPING AND CONVERTER HEATSHIELDS) (Check and service as
require$dBu.
1. Check for holes and gas leaks due to damage, corro-
sion, etc.
2.Check the joints and connections for looseness and gas
leaks.3. Check the hanger rubber and brackets for damage.

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.