1991 MITSUBISHI ECLIPSE fuel
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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”.
Page 20 of 1216
20INTRODUCTION AND MASTER TROUBLESHOOTING - Towing and Hoisting
Frame contact support location
OOAOI 71
I
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:
Rear:
Cautions
1. Never use a jack at the lateral rod or rear suspension
assembly.
2.In order to prevent scarring the centermember
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.
Page 26 of 1216
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
Page 27 of 1216
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
Page 29 of 1216
INTRODUCTION AND MASTER TROUBLESHOOTING - Mast& Tro6blerhootbia
MASTER TROUBLESHOOTING7 *
I,._ ,...
r. ENGINE OVERHEATSi ”
SymptomEngine overheatsProbable causeCooling system faulty
Incorrect ignition timingReference page: I._),7-5
8-169
ENGINE WILL NOT CRANK OR CRANKS SLOWLY
SymptomEngine will not crank
or cranks slowlyProbable causeStarting system faulty
,’
Reference page8-153
ENGINE WILL NOT START OR
HbRD TO START (CRANKS OK)
SymptomProbable causeReference page
Engine will not start or hard toNo fuel supply to injector
-start (Cranks OK)
Injection system problems
-Ignition system problems
8-16!$/ ”;Vacuum leaks11-5..“,:’l Purge control valve hose25-4
l Vacuum hoses
l Intake manifoldl Air intake plenum
l Throttle body
l EGR valveCompression too low
g-23,‘, :. ” ‘,;A;ROUGH IDLE OR ENGINE STALL
Symptom
Rough idle or engine stallsProbable cause
Vacuum leaks
l Purge control valve hosel Vacuum hosesl Intake manifoldl Air intake plenuml Throttle bodyl EGR valve
“. ._
Reference page or remedy
11-525-4
Ignition system problems
Idle speed set too low8-169Check idle speed control sys-
tem
Idle mixture too lean or too rich
Fuel injection system problems
Exhaust gas recirculation
(EGR) system
problems
Engine overheatsCompression too low
-
-
25-l 57-5
9-23
Page 30 of 1216
30INTRODUCTION AND MASTER TROUBLESHOOTING - Master Troubleshooting
ENGINE HESITATES OR POOR ACCELERATION
SymptomEngine hesitates or poor
accelerationProbable causeIgnition system problem
Vacuum leaks
l Purge control valve hose
l Vacuum hosesl Intake manifoldl Air intake plenum
l Throttle bodyl EGR valveReference page
8-169
11-525-4
Air cleaner clogged
Fuel line clogged
Fuel injection system problem
Emission control system problem
l EGR system always on
Engine overheats
Compression too low
-
-
-25-15
7-5
9-23
ENGINE
DIESELING
SymptomEngine dieseling (runs after
ignition switch is turned off)Probable causeIncorrect ignition timingReference page
8-169
EXCESSIVE OIL CONSUMPTION
Symptom
Excessive oil consumptionProbable cause
Oil leak
Positive crankcase ventilation line clogged.
Valve stem seal worn or damaged.Valve stem worn.
Piston ring worn or damaged.Reference page or remedy
Repair as necessary.25-7
g-55.114
g-55.114
g-66,128
Page 31 of 1216
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
Page 35 of 1216
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