1991 MITSUBISHI ECLIPSE air suspension

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”.

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
/-=..\

FRONT SUSPENSION - Specifications2-5Items
Rear roll stopper bracket to centermember
Centermember installation bolts (front)
Centermember installation bolts (rear)
Joint assembly and gear box connecting bolt
Steering gear box assembly to return tube
Steering gear box assembly to pressure hose
Steering gear box assembly to crossmember
Pressure hose bracket to crossmember
Transfer installation bolt
Nmftlbs. I’, ‘,
40-5029-36
80-10058-72
80-I 0058-72
15-20II-1412-18
9-13
12-189-13
60-8043-58
9-14
7-10
55-6040-43
60-8043-58
Gusset installation bolt
70-8051-58Left member installation bolt (front)
80-10058-72
Left member installation bolt (rear)
70-8051-58
Vo. 1 crossmember installation nut80-10058-72qight member installation bolt (front)
80-10058-72?ight member installation bolt (rear)
70-8051-58
+ont roll stopper to No. 1 crossmember40-5029-36
?ont roll stopper installation nut50-6536-47
Iront exhaust pipe to catalytic converter40-6029-43
‘rant exhaust pipe to hangerIO-157-11
‘-. LUBRICANTSNO2CD--
ItemsSpecified lubricantsQuantity
Outer surface of wheel bearing outer race
MOPAR Multi-mileage LubricantAs required
Wheel bearing inner racePart No. 2525035 or equivalent
Oil seal lip
Strut insulator bearing
Lower arm ball joint
Stabilizer link
Inner dust coverMOPAR Multi-mileage Lubricant
Part No. 2525035 or equivalent
7-10 g (.25-.35 oz.)
Outer dust cover
MOPAR Multi-mileage Lubricant
Part
No.2525035 or equivalent4-6
g (.14-.21 oz.)
B.J. boot grease
Repair kit grease
Vehicles with
1.8L engine
95 g (3.4 oz.)
Vehicles with
2.0L DOHC engine110 g (3.9 oz.)
95 g (3.4 oz.)
T.J. boot grease
Repair kit grease
Vehicles with
1.8L engine105 g (3.7 oz.)
Vehicles with
2.0L DOHC engine120 g (4.2 oz.)
105 g (3.7 oz.)
Spider assemblyRepair kit greaseAs required
NOTEThe grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot.

FRONT SUSPENSION - Drive Shaft
IllA0127
llE560
Grease
llE563
llE559(2) Fill the inside of the
B.J. and B.J., boot with the
specified grease.
Specified grease: Repair kit grease
Wil95
g (3.4 oz.)*I, 110 g (3.9 oz.)**-
NOTEThe grease in the repair kit should be divided in half for
use, respectively, at the joint and inside the boot.
*I:
*2:
(3) Secure the boot bands.
Caution
The boot bands should be tightened with the drive
shaft at a
0” joint angle.
5. APPLICATION OF GREASE TO SPIDER ASSEMBLY
Apply the specified grease furnished in the repair kit to the
spider assembly.
Specified grease: Repair kit grease
3. APPLICATION OF GREASE TO T.J. CASE
Fill the specified grease furnished in the repair kit to the T.J.
case.Specified grease: Repair kit grease
105 g (3.7 oz.)*‘I,120 g (4.2 oz.)**
NOTEA
The grease in the repair kit should be divided in half for use,-respectively, at the joint and inside the boot.
*I:
*2:
2. INSTALLATION OF BOOT BAND (SMALL)/ 1. T.J.
BOOT BAND
Set the T.J. boot bands at the specified distance in order toadjust the amount of air inside the T.J. boot, and then
tighten the T.J. boot band securely.
Standard value:
LHRH
75+3 mm8523 mm
(2.95f .I2 in.)(3.35 f .I2 in.)
<2.0L>80f3 mmSO+3 mm
(3.15f.12 in.)(3.15+ .I2 in.)

2-22FRONT SUSPENSION - Drive Shaft
REMOVAL AND INSTALLATION
Pre-removal OperationPre-installation Operation
l Removal of the Under Coverl installation of the Under Cover
60-72 Nm
43-52 ftlbs.
I60-72 Nm
43-52 ftlbs.
200-260 irn145-188 ft.lbs.
I24-34 Nm
17-25 ft.lbs.
Y36-46 Nm
26-33
ft.lbs.
llAO322Removal steps
I. Cotter pin
+I) l *2. Drive shaft nut
4*3. Lower arm ball joint connection4. Cotter pin
l *5. Tie rod end connection
6. Center bearing bracket installation bolt
7. Spacer (Vehicles without air conditioner)
::8. Drive shaft and inner shaft assembly
(L.H.)9. Drive shaft (R.H.)10. Circlip
NOTE(1) Reverse the removal procedures to reinstall.(2) 4* : Refer to “Service Points of Removal”.
(3) l + : Refer to “Service Points of Installation”.(4) m : Non-reusable parts
1 lA0266SERVICE POINTS OF REMOVAL
NOZQBAT2. REMOVAL OF DRIVE SHAFT
NUT/3. LOWER ARM
BALL
JOINT/5. TIE ROD END
Refer to P.2-16.
8. REMOVAL OF DRIVE SHAFT AND INNER SHAFT
ASSEMBLY
(L.H.)/9. DRIVE SHAFT (R.H.)
(1) Use the suitable tools to push out the drive shaft and
inner shaft assembly (L.H.) or the drive shaft
(R.H.) from
the front hub.
1

2-24FRONT SUSPENSION - Drive Shaft
DISASSEMBLY AND REASSEMBLY
NOZQE-B
T.J. boot repair kit
d-
‘Pr12
45,3 ;c
!'F?
14- 151
0
92
11AOH8
T.J. kit
llA0316B.J. boot repair kitB.J. kit
Disassembly steps
1. T.J. boot band
2. Boot band (small)3.
T.J. case and inner shaft assembly
4. T.J. case
5. Seal plate6. Inner shaft
16. B.J. boot band
17. Boot band (small)
7.Bracket assembly+I)l 418.B.J. boot
8.Outer dust seal19.B.J. assembly9.Inner dust seal20.Dust coverBearing dust seal kit
llA0317
Bracket assembly kit
10. Center bearing11. Center bearing bracket12. Circlip
4*13. Snap ring+e e+ 14. Spider assembly4I) l 4 15. T.J. boot
FJ)TEeverse the disassembly procedures to reassembly.(2) +e : Refer to “Service Points of Disassembly”.(3) l + : Refer to “Service Points of Reassembly”.(4) m : Non-reusable parts

2-26FRONT SUSPENSION - Drive Shaft
llE560
INSPECTIONN02QGEB
0
0
0
0Check the dust cover for damage or deterioration.Check the drive shaft for damage, bending or corrosion.
Check the inner shaft for damage, bending or corrosion.
-Check the drive shaft spline part for wear or damage.
=-Check the inner shaft spline for wear or damage.
Check for entry of water and/or foreign material into
B-J..Check the spider assembly for roller rotation, wear or
corrosion.Check the groove inside T.J. case for wear of corrosion.
Check the boots for deterioration, damage or cracking.
Check the center bearing for seizure, discoloration or
roughness of rolling surface.
SERVICE POINTS OF REASSEMBLY
NOZQHEEa
18, INSTALLATION OF B.J. BOOT/15. T.J. BOOT
(1) Wrap vinyl tape around the spline part on the drive
shaft, and then install the B.J. boot and T.J. boot, in that.*
order.Caution
Distinguish between B.J. boot and T.J. boot parts
according to the section “Parts Distinction”, and be
sure to assemble them correctly.
(2) Fill the inside of the B.J. and B.J. boot with the
specified grease.
Specified grease: Repair kit grease 95
g (3.4 OZ.)
NOTEThe grease in the repair kit should be divided in half for
use, respectively, at the joint and inside the boot.
(3) Secure the boot bands.
Caution
The boot bands should be tightened with the drive
shaft at a
0” break angle.14.APPLlCATlON OF GREASE TO SPIDER ASSEMBLY
Apply the specified grease furnished in the repair kit to the
spider assembly.
Specified grease: Repair kit grease

2-28FRONT SUSPENSION - Drive Shaft
Inner shaft
llA0083
1T.J. case.,
MB9909383%QilD998801
r
IHA00876. INSTALLATION OF INNER SHAFT
Use a pipe to hold the inner race of the center bearing and
“4force the inner shaft into place.
.a3. INSTALLATION OF T.J. CASE AND INNER SHAFT
ASSEMBLY
(1) Apply multipurpose grease to the inner shaft spline,
then press fit it into the T.J. case.
Grease: MOPAR Multi-mileage Lubricant
Part No.2525035 or equivalent
(2) Using the special tools, press the seal plate into the T.J.
case.
(3) Fill the specified grease furnished in the repair kit to the
T.J. case.Specified grease: Repair kit grease 105
g (3.7 oz.1
NOTEThe grease in the repair kit should be divided in half for
use, respectively, at the joint and inside the boot.
Caution
The drive shaft joint use special grease. Do not add
another type of grease.
2. INSTALLATION OF BOOT BAND (SMALL)/ 1. T.J.
BOOT BAND
Set the T.J. boot bands at the specified distance in order toadjust the amount of air inside the T.J. boot, and then
tighten the T.J. boot band securely.
eStandard value:
85f3 mm (3.35+ .12 in.)