1991 MITSUBISHI ECLIPSE clutch

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”.

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.
.&,

INTRODUCTION AND MASTER TROUBLESHOOTING - :;k%ii::& and25
GENERAL DATA AND SPECIFICATIONSNOOHA-
OOAOl59
GENERAL SPECIFICATIONS
z-
A-l
.8L Engine1.8L Engine2.0L DOHC2.0L DOHCItems“Medium”“High”~%n?urbo):Tz%$
Vehicle dimensions
mm(in.)Overall length
14,330(170.5)4,330(170.5)4,330(I 70.5)4,330(170.5)Overall width
21,690(66.5)1,690(66.5)
1,690
(66.5)
1,690(66.5)Overall height
31,306(51.4)1,306(51.4)1,306(51.4)
1,306(51.4)Wheel base
4
2,470(97.2)2,470(97.2)2,470(97.2)2,470(97.2)Tread Front
5
1,465(57.7)
1,465(57.7)
1,465
(57.7)1,465(57.7)
Rear6
1,450(57.1)1,450(57.1)1,450(57.1)1,450(57:l i
Overhang Front
7950(37.4)950(37.4)950(37.4)
950(37.4)
Rear
8
910(35.8)910(35.8)910(35.8)910(35.8)Minimum running ground
9
160(6.3)160(6.3)
160(6.3)160(6.3)clearancemm (in.)
Angle of approach
degrees10 15.3”15.3”15.3”
15.3”Angle of departure
degrees11 18.1”
18.1” ’18.1“
18.1”Vehicle weight
kg (Ibs.)
Curb weights
M/T
1,145(2,524)
1,165(2,568)
1,215
(2,679)
1,245(2,745)
AIT1 ,I 70(2,579)
1,190(2,623)
1,240
(2,734)
1,280(2,822)Gross vehicle weight rating
1,585(3,494)1,585(3,494)
1,630
(3,594)‘I ,670(3,682)Gross axle weight rating
Front
900(1,984)900(1,984)930(2,050)965(2,127)
Rear
685(1,510)685(1,510)
700
(1,543)705‘(1,554)Seating capacity
4
444
EngineModel No.
4G3746374G634G63
TransaxleModel No.
Manual transaxle
F5M22F5M22F5M22F5M33Automatic transaxle
F4A22F4A22F4A22F4A33
Clutch
TypeDry-single discDry-single discDry-single discDry-single disc& diaphragm& diaphragm& diaphragm& diaphragm
springspringspringspring

INTRODUCTION AND MASTER TROUBLESHOOTING - f~EEaZ% acld27
=r
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
../, *,, /S./..‘, _I, #_.a,‘.rr?
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

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 ServiceO:lllO.AUTOMATIC TRANSAXLE (Inspect fluid
I~~+v~!1. Drive until the fluid temperature reaches the usual
temperature
[70-80°C (160- 18O”F)l.2. Place vehicle on level floor.
3.Move selector lever sequentially to every position to fill
torque converter and hydraulic
circuitwith fluid, then
place lever in“N” Neutral position. This operation is
necessary to be sure that fluid level check is accurate.
4.Before removing dipstick, wipe all dirt from area arounddipstick. Then take out the dipstick and check the
condition of the fluid.
The transaxle should be overhauled under the following
conditions.l If there is a “burning” odor.
l If the fluid color has become noticeably blacker.
l If there is a noticeably great amount of metal
particles in the fluid.
5.Check to see if fluid level is in “HOT” range on dipstick.If fluid level is low, add ATF until level reaches “HOT”
range.Low fluid level can cause a variety of conditions
because it allows pump to take in air along with fluid. Airtrapped in hydraulic circuit forms bubbles which make
fluid spongy. Therefore, pressures will be erratic.
Improper filling can also raise fluid level too high. Whentransaxle has too much fluid, gears churn up foam and
cause same conditions which occur with low fluid level,resulting in accelerated deterioration of ATF.
transmission fluid.
In either case, air bubbles can cause overheating, fluid
oxidation, which can interfere with normal valve, clutch,and servo operation. Foaming can also result in fluid
escaping from transaxle vent where it may be mistakenfor a leak.
6. Be sure to examine fluid on dipstick closely.lO.AUTOMATIC TRANSAXLE (Change fluid)
Drain the fluid and check whether there is any evidence of
contamination.
Replenish with new fluid after the cause of any contamina-tion has been corrected.
(1) Remove drain plugs to let fluid drain.
(2) Remove the oil pan.
(3) Check the oil filter for clogging and damage and replaceif necessary.
(4) Clean the inside of oil pan and 5 magnets.
(5) Attach the five magnets to the concave part of the oil
(6)
Elan both gasket surfaces of transaxle case and oil
pan.(7) Install oil pan with new gasket and tighten oil pan bolts
to
IO-12 Nm (7.5-8.5 ft.lbs.1(8) Tighten drain plug with gasket to
30-35 Nm (22-25
ftlbs.).