1991 MITSUBISHI ECLIPSE brake

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”.

INTRODUCTION AND MASTER TROUBLESHOOTING - How to Use This Manual3Page number
Group title
IIndicates the incidental operation to be
performed before removal or after
installa-
52444BRAKES-Roar Brake Wlmd Cylinder
REAR BRAKE WHEEL CYLINDER
-
-
-
3ENjOVAL AND lNSTAU.AllONII
Remwal stepa
1. Brake drum
2. Bleeder screw
3. Brake tube connectionl * 4.Wheel cylinder assemblyl e 5.Wheel cylinder bootl + 6.Piston assemblyn** 7. Piston cue
NOTEI1 lReverse the removal procedures to reinstall.12)M : Refer to ‘Service Points of Aemcval”.(3)l * : Refer to ‘Service Points of Installation’.14) q :Nc+-r-reusab(epatts
SERWE POINTS REMOVAL’
-7. REMOVAL OF PISTON CUP
Using a screwdriver, remove the piston cup from the piston.
INSPECTION-
Check the following points. and if there is any abnormality, replacethe entire wheel cylinder assembly.
(1) Check piston and wheel cylinder walls for rust or damage.(2) Check clearance between the cylinder and the piston.
Measure in two perpendicular directions to figure the clear-
ance between the wheel cylinder inner diameter
fmax.value)and the piston outer diameter (minvalue).
Limit : 0.15 mm (4059 in.)
NOTE
If the difference is more than the limit, replace the piston and
wheel cylinder as an assembly.This number corresponds to
the number in “Removal
steps”,“Disassembly
steps”,“Installation steps”
or “Reassembly steps”.

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.

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

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.
.&,

26INTRODUCTION AND MASTER TROUBLESHOOTING - :;:%:a=and
Items
Chassis
TireFront suspension
TypeRear suspension
We
Brake
Type
SteeringGear typeFront
RearGear ratio
Fuel tank
Capacityliters (gals.)

1.8L Engine
“Medium”Pl85/70R14
PI 85/70Rl4
Independent
strut
Independentstrut
3l\Fk Torsion&k-k Torsion
Disc
DiscDisc
Disc
Rack and
pinion
03
Rack and
pinion
cn60 (16)
60
(16)
ItemsVehicle dimensions
mm(in.)Overall length
1Overall width
2Overall height
3Wheel base
4
TreadFront5
Rear6
OverhangFront7
Rear8Minimum running ground
9
clearancemm (in.)
Angle of approachdegrees
10Angle of departure
degrees 11
Vehicle weight
kg (Ibs.)Curb weightsMiT
Al-rGross vehicle weight rating
Gross axle weight rating
Front
RearSeating capacity
EngineModel No.
1.8L Engine
“Medium”2.0L DOHC
Kr%n?u rbo)
P205/55Rl6 89H
;;5/55R16 89V%55R16
88V
Independentstrut
zx;;k Torsion
Disc
Disc
Rack and
pinion
co60 (16)
2.0L DOHC
#b”;
P205/55Rl6 89
or
205155R16 88V
Independentstrut
3Lnk Torsion
Disc
Disc
Rack and
pinion
co
60 (16)
2.0L DOHC Engine(Non-Turbo)
4,330(I 70.5)
1,690(66.5)
1,306(51.4)
2,470(97.2)
1,465(57.7)
1,450(57.1)
950(37.4)
910(35.8)
160(6.3)
15.3
18.1”
1,230 (2,712)
1,255 (2,767)
1,630 (3,594)930 (2,050)
700 (1,543)
4
4G63
2.0L DOHC Engine
(FWD-Turbo)
4,350(171.3)
1,700(66.9)
1,306(51.4)
2,470(97.2)
1,465(57.7)
1,450(57.1)
960(37.8)
920(36.2)
160(6.3)
13.2”
18.1”
1,260 (2,778)
1,295 (2,855)
1,670 (3,682)965 (2,127)
705 (1,554)
1
4G63
2.0L DOHC Engine
(AWD-Turbo)
4,380(I 72.4)
1,700(66.9)
1,321(52.0)
2,470(97.2)
1,465(57.7)
1,455(57.3)
960(37.8)
950(37.4)
158(6.2)
14.0”
17.6”
1,405 (3,097)
1,440 (3,175)
I,81 0 (3,990)
1,005 (2,216)
805 (1,775)
4
4G63