1991 MITSUBISHI ECLIPSE Service Manual

INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions before Sew&e‘37
Nominal
sizeSAE
gi:ePermissible current
In engine
Othercompart-areasment
0.3mm2AWG22-5A
0.5
mm2AWG207A13A
0.85
mm’AWG189A17A
1.25
mm2AWG1612A22A
2.0mm2AWG1416A30A
3.0mm’AWG1221A40A
5.0mm2AWG1031A54A
r ‘.
oorsas
2. If additional optional equipment is to be installed, in ttievehicle, follow the procedure listed in the
ap@@priateinstruction manual; however, be sure to pay “careful
attention to the following points:
“9:(1) In order to avoid overloading the
wiring;’ take the
electrical current load of the optional
,equipment into
consideration, and determine the appropriate .wire size:(2) Where possible, route the wiring through the existing
harnesses.(3) If an ammeter or similar instrument is to be
connectedto a live-wire circuit, use tape to protect the wire, use a
clamp to secure the wire, and make sure that there is
no contact with any other parts.
(4) Be sure to provide a fuse for the load circuit of the
optional equipment.
TUBES AND OTHER RUBBER PARTS
Be careful to avoid spilling any gasoline, oil, etc., or rubber
parts, they might be adversely affected.
LUBRICANTSIn accordance with the instructions in this Service Manual,
apply the specified lubricants in the specified locations during
assembly and installation.
!’IV/ :>,I
BRAKE FLUID
Be careful to avoid spilling any brake fluid on painted surfaces,because the paint coat might be discolored or damaged.

18INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions b&ire Service
DOING SERVICE WORK IN GROUPS OF VO’bRMORE TECHNICIANS
.-I-7.IIf the service work is to be done by two or more technicians
working together, extra caution must be taken.
VoltagedistributionMaximum
voltage
NOTE ON INSTALLATION OF RADIO EQIJIPMEATeThe computers of the electronic control system has been
designed so that external radio waves will not interfere with
their operation.
However, if antenna or cable of amateur transceiver etc. is
routed near the computers, it may affect the operation of the
computers, even if the output of the transceiver is no more
than
25W.To protect each of the computers from interference by
transmitter (hum, transceiver, etc.), the following should be
observed.1. Install the antenna on the roof or rear bumper.
2.Because radio waves are emitted from the coaxial cable of
the antenna, keep it 200 mm (8 in.) away from the
computers and the wiring harness. If the cable must cross
hthe wiring harness, route it so that it runs at right angles to
the wiring harness.
3.The antenna and the cable should be well matched, and thestanding-wave ratio* should be kept low.
4.A transmitter having a large output should not be installed
in the vehicle.
5.After installation of transmitter, run the engine at idle, emit
radio waves from the transmitter and make sure that the
engine is not affected.
“STANDING-WAVE RATIO
If an antenna and a cable having different impedances are
connected, the input impedance Zi will vary in accordance with
the length of the cable and the frequency of the transmitter,
and the voltage distribution will also vary in accordance with
the location.
The ratio between this maximum voltage and minimum voltage
is called the standing-wave ratio. It can also be represented bythe ratio between the impedances of the antenna and the
cable.The amount of radio waves emitted from the cable increases
as the standing-wave ratio increases, and this increases the
possibility of the electronic components being adversely
affected.

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

20INTRODUCTION AND MASTER TROUBLESHOOTING - Towing and Hoisting
Frame contact support location
OOAOI 71
: 928mm (36.5 in.)
: 998mm (39.3 in.)
IRearISAFETY PRECAUTIONS
The following precautions should be taken when
towin the
vehicle.
1.DO NOT LIFT OR TOW THE VEHICLE BY ATTACHING TOOR WRAPPING AROUND THE BUMPER.
2. Any loose or protruding parts of damaged vehicle such as
hoods, doors, fenders, trim, etc., should be secured prior tomoving the vehicle.
3.Operator should refrain from going under a vehicle while it
is lifted by the towing equipment, unless the vehicle in
adequately supported by satefy stands.
4. Never allow passengers to ride in a towed vehicle.
5. State and local rules and regulations must be followed
when towing a vehicle.
Refer to the section “Special Handling Instructions for AWD
Models”.
HOISTING
POST TYPESpecial care should be taken when raising the vehicle on a
frame contact type hoist. The hoist must be equipped with the
proper adapters in order to support the vehicle at the proper
locations.Caution
When service procedures require removing rear sutpen-
sion, fuel tank, spare tire and lift gate, place addmonal
weight on rear end of vehicle or anchor vehicle to hoist to
prevent tipping of center of gravity changes.
FLOOR JACK
The usual type of floor jack is used at the following locations.
Front:
Under the mid point of centermember
Under the mid point of crossmember
Rear:
Under the jack up bracket of rear floor pan
Under the rear differential
Cautions
1. Never use a jack at the lateral rod or rear suspension
assembly.

2.In order to prevent scarring the centermember or crossmember
, place a piece of cloth on the
jack’s contact surface (to prevent corrosion caused by
damage to the coating).
3. A floor jack must never be used on any part of the
underbody.
4.Do not attempt to raise one entire side of the vehicle byplacing a jack midway between front and rear wheels.
This practice may result in permanent damage to the
body.

--
INTRODUCTION AND MASTER TROUBLESHOOTING - Towing and Hoisting2”1LIFTING, JACKING SUPPORT LOCATION
-4WD>
lOAFloor jack locations
OOAOO2 1
*Approximate center of gravity
@ Frame contact hoist, twin post hoist or scissors jack (emergency) locations
EMERGENCY JACKING
Jack receptacles are located at the body sills to accept the
scissors jack supplied with the vehicle for emergency road
service. Always block opposite wheels and jack on level
surface.

22 INTRODUCTION AND MASTER TROUBLESHOOTING - %%c%:k! ‘nstructions
SPECIAL HANDLING INSTRUCTIONS FOR AWD MODELSNWUAAB
TOWINGTowing methods
If a tow truck is usedLifting method for 4 wheels-Good
Remarks
l For AWD models, the basic principle is that
all four wheels are to be raised beforetowing.
l The shift lever should be set to 1 st gear and
thhrting brake should be applied.
l The selector lever should be set to “P”
position and the parking brake should beapplied.

OOAO032Front wheels lifted-No good
l The vehicle must not be towed by placing
only its front wheels or only the rear wheels
on a rolling dolly, because to do so willresult in deterioration of the viscous
coupling and result in the viscous coupling
causing the vehicle to jump forward
suddenly.OOA0034
Front wheels
IifteddNo goodlIf only the front wheels or only the rearwheels are lifted for towing, the bumper
will be damaged.
In addition, lifting of the rear wheels causes
the oil to flow forward, and may result in
heat damage to the rear bushing of the
transfer, and so should never be done.
llA0060Rear wheels lifted-No goodOOA0033

Special Handling lnstruction~INTRODUCTION AND MASTER TROUBLESHOOTING - for AWD Models23
7T
TFree roller
00P0030
T&a
TAxle standOOPOO37
Front tie-down bracket
16PO209
14A0198
OOPO036
SPEEDOMETER TESTIF A FREE ROLLER IS USED
1.Set the free roller on the floor (at the rear wheels) so that itis aligned with the vehicle’s wheelbase and the rear tread.
2.Carefully move the vehicle onto the tester and free roller.
3. Set the speedometer tester in place.
4. Perform the speedometer test.
For information concerning the measurement of speed andthe allowable error, refer to GROUP
8-Meters and
Gauges.Caution
Do not operate the clutch suddenly, or increase or
reduce speed suddenly during the work.
IF THE REAR WHEELS ARE JACKED UP
1. Move the vehicle onto the speedometer tester.
2. Jack up the rear wheels, and place axle stands at the
designated part of the side sill.
3. Perform the speedometer test.
For information concerning the measurement of speed andthe allowable error, refer to GROUP
8-Meters and
Gauges.
CautionDo not operate the clutch suddenly, or increase or
reduce speed suddenly during the work.
Front wheel side slip
To prevent the front wheels from moving from side to side,
attach tension bars to the front tie-down brackets, and secure
both ends at anchor plates.
Accident prevention procedures
(1) Attach a chain or wire to the rear tie-down hole. (Refer to
GROUP 8-Meters and Gauges.) Make sure the end of thewire or chain is secured firmly.
(2) Take all other necessary precautions.
BRAKE TESTIn order to stabilize the viscous coupling’s dragging force, the
brake test should always be conducted after the speedometer
test.
FRONT WHEEL MEASUREMENTS
1. Place the front wheels on the brake tester.
2. Perform the brake test.
CautionThe rear wheels should remain on the ground.
3. If the brake dragging force exceeds the specified value,
jack up the vehicle and manually rotate each wheel to
check the rotation condition of each wheel.
NOTE
If the brake dragging force exceeds the specified value, the
cause may be the effect of the viscous coupling’s draggingforce, so jack up the front wheels and check the rotation
condition of the wheels in this state for no effect by the
viscous coupling’s dragging force.

24 INTRODUCTION AND MASTER TROUBLESHOOTING - fSo%k%:~~it’ndrU~ionsREAR WHEEL MEASUREMENTS
After placing the rear wheels on the brake tester, follow the
same procedures as for the front wheel measurements.
,’
~.Braking force of AWD models with VCU
Balancing
machine
Pick-up stand
WA0024
Braking force
EachwheelLeft/right
sumLeft/right
differenceAt
90kg (19860% or more ofIbs.) pedal de-front axle weightpression force
Rear wheels: 330
kg (727 Ibs.) or more8% or less of axle weight
TotalAt 90kg (198830 kg (1,829 Ibs.)
Ibs.) pedal de-or more*pression force
* About 20 kg (44 Ibs.) of force by viscosity torque has been
added.
or...
I
Braking-stop distanceAt primary velocity of 50 km/h
(31 mph): Within 16.0m (52.5 ft.)
WHEEL BALANCE.r=lFRONT WHEEL MEASUREMENTS
1. Jack up the rear wheels, and place an axle stand at the
designated part of the side sill.
2. Jack up the front wheels and set a pick-up stand and
balancing machine in place.
Caution
1.Set so that the front and rear of the vehicle are at
the same height.
2. Release the parking brake.
3. Rotate each wheel manually and check to be sure
that there is no dragging.
3. Use the engine to drive the tires, and then make the
measurement.Caution
1.If an error is indicated in the state of engine drive,
motor drive can be used concurrently.
2. Do not operate the clutch
suddenly, or increase or
reduce speed suddenly during the work.
REAR WHEEL MEASUREMENTS
1. Jack up the front wheels, and place an axle stand at the
designated part of the side sill.
2. Jack up the rear wheels, and then, after setting a pick-up
stand and balancing machine in place, follow the same
procedure as for front wheel measurements.
.&,