Mitsubishi Eclipse Service Manual 1995-1999

BACKUPService ManualECIBSE/ECIISE

Volume 1Chassis & BodyIncludes Engine & Transaxle

Overhaul

FOREWORD

This Service Manual has been prepared with thelatest service information available at the timeof publication. It is subdivided into various groupcategories and each section contains diagnostic,disassembly, repair, and installation proceduresalong with complete specifications and tighteningreferences. Use of this manual will aid in properlyperforming any servicing necessary to maintain orrestore 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.

T h a n k y o u . G~mm~emymanual@hotma~l.com

WE SUPPORTVOLUNTARY TECHNICIANCERTIFICATION THROUGH

National lnritlfulc forA U T O M O T I V E

S E R V I C EE X C E L L E N C E

MITSUBISHIMOTOR SALES OF AMERICA. Inc.

Mitsubishi Motors Corporation reserves the right to make changes indesign or to make additions to or improvements in its products withoutimposing any obligations upon itself to install them on its productspreviously manufactured.

@ 1996 Mitsubishi Motors Corporation Printed in U.S.A.

-I GRWB HVPEX. ... wy+

General . . . . . . . . . . . . . . . . . . . . . ...?, . ,.,m

Engine . . . . . . . . . . . . . ..:. . . ......... mmEngine Lubrication . . . . . . . .. :1. J . m

Fuel . . . . . . . . . . . . . . . . . . . . . ...i . . I mmEngine Cooli.ng, . . . . .,I . . . . . . ; ; ;-I.

*:m

Intake and Exhaust, .. . . . . . . . . . . . .. . :I-

Engine and Emission Control,... F ;im

Clutch . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Transaxle . . . . . . . . . . . . . .

Automatic Transaxle . . . . . . . . . . .

Propeller Shaft . . . . . . . . . . . . . . . . .

Front Axle . . . . . . . . . . . . . . . . . . . . . maRear Axle . . . . . . . . . . . . . . . . . . . . . . maWheel and Tire . . . . . . . . . . . . . . . . .

Power Plant Mount . . . . . . . . . . . . . mFront Suspension . . . . . . . . . . . . . .

Rear Suspension . . . . . . . . . . . . . . mService Brakes . . . . . . . . . . . . . . . .

Parking Brakes . . . . . . . . . . . . . . . . mmSteering . . . . . . . . . . . . . . . . . . . . . . .

Body . . . . . . . . . . . . . . . . . . . . . . . . . . mmExterior . . . . . . . . . . . . . . . . . . . . . . .

Interior and SupplementalRestraint System (SRS) . . . . . . . .Heater, Air Conditioning andVentilation . . . . . . . . . . . . . . . . . . . .Alphabetical Index . . . . . . . . . . . . . .

NOTE: Electrical system information is containedin Volume 2 Electrical of this paired Service Manu-al.

WAR,NINGS REGARDING SERVICING OF SUPPLEMENTALRESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES _,

WARNING!(1) Improper service or maintenance of any component of the SRS, or any SRS-related component,

can lead to personal injury or death to service personnel .(from inadviertent firing. of the alr bag)or to the driver and passenger (from rendering the SRS inoperative).

(2) If it is possible that the SRS components are subjectedto heat over 93C 4290 In baklng orin drying after painting, remove the SRS components (air bag module, SRS-EClJ) beforehand.

(3) Service or maintenance of any SRS component or SRS-related component must be performedonly at an authorized MITSUBISHI dealer.

(4) MITSUBISHI dealer personnel must thoroughly review this manual, and especially Its GROUP 526- Supplemental Restraint System (SRS), before beginning any service or maintenance of any compo-nent of the SRS or any SRS-related component.

NOTE & /

Section titles with the asterisks () in the table of contents in each group indicate operations requiring warnings.

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GENERALCONTENTS oolo9ooo171

GENERAL DATA AND SPECIFICATIONS .. .28

HOW TO USE THIS MANUAL . . . . . . . . . . . . . 3Explanation of Manual Contents. . . . . . . . . . . . . . 4Model Indications. . . . . . . . . . . . . . . . . . . . . . . . . . . 3Maintenance, Repair andServicing Explanations.. . . . . . . . . . . . . . . . . . . . . . 3Special Tool Note. . . . . . . . . . . . . . . . . . . . . . . . . . . 3Terms Definition. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Tightening Torque Indication. . . . . . . . . . . . . . . . . 3

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS . . . . . . . . . . . . 6

Connector Inspection Service Points. . . . . . . . . . 10Connector Measurement Service Points. . . . . . . . 9How to Cope with Intermittent Malfunctions. . . 11How to Use the Inspection Procedures. . . . . . . 8Inspection Service Points for a Blown Fuse. . . 12Troubleshooting Contents. . . . . . . . . . . . . . . . . . . . 6

LUBRICATION AND MAINTENANCE . . . . . . . 33

MAIN SEALANT AND ADHESIVE TABLE .. .55

MAINTENANCE SERVICE . . . . . . . . . . . . . . . . . .38Air Cleaner Element. . . . . . . . . . . . . . . . . . . . . . . . 39Automatic Transaxle Fluid. . . . . . . . . . . . . . . . . . . 45Ball Joint and Steering Linkage Seals. . . . . . . . 50Brake Hoses .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Disc Brake Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Drive Belt (For Generator, Water Pump, PowerSteering Pump). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Drive Shaft Boots. . . . . . . . . . . . . . . . . . . . . . . . . . . 50Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42Engine Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Evaporative Emission Control System. . . . . . . . . 39Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Fuel Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38Ignition Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40Manual Transaxle Oil. . . . . . . . . . . . . . . . . . . . . . . .44Rear Axle Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . .50Rear Drum Brake Linings andRear Wheel Cylinders. . . . . . . . . . . . . . . . . . . . . . .49Spark Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40SRS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51Timing Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40Transfer Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

PRECAUTIONS BEFORE SERVICE . . . . . . . . 20

RECOMMENDED LUBRICANTS .ANDLUBRICANT CAPACITIES TABLE . . . . . . . . . .34

SCHEDULED MAINTENANCE TABLE . . . . . .37

SPECIAL HANDLING INSTRUCTIONS FORAWD MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . .32

TOWING AND HOISTING . . . . . . . . . . . . . . . . . .22

VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . .13Engine Model Stamping. . . . . . . . . . . . . . . . . . . . . 15Theft Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .18Vehicle Identification Code Chart Plate. . . . . . . 13

Vehicle Identification Number List. . . . . . . . . . . . 14

Vehicle Identification Number Location. . . . . . . . 13

Vehicle Information Code Plate.. . . . . . . . . . . . . . 15Vehicle Safety Certification Label. . . . . . . . . . . . . 15

00-2

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GENERAL - How to Use This Manual

HOW TO USE THIS MANUAL * 3 mu%&MAINTENANCE, REPAIR ANDSERVICING EXPLANATIONSThis manual provides explanations, etc. concerningprocedures for the inspection, maintenance, repairand servicing of the subject model. Unless other-wise specified, each service procedure covers allmodels. Procedures covering specific models areidentified by the model codes, or similar designation(engine type, transaxle type, etc.). A descriptionof these designations is covered in this manualunder VEHICLE IDENTIFICATION.

ON-VEHICLE SERVICEOn-vehicle Service are procedures for performinginspections and adjustments of particularly impor-tant locations with regard to the construction andfor maintenance and servicing, but other inspec-tions (for looseness, play, cracking, damage, etc.) must also be performed.

SERVICE PROCEDURESThe service steps are arranged in numerical orderand attention must to be paid in performing vehicleservice are described in detail in SERVICE POINTS.

TERMS DEFINITIONSTANDARD VALUEIndicates the value used as the standard for judgingthe quality of a part or assembly on inspectionor the value to which the part or assembly is cor-rected and adjusted. It is given by tolerance.

LIMITIndicates a maximum or minimum value, the partor assembly should be kept within, in order to be

functional. This value is established outside thestandard value range.

REFERENCE VALUEIndicates the adjustment value prior to starting thework (presented in order to facilitate assembly andadjustment procedures, and so they can be com-pleted in a shorter time).

CAUTIONIndicates the presentation of information particularlyvital to the worker during the performance of mainte-nance and servicing procedures in order to avoidthe possibility of injury to the worker, or damageto component parts, or a reduction of componentor vehicle function or performance, etc..

TIGHTENING TORQUE INDICATIONThe tightening torque shown in this manual is abasic value with a tolerance of f 10% except thefollowing cases when the upper. and foyer iim@of tightening torque are given.(1) The tolerance of the basic value is tiithin f

10%.(2) Special bolts or, the like are in @se:,(3) Special tightening methods are used.

/SPECIAL TOOL NOTE ,_. _:,When the MMC special tool is described, pleaserefer to the special tool cross~ referencechart, Whichis located at the beginning of each group, for across reference from the MMGspecial tool, numberto the special tool number that is available in yourmarket. ,I . ,,

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MODEL INDICATIONSThe following abbreviations are used in this manual for classification of model types.

M/T : Indicates the manual transaxle, or models equipped with the manual transaxle.A/T : Indicates the automatic transaxle, or models equipped with the automatic transaxle.MFI: Indicates the multiport fuel injection, or engines equipped with the multiport fuel injection.Turbo: Indicates the engine with turbocharger, or models equipped ,with such an engi.ne.Non-turbo: Indicates the engine without turbocharger, or models equipped with, such anengine.FWD: Indicates the front wheel drive vehicles.AWD: Indicates the all wheel drive vehicles.ABS: Indicates the anti-lock braking system or models equipped with the anti4ock braking &em.

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00-4 GENERAL - How to Use This Manual

EXPLANATION OF MANUAL CONTENTS

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Maintenance and Servicing Procedures.

The numbers provided within the diagram indicate thesequence for maintenance and servicing procedures.0 Removal steps :

The part designation number corresponds to thenumber in the illustration to indicate removalsteps.

l Disassembly steps :The part designation number corresponds to the,number in the illustration to indicate disassemblysteps.

0 Installation steps :Specified in case installation is impossible in reverse order of removal steps. Omitted if installa-tion is possible in reverse order of removal steps.

l Reassembly steps :Specified in case reassembly is impossible inre-verse order of disassembly steps. Omitted ifreassembly is possible in reverse order of dir&-sembly steps.

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Classifications of Major Maintenance / Service pointsWhen there are major points relative to maintenance and servicing procedures (such as essential maintenance andservice points, maintenance and service standard values, information regarding the use of special tools, etc.), theseare arranged together as major maintenance and service points and explained in detail. I+A, : Indicates that there are essential points for removal or disassembly.)A4 : Indicates that there are essential ooints for installation or reassembly.

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Symbols for Lubrication, Sealants and Adhesives 1Information concerning the locations for lubrication and &I : Greasefor application of sealants and adhesives is provided, by (multipurpose grease unless there is ausing symbols, in the diagram of component parts or on brand or type specified)the page following the component parts page, and ex-plained. ; ; Sealant or adhesive

. Brake fluid or automatic transmission fluid

m : Engine oil, gear oil or air conditioning com-pressor oil

: Adhesive tape or butvl rubber taoe

GENERAL - How to Use This Manual

1 STEERING - Power Steering Gear BO X 37A-23POWER STEERING GEAR BOXREMOVAL AND INSTALLATION

6A

c lmnovel steps1. Joint assemMy and gear box mnnediw box2. Sdsnoa vaive con&or .I .,

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REMOVAL SERVICE POINTS 44n, TIE-ROD END DISCONNECTKM

. Operating procedures, cautions, etc. on removal, instalMtibn:dis-assembly and rwssembly, qfw

1. Be sun 10 tie the cord of the special tool lo the nearby described.

2. Loosen the nut but do not remove il.\

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FOG LIGHT RELAY CONTlNUfTY CHECK

I Tslll7iMlsaltwy vobw 0-0 indicates that there is

1 3 4 .5 , continuity between the termi-Power is ml suppkl o - - - a nals.--yr~~~-Power is supplied H indicates terminals to

which battery voltagqis applied.\.)t.canm -.-*..

37A-28 STEERING - Power Steering Gear Box

LUBRICATION AND SEALING POINTS -4anventlonal power stmlng gear box>

00-6 GENERAL - How to Use Troubleshooting/Inspection Service Points ,(,. _.*s10w To USE TR~~BLE~H~~TING~~N~PE~T~~~ SERVICE Pomm_ . . oolooo2oo60Troubleshooting of electronic control systems for which the scan tool canbe u%dfollows the basic outlinedescribed below. Furthermore, even in systems for which the scan tool cannot be used, part of thesesystems still follow this outline.

TROUBLESHOOTING CONTENTS i 4

1. STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTINGThe main procedures for diagnostic troubleshooting are shown.

2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTSIf verification of the trouble symptoms is difficult, procedures for checking operation and verifyingtrouble symptoms are shown.

3. DIAGNOSTIC FUNCTIONThe following diagnostic functions are shown.l , Method of reading diagnostic trouble codes0 Method of erasing diagnostic trouble codesl Input inspection service points

4. INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES:

5. INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODESIndicates the inspection procedures corresponding to each diagnostic trouble code. (Refer to thenext page on how to use the inspection procedures.) ,I

6. INSPECTION CHART FOR TROUBLE SYMPTOMSIf there are trouble symptoms, even though the scan tool displays no diagnostic troublecode, inspectionprocedures for each trouble symptom will be found by means of this chart.

7. INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS

Indicates the inspection procedures corresponding to each trouble symptoms classifiedin the InspectionChart for Trouble Symptoms. (Refer to the next page on how to use the inspection procedures.)

8. DATA LIST REFERENCE TABLEInspection items and normal judgement values have been provided in this chart as reference infdmation.

9. CHECK AT ECU TERMINALSTerminal numbers for the ECU connectors, inspection items and standard values have been providedin this chart as reference information.

Terminal Voltage Checks1. Connect a needle-nosed wire probe or paper clip to a voltmeter probe.2. Insert the needle-nosed wire probe into each of the ECU connector termi~nals from the wire side,

and measure the voltage while referring to the check chart.

NOTE1. Measure voltage with the ECU connectors connected.2. You may find it convenient to pull out the ECU to make it easier to reach the connector

terminals.3. Checks dont have to be carried out in the order given in the chart. I

Cautionr

Short-circuiting the positive (+) probe between a connector terminalandground &ould damagethe vehicle wiring, the sensor, the ECU, or all three.Use care to prevent this !

3. If voltage readings differ from Normal Condition values, ,check related sensor&, actuators, andwiring, then replace or repair.

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GENERAL - How to Use Troubleshooting/Inspection Service Points 00-74. After repair or replacement, recheck -with the voltmeter to confirm @J the repair ,has correbted

the problem.

Terminal Resistance and Continuity Checks1. Turn the ignition switch to off.2. Disconnect the ECU connector.3. Measure the resistance and check for continuity between the terminals of the ECU harnqss-side;,

connector while referring to the check chart. 1NOTE : ?Checks dont have to be carried out in the order given in the chart.

Cautlon .,If resistance and continuity checks are performed dn the wrong terminals, damage t&i46vehicle wiring, sensors, ECU, and/or ohmmeter may occur.

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Use care to prevent this!:. ^

/i4. If the ohmmeter shows any deviation from the Normal Condition value, check the corresponding

5.sensor, actuator and related electrical wiring, then repair or replace.After repair or replacement, recheck with the ohmmeter to confirm that the repair 4es;qq@edthe problem. 1 5.

10. INSPECTION PROCEDURES USING AN OSCILLOSCOPEc

When there are inspection procedures using an oscilloscope, these are listed here.:i, ; i,

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00-8 GENERAL - How to Use Troubleshoo;ting/lnspection Service ~Po;k~s jI

HOW TO USE THE INSPECTION PROCEDURES. : . %\ .j I ,

The causes of a high frequency of problems occurring in electronic circuitry are generally ;l$ &nec$ors,components, the ECU and the harnesses between connect&s, in that ot-der. These in@ecti&prb&duresfollow this order, and they first try to discover a problem with a connector or a defeotive.componfBt.

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1. Indicates insoectiori carried but usink the scan

Indicates the opeqtion and inspection proce-dures. .-.~,

Indicates the OK judgement cuhtfitibn!L

17 Control mode selection switch

2. Thick box lines:Detailed inspection prOCe&r8S &ethods)such as component inspection and circuit in-spection are listedon a seplfatb pa@,&nd aregiven here for reference.., :

3. Indicates voltage and resistance to, ~~~~~red at a pWic@ar c$ut-nectar.(Refer to Connector Measurement Service Points.)The connector position can be located in the wiring diagram in Volume

1 1-2 manual bv means of this svmbol.

Measure bt switch connect - a I0 Djs --.

Of A-44:onn,ect MB oonnector- and measure at rhe harness

side.

Indicates opiration and insp&ion prOCedUr8S, inspection terminalsand inspection conditions.Indicates the OK judgement conditions. I

.Check trouble SymptOm.

A h

Inspect the contact condition at each connector terminal.(Refer to Connector Inspection.)The connector position can be located in the wiring diagram in Vol-ume-2 manual by means of this symbol.

Ie EOS:ECU. Caution

\ \----After carrying out connector inspection, always be sure to recon-nect the connector as it was before.

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5. Confirm that there are troublesymptoms. If trOUbl8SymptOmS havedisap-,, peared, the connector may have been inserted incorrectly and the trouble

symptom may have disappeared during inspection._ If it seems that trouble symptoms still remain, proceed to the next stage

of instructions.i_

6. If trouble symptoms still remain up to this stage, there is a possibility that there is anopen or short circuit in the harness between the conn8ctors, so check the harness.Alternatively, the cause may be a defective ECU, so try replacing the ECU and checkif the trouble symptom disappears.

HARNESS INSPECTIONCheck for an open or short circuit in the harness between the terminals which were defective accordingto the connector measurements. Carry out this inspection while referring to Volume 2 Electrical manual.Here, Check harness between power supply and terminal xx also includes checking for blown fuses.For inspection service points when there is a blown fuse, refer to Inspection Service Points for a BlownFuse.MEASURES TO TAKE AFTER REPLACING THE ECUIf the trouble symptoms have not disappeared even after replacing the ECU, repeat the inspection procedurefrom the beginning.

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GENERAL - How to Use Troubleshooting/Inspection Service Points 00-9

ness connector

/Inspection harnessfor connector pincontact pressure

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CONNECTOR MEA$UREM@lT ,SERlJCE PQilNTSI Turn the ignition switch to CFF when connecting and discon-necting the connectors, and turn the ignition switch to ONwhen measuring if there are no instructions to the contrary.

IF INSPECTING WITH THE CONNECTOR ._ CONNECTED(WITH CIRCUIT IN A CONDITION OF CONTINUlmWaterproof ConnectorsBe sure to use the special tool (harness connector). Neverinsert a test probe from the. harness side, because to doso will reduce the waterproof performance and result in corro-sion.

Ordinary (non-waterproof) Connectors

Check by inserting the test probe from. the harness side.Note that if the connector (control unit, etc.) is too small topermit insertion of the test probe, it should not be forced;use a special tool (the extra-thin probe in the harness setfor checking) for this purpose. b 4:

IF INSPECTING WITH THE CONNECTOR DISCONNECTED,

Use the special tool (inspection harness for conne& pincontact pressure in the harness set, for inspection). The inspection harness for connector pin contact pressureshould be used. The test probe shoufdnever be forcibly in-serted, as it may cause a defective contact.

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Touch the pin directly with the test bar.

Caution . . II-

At this time, be careful not to short the connector pinswith the test probes. To do so may damage the circuitsinside the ECU.

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00-10 GENERAL - How to Use TroubleshootindlnsPection Service: l?oinW

Connector disconnected or improperlyconnected

1650256

Defective connector contact

breakageat terminalsection

16302540 0 0 0 0 2 1 9

CONNECTOR INSPECTION SERVICE POINTSVISUAL INSPECTIONl Connector is disconnected or improperly connectedl Connector pins are pulled outl Harness wire breakage due to harness tension at terminal

sectionl Low contact pressure between male and female terminalsl Low connection pressure due to rusted terminals or foreign

matter lodged in terminals

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CONNECTOR PIN INSPECTION,.

If the connector pin stopper is damaged, the terminal connec-tions (male and female pins) will not be perfect even whenthe connector body is connected, because the pina: may pull,out of the back side of the connector. Therefore, gently pullthe wires one by one to make sure-that no pins pull outof the connector. ,,/ .Y. ,.

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CONNECTOR ENGAGEMENT INSPECTION Use the special tool (connector pin connection pressure in-spection harness of the inspection harness set) to inspectthe engagement of the male pins and female pins. [Pin drawing )force : 1 N (.2 Ibs.) or more]

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G E N E R A L - How to Use Troubleshooting/inspection Servid b%irrtiC I,~&gq__

HOW TO COPE WITH INTERMITTENT MALFUNCTldNSMost intermittent malfunctions occur under certain conditions. If those conditions can be identified, the

I cause will be easier to find.

TO COPE WITH INTERMITTENT MALFUNCTION;1. Ask the customer about the malfunction

Ask what it feels like,*what it sounds like, etc.Then ask about dnvrng conditions; weather,frequency of occurrence, and so on.

2. Determine the conditiqw from the custom-ers responsesTypically, almost all intermittent malfunctionsoccur from conditions like vibration, tempera-ture and/or moisture change, poor connections.From the customers replies, it should be rea-soned which condition is influenced.

3. Use simulation testIn the cases of vibration or poor connections,use the simulation tests below to attempt to

duplicate the customers complaint. Determinethe most likely circuit(s) and perform thesimula-tion tests on the connectors and parts of thatcircuit(s). Be sure to use the inspection proce-dures provided for d,iagnostic trouble codes and t roub le symptoms. r_For temperature and/or moisture conditions re-lated intermittent malfunctions, using commonsense, try to change the .condkions of the sus-petted circuit components, then use thesimula-tion tests below,

4. Verify the intermittent malfunction is elimi-natedRepair the malfunctioning part and try to dupli-cate the condition(s) again to verify the intermit-tent malfunction has been eliminated.

1690253

16SO252

SIMULATION TESTSFor these simulation tests, shake, then gently bend, pull,and twist the wiring of each of these examples to duplicatethe intermittent malfunction.l Shake the connector up-and-down, and right-and-left.l Shake the wiring harness up-and-down, and right-and-left.l Vibrate the part or sensor.

NOTEIn case of difficulty in finding the cause of the intermittentmalfunction, the data recorder function in the scan tool iseffective.

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00-12 GENERAL - How to Use Troubleshooting/Inspection Service Pdintg;NS$XTION SERVICE POINTS FOR A BLOWN

~,I :

123Remove the fuse and measure the resistance betkeen the

OS2 load side of the fuse and ground. Set the switches of all,circuits which are connected ib this fusb toa konditlonzofcontinuity. If the resistance is almost W&&t this time, there

Battery is a short somewhere between.these switches a?d tht?_;l?ad.I If the resistance is not 0 Q, there is no short af,,Jhe, present

time, but a momentary short has brobably caused ,the fuseto blow.

fuseThe main causes of a short circultare the following .0 Harness being clamped by the vehicle-body

Load 0switch

Damage to the outercasing of the harness due to wearor heat

l Water getting into the connector or circuitry ,Load 0 Human error (mistakenly shorting a circuit, etc.), 2.

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GENERAL - Vehicle Identification

A0020009

1 2 3 4 5 6 7 6 9 1 0 1 1

VEHICLE IDENTIFICATI~ -+ .I\ -.~aorooo;;l&VEHICLE lDENTlFlCATl,Wi NUMBER i-&TltihThe vehicle identification nymb&,(kkN.) is 'locafed &6 dpl.~ _i

Body 4: 3+toor hatchback , ,I ,, ~~ ,:

5: e-door convertible

:ngine Y: 2.0dm3 (122.0cu.in.) [DOHGMFI~

F: 2.Odm3 (122.Ocu.in.) [DOHC-MFI-Turbo]

) G: 2.4dm3 (146.5cu.in.) [SOHC-MFI]

;heck digits* 1 1 2 3 4 5 6 7 8 9 X I

Jlodel year v: 1997

Iant E: Mitsubishi Motor Manufacturing ofAmerica, Inc. I

serial number 000001 to 999999

NOTE* Check digit means a single number or letter X used to verify the

accuracy of transcription of vehicle identitication number.

00-14 GENERAL - Vehicle Identificatibn ,.VEHICLE IDENTIFICATION NUMBER LISTVEHICLES FOR FEDERAL

V.I.N. (except sequence number)

4A3AK24Y-VE

4A3AK34YwVE

4A3AK44YmVE

4A3AK54F,VE

4A3AL54FeVE

4A3AX55FwVE

4A3AX35GmVE

Brand Engine displacement Modelcode

Mitsubishi Eclipse 2.0 dm3 (122.0 cu.in.) D31AMNSML4M . [DOHC-MFI (42OA)] D3!AMRSML4M

D31AMNJML4M/

D31AMRJML4M

DSlAMNHML4MD31 AMRHML4M

2.0 dm3 (122.0 cu.in.) D32AMNGFL4M[DOHC-MFI-Turbo (4G63)] D32AMRGFL4M

Mitsubishi Eclipse D33AMNGFL4M b,Mitsubishi Eclipse 2.0 dm3 (122.0 cu.in.)Spyder [DOHC-MFI-Turbo (4G63)]

2.4 dms (146.5 cu.in.) D39ABNJEL4M[SOHC-MFI (4664)J D39ABFtJEL4M

VEHICLES FOR CALIFORNIA

V.I.N. (except sequence number)

4A3AK24Y-VE

4A3AK34YwVE

4A3AK44YwVE

4A3AK54F-VE

4A3AL54FwVE

4A3AX55F-VE

4A3AX35G,VE

Brand Engine displacement Model code

Mitsubishi Eclipse 2.0 dm3 (122.0 cu.in.) D31 AMNSMLSMcFWD> [DOHC-MFI (420A)] D31 AMRSMLSM

D31AMNJMLSMD31 AMRJMLSM

D31AMNHMLSM031 AMRHMLSM

2.0 dms (122.0 cu.in.) D32AMNGFLSM[DOHC-MFI-Turbo (4G63)] DSPAMRGFLSM

Mitsubishi Eclipse D33AMNGFLSM D33AMRGFLSM

Mitsubishi Eclipse 2.0 dm3 (122.0 cu.in.) D36ABNGFLSMSpyder [DOHC-MFI-Turbo (4G63)] D36ABRGFLSM

2.4 dm3 (146.5 cu.in.) D39ABNJELSM[SOHC-MFI (4G64)] D39ABRJELSM

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GENERAL - Vehicle Identificatibir

00X0066

Heat Drotector /I-,7/ b=1

/

il -:.-/c lII

q--q@) \zBooxoo4o

VEHICLE INFORMATION COC)E PLATE 1 ,_ ;_ I I a:Vehicle information code plate is riveted onto the ;bulkheadin the engine compartment. I ,I!

The place shows model code, en@h& r&d& transaxle model,and body color code.

No. 1 Item

1 MODEL

4G63 Engine model-

CAGA Exterior code ,, .,

F4A33 .: Transaxle: code

R25 87V 03V I%&$ Body&$& code

87V: Interiotcoae

03V: Equipment code

,

VEHICLE SAFETY CERTIFICATION LABEL1. The vehicle safety certification label is attached to face

of left door pillar.2. This label indicates Gross Vehicle Weight Rating

(G.V.W.R.), Gross Axle Weight Rating (G.A.W.R.$ front,rear and Vehicle Identification Number (V.I.N.).

ENGINE MODEL STAMPING1. The engine model number is stamped at the front side

on the top edge of the cylinder block as shown in thef o l l o w i n g .

Engine model 1 Engine di.sDlacement

1 2.0 dm3 (122.0 cu.in.)I

I I

1 2.0 dm3 (122.0 cu.in.)

1 2.4 dm3 (146.5 cuin.)4664

2. The 4G6 and 420A engine serial number is stampednear the engine model number, and the serial numbercycles, as shown below.

Engine serial number AA0201 to YY9999

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00-I 6 GENERAL - Vehicle Identification

Theft protection labelFor original parts

.mi Ilh\iiLl \llliV rl\\iliil > \ \\,\\,,~r:~:~..i..la,*lrl~~!~~~!)~~))~))~~~t~~tJt~~~~t ~~~~J~~~~~~~~~~~(~~(~(~~[((((((((,,,,,,~~~~),),,,,,, iz:..\,,,t), ,, nw, ,I I 1 I

MITSUBISHI IHSlOflSllW MlT!NBlSHl

0 0 2 0 0 1 4

For replacement parts

iMITSUBISHI :~~~$jjjjj$)jjj; []

0 0 2 0 0 1 5

0 0 0 0 4 7 4 3

THEFT PROTECTIONIn order to protect against theft, a Vehicle Identification Number(VIN) is stamped in, or attached as a label to, the followingmajor parts of the engine and transaxle, as well as mainouter panels: q.1 .I

Engine cylinder block, Transaxle housing. Fehder, Door, Quar-ter panel, Hood, Liftgate, Trunk lid, BumpersIn addition, a theft-protection label is attached to replacementparts for the body outer panel main components, and thesame data are stamped into replacement parts for the engineand the transaxle.

Cautions regarding panel repairs: .~,, I -1. When repainting original parts, 90 so after first mask-

ing the theft-protection label, and, after painting, besure to peel off the masking tape.

2. The theft-protection label for replacem,ent parts iS cov-ered by masking tape, sd such part&an be pa@edas is. The masking tape should be removed aft& p&i@-ing is finished.

3. The theft-protection label should not be ietioved fromoriginal parts or replacement parts.

, *

. .-^

.

i

2, _:-

_.0 *

\

2

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GENERAL - Vehicle Identificatio6 O&jiI I _(_, 1 ,.I,,_ ,x ,~

LOCATIONS

Target area (A: for original equipment parts, B: for replacement parts)

Engine

Manual transaxle

A

00003676

00x0092

Automatic transaxle

.

6IOOmm

00003679

00x0093 @oAo*~I

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00-l 8L.

GENERAL - Vehicle Identification ~ ,,,,,( ,/ .


Fender A D o o r

,, \_,: .

GENERAL - Vehicle ldentificqtion ,,I


! ,* .1b1 )J 1.

Front bumper Rear bumper

Trunk lid

B

11

A ooxoiae oooos320

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831x0533

00-20 GENERAL - Precgutipns before Service., .,. _

PRECAUTIONS BEFORE SERVICE . .._..SUPPLEMENTAL RESTRAINT SYSTEM (SRS) .* ,. .I.t1. Items to follow when servicing SRS

: (1) Be sure to read GROUP 528 - Supplemental Restraint System (SRS).For safe operations, please follow the directions and heed all warnrngs:

(2) Always use the designated special tools and test equipment.~!~

,. (3) Wait at least 60 seconds after disconnecting the battery cable before @ing (any further work;

The SRS system is designed to retain enough voltage to deploy the air bag even after the batteryhas been disconnected. Serious injury may result from unintended air bag deployment if workis done on the SRS system immediately after the battery cable is disconnected.

(4) Never attempt to disassemble or repair the SRS components (SRS-ECU air bag module andclock spring). If faulty, replace it.

(5) Warning labels must be heeded when servicing or handling SRS components. Warning labelsare located in the following locations.0 Sun visor

._l Glove box. SRS-ECU ,l Steering wheell Air bag modulel Clock springl Steering gear and linkage clamp

(6) Store components removed from the SRS in a clean and dry place.The air bag module should be stored on a flat surface and placed so that the pad surface isfacing upward.Do not place anything on top of it.

(7) Be sure to deploy the air bag before disposing of the air bagmodule or disposing of a vehicleequipped with an air bag. (Refer to GROUP 528 - Air Bag Module Disposal Procedures.)

(8) Whenever you finish servicing the SRS, check the SRS warning light operation to make surethat the system functions properly.

2. Observe the following when carrying out operations on places where SRS components are installed,. ,including operations not directly related to the SRS air bag.(1) When removing or installing parts do not allow any impact or shock to the SRS components.(2) SRS components should not be subjected to heat over 93C (2OOF), so remove the SRS compo-

nents before drying or baking the vehicle after painting.After re-installing them, check the SRS warning light operation to make sure that the systemfunctions properly.

SERVICING THE ELECTRICAL SYSTEM1. Note the following before proceeding with work on the

electrical system.Note that the following must never be done:Unauthorized modifications of any electrical device orwiring, because such modifications might lead to a vehiclemalfunction, over-capacity or short-circuit that could resultin a fire in the vehicle.

2. When servicing the electrical system, disconnect the nega-tive cable terminal from the battery.

GENERAL - Precautions before Service (j*g?f./* . .

Caution1. Before connecting or disconnecting the negative

cable, be sure to turn off the ignition p$tch andthe lighting switch. I :

(if this is not done, thereis the possibility df semi-conductor parts being damaged.)

2. After completion of the work steps [when the bat-terys negative (-) terminal is connected], warmup the engine and allow it to.idie for approximatelyfive minutes under the conditions descri@d be-low, in order to stabilize the engine control condi-tions, and then check to be sure that idling issatisfactory. ,.Engine coolant temperature: 99-95% (;17&293F)Lights, electric fans, accessories: OFFTransaxle: Neutral position(A/T models: N or P)Steering wheel: neutral (center) position

so0059mm (in.)

Scan tool

ROM pack

VEHICLE WASHINGIf high-pressure car-washing equipment or steam car-washingequipment is used to wash the vehicle, be s&to maintainthe spray nozzle at a distance of at least 300 mm (12 in.)from any plastic parts and all opening parts (doors, luggagecompartment, etc.).

APPLYING ANTI-CORROSION AGENT,,OROTHER UNDERCOAT AGENTS. ,Be careful not to adhere oil or grease to the heated oxygensensor. If adhered, the sensor may malfunction.Protect the heated oxygen sensor with a cover before applyinganti-corrosion agent, etc.

SCAN TOOLTo operate the scan tool, refer to the MUT-II OPERATINGINSTRUCTIONS.

CautionTurn the ignition switch off befoie connecting and discon-necting the scan tool.

00-22 GENERAL - Towing and Hoisting

Sling type

Wheel lift type

Flat bed type

00X0085

Wheel lift type

Flat bet type

Dolly type

OOXOO8f j

TOWING AND HOISTING 001lMo8ll068

WRECKER TOWING RECOMMENDATIONFRONT TOWING PICKUP

CautionThis vehicle cannot be towed by a wrecker using slingtype equipment to prevent the bumper from deformation.if this vehicle is towed, use wheel lift type, fiat bed typeor doily type equipment.

The vehicle may be towed on its rear wheels for extendeddistances provided the parking brake is released. It is recom-mended that vehicles be towed using the front pickup whenev-er possible.

REAR TOWING PICKUPCaution1. This vehicle cannot be towed by a wrecker using

sling-type equipment to prevent the .bumper from de-formation. *if this vehicle is towed, use wheel lift t$pe?* flat bedtype or doily type equipment. : (

2. Do not use steering column lock to secure front wheelposition for towing.

3. Make sure the transaxle is in Neutral if vehicle willbe with drive wheels on the ground. . .

Automatic transaxle vehicle may be towed on the front wheelsat speeds not to exceed 50 km/h (30 mph) for distancesnot to exceed 30 km (18 miles).

C a u t i o nif these limits cannot be met, the front wheels must beplaced on a tow doily or a fiat bet type must be used.

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GENERAL - Towing and Hoisting

Sling type

Wheel lift type

Flat bed type

Dolly type

00x0087

TOWING WHEN KEYS ARE, NOT, AVAILABLE 1 j .When a locked vehicle must be towed and keys are, not +@I-able, the vehicle may be lifted and towed from the front;provided the parking brake is released. If not released,. therear wheels should be placed on a tow dolly.

SAFETY PRECAUTIONSThe following precautions should be taken when towing thevehicle.1. DO NOT LIFT OR TOW THE VEH(pLE BY ATTACHING

TO OR WRAPPING AROUND TH,E BUMPER.2. Any loose or protruding parts of Uamaged vehicle such

as hoods, doors, fenders, Irim, etc., should be securedor removed prior to moving the. vehicle.

3. Operator should refrain from going under a vehicle whileit is lifted by the towing equifiment, unless the vehicleis adequately supported by safety 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.

Caution1. If only the front wheels or only. the rear wheels are

lifted for towing, the bumper will be damaged.In addition, lifting of the rear wheels causes the oilto flow forward, and may result in heat damage tothe rear bushing of the transfer, and $0 should neverbe done.

2. Do not tow the vehicle with only iti front wheels oronly the rear wheels on a rollibg dolly, or the viscouscoupling will be damaged. In a tiorst case, the vehiclemay jump forward suddenly.

3. If this vehicle is towed, use flat bed w$e or dollytype equipment.

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00-24 GENERAL - Towing and ; Hoisting . .

LIFTING, JACKING SUPPORT LOCiiTlONFLOOR JACK

H Genterr_ //-- //----- __-

nember xPiece nf wood

1 A\Rear crossmember

CautionNever support any point other than the specified one, or it will be deformed.

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G E N E R A L - Towing and Hofating ,, di?fw* .v -2 , ?/ ,,_ xl(iyt*,%w/ld , n,.P

RIGID RACK

J

Notch

, , , ,

: ,

.,(1,

e./: . ..J. ,>, *./:(.. l,bl

o&y& : ,*.z. ,I

~:oootg?25 -1, _ jr(

For lifting, put rubber or similar between the side sill and rigid rack, or the side sill area will;be damaged. IPOST TYPESpecial care should be taken when raising the vehicle on a frame contact type ho/s!. The hoist:@&be equipped with the proper adapters in order to support the vehicle at the prop&, Id&ions. :

CautionWhen service procedures require removing rear suspension, fuel tank and spare tire, place additionallweight on rear end of vehicle or anchor vehicle to hoist to prevent tipping of center of gravitychanges.

., . _ .,.. a

Notch

OONOOJO

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00-26 GENERAL - Special Handling lnstructidng for AWD Models

{/.;----pf-&

-:,*d es--. m-e m-v

ooPoo36

0 0 0 0 3 6 8 5

SPECIAL HANDLING INSTR~Ctldki&FOR AWD MODELS 0 0 1 0 0 7 4 0 0 1 0Speedometer tests, brake tests and wheel balance measure-ment for full-time AWD vehicles should be carried out accord-ing to the following procedures.

SPEEDOMETER TESTRefer to GROUP 54 - Combination Meter.

BRAKE TESTIn order to stabilize the viscous couplings dragging force,the brake test should always be conducted after the speedom-eter test.

FRONT WHEEL MEASUREMENTS1. 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 manualfy .rotate each wheel -tocheck the rotation condition of each wheel. .,,

NOTE : ; * c;;,,If the brake dragging force exceeds the specified &lue;the cause may be the effect of the viscous ooupli@sdragging force, so jack up the front viheels and checkthe rotation condition of the wheels in this state for noeffect by the viscous couplings dragging force. j

_I .*.,.A, :,

REAR WHEEL MEASUREMENTSAfter placing the rear wheels on the brake tester, follow thesame procedures as for the front wheel measurements.

Brake force of AWD models with VCUIf both front wheels are locked and rear wheel measurementis difficult, the measurement in this condition can be consid-ered to comprise the total.

Items Brake forceTotal for left and At 90 kg (198 Ibs.) ped- 20 % or more of rearright rear wheels al depression force axle weight

Differenceforleft 8% or less of rear 8% or less of rearand right front axle weight axle weightwheels/differ-ence for left andright rear wheels

Total for front At90 kg(198Ibs.)ped- 50% or more of theand rear wheels al depression force vehicles weight

or...

Braking-stop distance At primary velocity of 50 km/h (31mph): Within 15.0 m (49.2 ft.)

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GENERAL - Special Handling Instructions for AWL? Models

Balancing machine

Pick-u; stand40040014

00003666

W H E E L B A L A N C E , !,;

00-28 GENERAL - General Data and Specifications 1(_

GENERAL DATA AND SPECIFICATIONS 00199999191ECLIPSE

I-- 7 41 l : MD

2: AWD6,

00x0143 _

,I .

GENERAL SPECIFICATIONS

Items D31AMNSML4M D31AMRSML4M D31AMNJML4M D31AMRJML4MD3lAMNSMLSM D31AMRSMLSM DSlAMNJMLSM DSlAMRJMLSM

Vehicle Overall length mm (in.) 14,380 (172.4) 4,380 (172.4) 4,380 (172.4) 4,380 (172.4)dimen- Overall width mm 21,735 (68.3) 1,735sions (in.)

(68.3) 1,735 (68.3) 1,735 (68.3)Overall height (unladen) 31,295 (51 .O) 1,295 (51 .O) 1,295 (51 .O) 1,295(51 .O)mm (in.)Wheelbase mm (in.) 42,510 (98.8) 2,510 (98.8) 2,510 (98.8) 2,510 (98.8)Tread - Front mm (in.) 5 1,515 (59.6) 1,515 (59.6) 1,515 (59.6) 1,515 (59.6)Tread - Rear mm (in.) 6 1,510 (59.4) 1,510 (59.4) 1,510 (59.4) 1,510 (59.4)Overhang - Front 7 935 (36.8) 935 (36.8) 935 (36.8) 935 (36.8)mm (in.)Overhang - Rear 8 935 (36.8) 935 (36.8) 935 (36.8) 935 (36.8)mm (in.)Minimum running ground 9145 (5.7) 145 (5.7) 145 (5.7) 145 (5.7)clearance mm (in.)Angle of approach 1011.8 11.8 11.8 11.8degreesAngle of departure 1115.8 15.8 15.8 15.8degrees

I/chicle Curb weight 1,236 (2,725) 1,266 (2,791) 1,245 (2,745) 1,275 (2,811)Height Gross vehicleweight rating 1,660(3,660) 1,660 (3,660) 1,690 (3,726) 1,690 (3,726)cg (Ibs.) Gross axle weight rating- 1 ,010 (2,227) 1 ,010(2,227) 1,010 (2,227) 1,010 (2,227)

FrontGross axle weight rating - 800 (1,764) 800 (1,764) 800 (1,764) 800 (1,764)Rear

seatingcapacity 4 4 4 4

Zngine Model No. 420A (DOHC) 420A (DOHC) 420A (DOHC) 420A (DOHC)Piston displacement 1,996 (121.8) 1,996 (121.8) 1,996 (121.8) 1,996 (121.8)cm3 (cu.in.)

rrans- Model No. F5MCl F4ACl F5MCl F4AClaxle Type 5-speed manual 4-speed 5-speed manual 4-speed

automatic automatic

Qel Fuel supply system Electronically Electronically Electronically Electronicallyrystem controlled multi- controlled multi- controlled multi- controlled multi-

port fuel injec- port fuel injec- port fuel injec- port fuel injec-tion tion tion tion

TSB Revision I

GENERAL - General Data and Specifications PO439

Items D31AMNHML4M D31AMRHML4M D32AMNGFL4M D32AMRGFL4hD31 AMNHMLSM D31AMRHMLSM D32AMNGFLSM D32AMRGFLSt

,Vehicle Overall length mm (in.) 14,380, (172.4) 4,380 (172.4) 4,380 (172.4) 4,380 (172.4)dimen-sions

Overall width mm (in.) 2 1,735 (68.3)1,740 (68.5)*

1,735 (68.3)1,740 (68.5)*

1,740 (68.5) 1,740 (68.5)!, z, ;

Ov$ )height (unladen) 3 1,295 (51 .O) 1,295 (51 .O) 1,295 (51 .Q) 1,295 (51 .O)

Wheelbase mm (in.) 42,510 (98.8) 2,510 (98.8) 2,510 (9i$ 2,510 (98.8)Tread - Front mm (in.) 5 1,515 (59.6) 1,515 (59.6) 1,515 (59.6) 1,515 (59.6)Tread - Rear mm (in.) 6 1,510 (59.4) 1,510 (59.4) 1,51.0 (59.4) 1,510 (59.4)Overhang - Front 7 935 (36.8) 935 (36.8) 935 (3.6.8) 935 (36.8)mm (in.)Overhang - Rear 8 935 (36.8) 935 (36.8) 935 (36.8) 935 (36.8)mm (in.)Minimum running ground 9145 (5.7) 145 (5.7) 145 (5.7) 145 (5.7)clearance mm (in.) ,

Angle of approach 1011.8 11.8 ?I .8 11.8degrees

Angle of departure 1115.8 15.8 1 5 . 8 15.3 : degrees

Vehicle Curb weight 1,285 (2,833) 1,315 (2,899) i ,322 (2,91$ 1,357 (2,992)Neight(g (Ibs.) Gross vehicle weight rating1,750 (3,858) 1,750 (3,858) 1,750 (3,858) 1,759(3,858)

Gross axle weight rating - 1 ,010 (2,227) 1 ,010 (2,227) 1,025 (2,260)Front

l,c)25 .(?,$W

Gross axle weight rating - 800 (1,764) 800 (1,764) 775 (1,709) 775 (1,709)Rear

Seating capacity

ingine Model No.Piston displacementcm3 (cu.in.)

-rans- Model No.axle Type

uel Fuel supply systemystem

4 4 4 4420A (DOHC) 420A (DOHC) 4G63 (DOHC) 4G63 (dOHd)1,996 (121.8) 1,996 (121.8) 1,997 (121.9) 1,997 (12! .9)

f. :!F5MCl F4ACl F5M33 F4A33 5-speed manual 4-speed 5-speed manual 4-speed

automatic automatic

Electronically Electronically Electronically Electronicallycontrolled multi- controlled multi- controlled multi- controlled multi-port fuel injec- port fuel injec- port fuel injec- port fuel injec-tion tion tion tion

NOTEl 1: Vehicles with side air dam.

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00-30 GENERAL - General Data and S.pecifications

Items

Vehicle dimensions

vehicle weight kg[Ibs.)

Overall length mm (in.)Overall width mm (in.)Overall height (unladen) mm (in.)Wheelbase mm (in.)Tread - Front mm (in.)Tread - Rear mm (in.)Overhang - Front mm (in.)Overhang - Rear mm (in.)Minimum running groundzlearance mm (in.)Angle of approach degreesAngle of departure degrees

Curb weightGross vehicle weight ratingGross axle weight rating - FrontGross axle weight rating - Rear

-123456789

1011-

Seating capacity

Engine Model No.Piston displacement cm3 (cu.in.)

c133AMNGFL4M ( 033AMRGFL4M.c133AMNGFLSM 033AMRGFLSM4I;380 (172.4)1 ,740 (68.5)1 ,310 (51.6)2!,510 (98.8)1 ,515 (59.6)1 ,510 (59.4)E135 (36.8)E135 (36.8)1 45 (5.7)

4,380 (172.4) 1,740 (68.5)1,310 (51.6)2,510 (9818)1,515 (59.6)1,510 (py9 3 5 (368)935 (36.8)145 (5.7)

1 2.21 6.2

,427 (3,146),850 (4,079),050 (2,315)50 (1,874)

4

41

v5

Elm

I1 . 2 . 216.2

1,462 (3,223)1,850 (4,079)1,050 (2,315)659 (1,874) .$

4

G63 (DOHC)997 (121.9)

r15M33-speed manual

4G63 (DOHC)1997 (12+f)

,.. .~

W4A33 4-speed automatic

Ic:lectronically controlled 1 Electrohlcally controlledultiport fuel injectton multiport fuel injection

: ,. 2,;

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GENERAL - General Data and Specifications :OOt31

ECLIPSE SPYDER

GENERAL SPECIFICATIONS

6. 00X0144 I .

Items D38ABNGFL4M D38ABRGFL4M D39ABNJEL4M D39ABRJEL4M038ABNGFLSM 038ABRGFLSM D39ABNJELSM 039ABRJELSM

Vehicle Overall length mm (in.) 14,380 (172.4) 4,380 (172.4) 4,360 (172.4) 4,380 (172.4)dimen- Overall width mm (in.) 21,740(68.5) 1,740 (68.5) 1,735 (68.3)

1,740 (68.5)*1,735 (68.3)

sions 1,740 (68:5)*Overall height (unladen) 31,340 (52.8) 1,340 (52.8) 1,340 (52.8) 1,340 (52.8)mm (in.)Wheelbase mm (in.) 42,510 (98.8) 2,510 (98.8) 2,510 (98;8) 2,510 (98.8)Tread - Front mm (in.) 5 1,510 (59.4) 1,510 (59.4) 1,510 (59.4) 1,519 w.q,Tread - Rear mm (in.) 6 1,505 (59.2) 1,505 (59.2) 1,505 (59.2) 1,505 (59.2)Overhang - Front 7 935 (36.8) 935 (36.8) 935 (36.8) 935 (36.8)mm (in.) :Overhang - Rear 8 935 (36.8) 935 (36.8) 935 (36.8) 935 (36.8)mm (in.)Minimum running ground 9160 (6.3) 160 (6.3) 160 (6.3) 1 6 0 ( 6 . 3 )clearance mm (in.)Angle of approach 1012.2 12.2 12.2 12.2 Idegrees

Angle of departure 1115.8 15.8 15.8 1 5 . 6 degrees

Jehicle Curb weight 1,385 (3,053) 1,425 (3,142) 1,305 (2,877) 1,335 (2,943)weight Gross vehicle 1,765 (3,935) 1,785 (3,935)rg (Ibs.) weight rating

1,850 (4,079) 1,850 (4,079)Gross axle weight rating - 1,030 (2,271) 1,030 (2,271) 1 ,010 (2,227) 1,010 (2,227)FrontGross axle weight rating - 820 (1,808) 820 (1,806) 800 (1,764) 800 (1,764)Rear

seatingcapacity

Engine Model No.Piston displacementcm3 (cu.in.)

Trans- Model No.sxle Type

Fuel Fuel supply systemsystem

NOTE*l: Vehicles with side air dam.

4 4 4 4

4G63 (DOHC) 4G63 (DOHC) 4664 (SOHC) 4664 (SOi-lC)1,997 (121.9) 1,997 (121.9) 2,351 (143.4) 2,351 (143.4)

F5M33 F4A33 F5M31 F4A235-speed manual 4-speed 5-speed manual 4-speed

automatic automatic

Electronically Electronically Electronically Electronicallycontrolled multi- controlled multi- controlled multi- controlled mufti-port fuel injec- port fuel injec- port fuel injec- port fuel injec-tion tion tion tion

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00-32 GENERAL - Tighteqing Torque . ,, _ _/,

TIGHTENING TORQUE., 4 l. r &.7S ,%*,&.^:oo&&&

Each torque value in the table is a standard valuefor tightening under the following conditions.(1) Bolts, nuts and washers are all made of steel

and plated with zinc.(2) The threads and bearing surface of bolts and

nuts are all in dry condition.

The values in the table arenot applicable:(1) If toothed washers are inserted.(2) If plastic parts are fastened. .-(3) If bolts are9ightened to plastic or die-cast in-

setted nuts.(4) If self-tapping screws or self-locking nuts are

used.

Standard bolt and nut tightening torque

Ml4 1.5

Ml6 1.5

Ml8 1.5

M20 1.5

M22 1.5

M24 1.5

Flange bolt and nut tightening torque

72 (53) 137(101) 157 (p)

111 (82) 206(152) ?35(i74)

167(123) 304(224) ~ 343i(253)

226(166) 412 (304) 481,(354)

304(224) 559(412) q47,(41')

392 (289) 735(542) '2 853 (629)

I

Ml2 ) 1.75 ) 42(31) 81 (60) 1 SS(71) ,, '!I I ,,','

., .I,, .^"

.?a ;

i j' ..J,'.r,: JT!,,

I

1 0 #

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GENERAL - Lubrication arid Maintenance, OQ-33,I.

LUBRICATION AND MAINTENANCE s 00100120067Maintenance and lubrication service recommenda-tions have been compiled to provide maximumprotection for the vehicle owners investmentagainst all reasonable types of driving conditions.Since these conditions vary with the individual ve-hicle owners driving habits, the area in which thevehicle is operated and the type of drivihg to whichthe vehicle is subjected, it is necessary to prescribelubrication and maintenance service on a time fre-quency as well as mileage interval basis.Oils, lubricants and greases are classified andgraded according to standards recommended bythe Society of Automotive Engineers (SAE), theAmerican Petroleum Institute (API) and the NationalLubricating Grease Institute (NLGI).

MAINTENANCE SCHEDULESInformation for service maintenance is providedunder SCHEDULED MAINTENANCE TABLE.Three schedules are provided; one for RequiredMaintenance, one for General Maintenance andone for Severe Usage Service.Item numbers in the SCHEDULED MAINTE-NANCE TABLE correspond to the item nimbersin the MAINTENANCE SERVICE section.

SEVERE SERVICEVehicles operating under severe service conditionswill require more frequent service.Component service information is included in ap-propriate units for vehicles operating under oneor more of the following conditions:1. Police, taxi, or commercial type operation2. Operation of Vehicle

(1) Short-trip operation at freezing temperature(engine not thoroughly warmed up)

(2) More than 50% operation in heavy city traf-fic during hot weather above 32C (90F)

(3) Extensive idling(4) Driving in sandy areas(5) Driving in salty areas(6) Driving in dusty conditions

ENGINE OILEither of the following engine oils should be used:(1) Engine oil displaying EOLCS certification mark(2) Engine oil conforming to the API classification

SH EC11 or SH/CD ECII.For further details, refer to LUBRICANTS SELEC-TION section.

Caution,

Test re+s submitted to EPA have shown that:laboratory animals develop skin cancer afterprolonged contact with used engine oil. Accord-ingly, the potential exists for humans to developa number:, of skin disorders, including can$qr,.from such exposure to used e.pgine,_$l.Care should be taken, therefore, when changingengine oil, to minimize the am;lount,and lengthof exposure time to used engine oill gn, yourskin. Protective clothing and gloveq that cannotbe penetrated by @I, should be; worn. Theskin,should be thoroughly ,w$shed with soap andwater,,or use waterless hand ,cleqney,,to remove,any used engine oil. Do not use gasoline, thin-ners, or solvents.

GEAR LUBRICANTSThe SAE grade number al& indicates t$ ciscdsi& of Multi-purpose Gear Lubricants.The API classification system ,dgfines, @Ear lub$.cants in terms of usage. Typidally gear lubricantsconforming to API GL-4 or GL-5 with a viscositjlof SAE 75W-85W are recommended for mahugltransaxle.

LUBRICANTS - GREASESSemi-solid lubricants bear the NLGI designationand are further classified as grades 0, 1, 2; 3 etc.Whenever Chassis Lubricant is specified, Multi-purpose Grease, NLGI grade 2, should be used.

FUEL USAGE STATEMENTYour car must use unleaded gas&e only.This car has a fuel filler tube especially deSignedto accept only the smaller-diameter unleaded gaso-line dispensing nozzle.

CautionUsing leaded gasoline in your car will damagethe catalytic converter and oxygen sensor, andaffect the warranty coverage validity.

Your car is designed to operate on premium uri- 1leaded gasoline having a minimum octane rating of 91 or 95 RON (Research Octane Number).If premium unleaded gasoline is not av$?ble,,,un-leaded gasoline having a octane rating of 87, tir91 RON (Research Octane Number) may be used.In this case, the performance and fuel consumptionwill suffer a little degradation.

Gasolines Containing AlcoholSome gasolines sold at service stations containalcohol, although they may not be so identified.

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00-34Lubrication and MaintenanWRecqmmended

GENERAL - Lubricants and Lubricant Capacities Table

Use of fuels containing alcohol is not recommendedunless the nature of the blend can be determinedas being satisfactory.Gasohol - A mixture of 10% ethanol (grain alcohol)and 90% unleaded gasoline may be used in yourcar.If driveability problems are experienced as a resultof using gasohol, it is recommended that the carbe operated on gasoline.Methanol - Do not use gasolines containingmethanol (wood alcohol). Use of this type of alcoholcan result in vehicle performance deterioration anddamage critical parts in the fuel system compo-nents. Fuel system damage and performance prob-lems, resulting from the use of gasolines containingmethanol, may not be covered by the new car war-ranty.

Gasolines containing kiltBE (Methyl Tettiaiy bir-tyl Ether)Unleaded gasoline containing 15% or IeFs MTBEmay be used in ypur car. Fuel containing MTBEover 15% vol. may cause reduced engine perfor-mance and produce vapor lock or hard starting.

MATERIALS ADDED TO FUELIndiscriminate use of fuel system -cleaning ageritsshould be avoided. Many of these materials in-tended for gum and varnish removal mtiy cohtainhighly active solvents or similar ingredients thatcan be harmful to gasket and diaphragm materialsused in fuel system component parts.

RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIESTABLEw1001am14

RECOMMENDED LUBRICANTS

Items

Engine

:Recommended lubricants

Engine oil displaying EOLCS certification mark or conformingto the API classification SH EC11 or SH/CD ECB (For further,details, refer to LUBRICANTS SELE6flON section)

i iI Manual transaxle ( 2.0L Engine (Non-turbo) / TEXACO MTX FLUID FM * I

2.0L Engine (Turbo) and 2.4L API classification GL-4, SAE 75W-90 or 7&85WEngine ,

I I _(Automatic transaxle DIAMOND ATF SP II or equivalent

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r- ~~Transfer ( API classification GL-4, SAE 75W-90 or 75WL85WDifferential (rear axle) API classification GL-5 or higher

Above -23C (-10F): SAE 90,85W-90,8OW-90From -34% (-30F) to -23C (-10F):SAE 8OW, 8OW-90 .Below -34C (-30F): SAE 75W

Power steering

Brake and clutch

Automatic transmission fluid DEXRON II

Conforming to DOT3 or DOT4

1

Engine coolant DIA-QUEEN LONG-LIFE COOLANT (Part No. 0103044) orHigh quality ethylene-glycol antifreeze coola?t I

GENERAL - Recommended Lubricants and Lubricant Capacities Table

LUBRICANT CAPACITIES

00-35

Description Metric measure U.S. measure :

Engine oil Crankcase 2.0L Engine (Non-turbo) 3.8 dm3(excluding oil filter)

4 qts.

2.0L Engine (Turbo) and 2.4L 4.0 dm3Engine

4.2 qts.

Oil filter 2.0L Engine (Non-turbo) 0.5 dm3 .53 qt.

2.0L Engine (Turbo) and 2.4L 0.3 dm3Engine

.32 qt.

Oil cooler 0.1 dm3 .ll qt.

Cooling system (including heater and engine coolant reserve system)7.0 dms 7.4 qts.

Manual transaxle FWD 2.0 dms 2.1 qts.

AWD 2.3 dms 2.4 qts.

Automatic transaxle 2.0L Engine (Non-turbo) 8.6 dm3 9.1 qt.%

2.0L Engine (Turbo) 6.7 dm3 7.1 qts.

2.41 Engine 6.1 dms 6.4 qts.

Transfer 0.5 dm3 .53 qt.

Differential (rear axle) 0.85 dm3 .9 qt.

Power steering 0.9 dm3 .95 q t .

Fuel tank 64 dm3 i7.0gals. I

EOLCS certification mark

M03AOlS

M03A014

LUBRICANTS SELECTIONENGINE OIL

CautionNever use non-detergent or straight mineral oil.Oil Identification SymbolUse only engine oils displaying the EOLCS certification markon the container.

2.

If these oils are not available, an API classification SH ECIIor SH/CD EC11 can be used.

,/

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00-36 GENERAL - Recommended Lubricants and Lubkicant Capacities Table

Non-turbo

I I

2.4L 5AE IOW- JOEngine ISM *w-30, PREFERRED 1

TurboM03BOlO

MO36002~0001126

,, q--T 1

Oil Viscosity -3.

The SAE grade number indicates the viscosity Of the &ii.A proper SAE grade number should be selected accygingto ambient temperature.

NOTEl : SAE 5W-30 may be used for operation in very cold weather

areas where the lowest ambient temperature is below- 10F (- 23C).

COOLANT SELECTIONCOOLANTRelation between Antifreeze Concentration and Specific Gravity

Engine coolant temperature C (F) and specific gravity

10 (50) 20 (68) 30 (86) 40 (104) 50 (122)

1.054 1.050 1.046 1.042 1.036

1.063 1.058 1.054 1.049 1.044

1.071 1.067 1.062 1.057 1.052

Freezing Safe operating Engine coolanttemperature temperature concentrationC (F) C (F) (Specificvolume)

-16 (3.2) -11 (12.2) 30%

-20 (-4) -15 (5) 35%

-25 (-13) -20 (-4) 40 Yo

1.079 1.074 1.069 1.064 1.058 -30 (-13) -25 (-13). +% .I,i*; i

*1.087 1.082 1.076 1.070 1.064 -36 (-32.8) -31, (-23;); 50 %

1.095 1.090 1.084 1.077 1.070 -42 (-44) -37,(-35!:, : 55%1.103 1.098 1.092 1.084 1.076 -50 (-58) -45 (-A>:: < $b%

ExampleThe safe operating temperature is-15C (5F) when the measured specific gravity is 1.058 at the coolanttemperature of 20C (68F).

Caution1. If the concentration of the coolant is below 30%, the anti-corrosion property, will e adversely

affected. In addition, if the concentration is above 60%, both the anti-freeze and engine coolingproperties will decrease, affecting the engine adversely. For these reasons, be sure to maintainthe concentration level within the specified range.

2. Do not use a mixture of different brands of anti-freeze.

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7 I

>

I . ,, !

GENERAL - Scheduled Maintenance Table :

SCHEDULED MAINTENANCE TABLE 00100140124SCHEDULED MA IN TE NA NC E SERVICES FOR EMISSION cOti~R0L AND~#OPERVEHICLE PERFORMANCE i 9

Inspection and services shotild be performed any time a malfunction is observed or suspected. Retainreceipts for all vehicle emission services to protect your emission warranty.

GENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE, P+FOkMJINCk ,,,

No. General maintenance

7 liming belts

^ .T / .: .I

Service to be performed Kilometers in thousands 24 &I 72 96 120,., 144 166

Mileage in thousands 15 30 45 60 75 90 I&

Replace at1 x; + r&;ooo*

il,. I ml$loo mw

0 Drive belt (for generator, water pump, power Check condition atsteerina oumo) I Ix1 lx1 lx1 I

9 Engine oil Non-turbo Change Every 6 months or Every 12.009 km (7.509 miles)

Turbo Every 6.066 km (5,ooO miles)

10 Engine oil filter Non-turbo Replace Every Years or X X X X X X X

Turbo Replace Every Year or Every 16,006 km (10,CxXI miles)

11 I Manual transaxle oil 1 Check oil level at Y Y Y

12 Automatic transaxle fluid

13 Transfer oil

Check fluid level Every year or

Check oil level at

X X X X X X X

I X X X

14 Engine coolant Change Every 2 years or X X X

15 Disc brake pads Check for wear Every year or X X X X X X X

16 Rear drum brake linings and rear wheel cylin- Check for wear and leaks Evety 2 years or X X Xders (vehicles without disc brakes for allwheels)

17 Brake hoses Check for detedoration or leaks Every year or X X X X X X X

I6 Ball joint and steering linkage seals Check for grease leaks and damage Every 2 years or X X X

I9 Drive shaft boots Check for grease leaks and damage Every year or X X X X X X X

!O Rear axle oil Check oil level at x x x

!I 1 SRS*4 system 1 Check system 1 AtlOyears I

!2 Exhaust system (connection portion of muffler, X X Xplpings and convener heat shields)

Check and service as required Every 2 years or

NOTES1: ForCalifornia, this maintenance is recommended but not required2: Not required if belt was previously changed.3: If the mileage is less than 12,000 km (7,5Orl miles) each year, the oil filter should be replaced at every oil change.4: Supplemental Restraint system

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00-38 GENERAL - Scheduled Maintenance Table/Maintenance Service

SCHEDULED MAINTENANCE UNDER SEVERE USAGE CONDlTlaNSThe maintenance items should be performed according to the following table:.1

1: Vehicles with turbocharger.

Severe usage conditionsA - Driving in dusty conditionsB - Trailer towing or police, taxi, or commercial type

operationC - Extensive idling, driving in stop and go trafficD - Short-trip operation at freezing temperatures (en-

gine not throughly warmed up)

.

, .E - Driving in sandy areasF - Driving in salty areasG - More than 50% operation in heavycity traffic or at

sustained high speeds during hot weather above32C (90F) .

H - Driving on off-road

..-

MAINTENANCE SERVICE ,_ oo&ow1. FUEL SYSTEM (Tank, Pipe Limp,~~@m&io~s

and Fuel Tank Filler Tube Cap) (Check forleaks)/2. FliEL HOSES (Check condition)

1. Check for damage or leakage in the .fuel lines. andconnections and looseness of the fuel tank filler tube

2. &&+k the surface of fuel hoses for heat and mecbani&damage. Hard and brittle rubber, cracking, checking, ttiars,cuts, abrasions and excessive swelling iridicatedeterioration of the rubber.

3. If the fabric casing of the rubber ,hos@ is exposed bycracks and abrasions in the fuel systev, the hoses sbou,ldbe changed.

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GENERAL - Maintenance Service 00-38

3. AIR CLEANER ELEMENT (Replace) 00100180058The air cleaner element will become dirty and loaded withdust during use, and the filtering effect will be substantiallyreduced.Replace it with a new one.(1) Unclamp the air cleaner cover.(2) Take out the air cleaner element, install a new one.(3) Be sure when clamping the air cleaner cover in place

that the cover is completed closed.

4. EVAPORATIVE EMISSION CONTROL SYSTEM(Check for leaks and clogging) - except evapo-rative emission canister 001001wos1

1. If the fuel-vapor vent line is clogged or damaged, a fuelvapor mixture escapes into the atmosphere causingexcessive emissions. Disconnect the line at both ends,and blow it clean with compressed air. Remove the fueltank filler tube cap from the fuel tank filler tube and checkto see if there is evidence that the packing makes impropercontact to the fuel tank filler tube.

2. The fuel tank pressure control valve installed on the vaporline should be checked for correct operation.

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00-40 GENERAL - Maintenance &vice,

Incorrect Correct

6ENO960

5. SPARK PLUGS (Replace).. WI-1. Spark plugs must spark properly to assure proper engine

performance and reduce exhaust emission 1evef.i I.Therefore, they should be re,placed periodically with newones.

2. The new plugs should be checked iqr tii6 rj;ropc!r gap.Spark plug gap: , . .

(2.0L Engine (Turbo)> 0.7-0.8 mm (.028-.030 i.n.) .

,

1.22-1.35 mm (.048-,053in.) : j .;I .

1.0-l .l rn? (.039-.043 in.)

3. Install the spark plug and tighten to the sp@oified.

Tightening torque:

25 Nm (18 ft.lbs:)n

% ~

28 Nm (20 ft.lbs.) .L1.

6. IGNITION CABLES (Replace) 00100210054The ignition cables should. be replaced periodically with newones. After replacing, make sure that the ignition cables arerouted properly and fully seated.

NOTEWhen disconnecting an ignition cable; be sure to hold thecable boot. If the cable is disconnected by pulling on thecable alone, an open circuit might result.

7. TIMING BELT (Replace) 00100220027Replace the belt with a new one periodically to assure properengine performance.For disassembly and assembly procedures;

Refer to GROUP 11A - Timing Belt.Refer to GROUP 11C - Timing Belt.Refer to GROUP 11 E - Timing Belt.

8. DRIVE BELT (For Generator, Water Pump,Power Steering Pump) (Check condition)

00100250070

Check the tension of the drive belt. Check the drive beltfor evidence of cuts and cracks, and replace it if defective.

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GENERAL - Maintenance Service

w 6EN0596

6EN0887

gauge CENOlOB

Generator pulley

Crankshaft &Hey M50AOll

Water pump pulley

pump pulley

I

GENERATOR AND WATER PUMP DRIVE BELTTENSION,CHECK Check the belt tension with the tension gauge, or check thebelt deflection by pressing. the middle point of .the belt bya force of 98 N (22 Ibs.).

Standard value:

Tension N (Ibs.)

Deflection mm (in.)

245 - 490 (55.1 - lld.ij .,

9.0 - 11.5 (.35 - .45)

,

Check the belt tension with the tension gauge at the middlepoint of the belt, or check the belt deflection by pressing,the belt point by a force of 98 N (22 Ibs.). * .

Standard value:

Tension N (Ibs.)

Deflection mm (in.)

400 - 490 (90 - 110) -- L

9.0 - 12.0 (.3& .47)

,I I

, . .

POWER STEERING PUMP DRIVE BELT TENSION CHECK

1. Pull or push at the mid point of the belt with a force

of 98 N (22 Ibs.) to measure dirve belt deflection.

Standard value: 5.5-8.0 mm (.22-.32 in.)

2. Use a tension gauge to measure belt tension.Standard value: 245-490 N (55.1-110.2 Ibs.)

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00-42 GENERAL - Maintenance Service

Drain pl.gasket

Oil pan side

GENERAL - Maintenance Service

\ \

BOOXOO6s

&OL Engine (Turbo) and2.4L Engine>

10. ENGINE OIL FILTER (Replace) 001-6The quality of replacement filters varies considerably. Only.high quality filters should be used to assure mdst efficientservice.Genuine oil filters are capable of :withstanding a pressure,of 1,765 kPa (256 psi). These high quality filters are highlyrecommended. The followings part are available as follows.

Oil Filter Part No.:

Mitsubishi Genuine Parts:MD1 35737, MD1 36466, MD325714 or eqF!valept

:Chrysler Genuine Parts: MO5281090 or equlvalent

ENGINE OIL FILTER SELECTIONThis vehicle is equipped with a full-flow, throwiaway oil filter.The same type of replacement filter is recommended aa areplacement filter for this vehicle. It is possible, pqticularlyin cold weather, that this vehicle may develop high off pressurefor a short duration. You should be sure that any replacementfilter used on this vehicle is a high-quality filter and is &ble of withstanding a pressure of 1,765, kPa (256 ,psi)(manufacturers specifications) to avoid filter and enginedamage.The following is a high-quality filter and is strongly ;recommended for use on this vehicle. .

: ,:.Mitsubishi Engine Oil Filter Part No; ,Mh3573?,MD136466 or MD325714 -

Chrysler Engine Oil Filter Part No. M0526jOd

Any replacement oil filter should be installed ii accordancewith the oil filter manufacturers installation instructions~ : (1) Remove the engine oil filler cap.L(2) Remove the engine oil drain plug, and drain out the&ine

oil. ,/(3) Remove the engine oil filter by using the oil filter &ench.(4) Clean the oil filter mounting surface of the oil filter bracket.

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GENERAL - Maiirtenance &ice ,I x1, ,,, I)

Oil levelIV

(5) Coat engine oil to the O-ring of, new .oil filter: 1 s . (6) Screw on the oil filter by hand until it touches the surface

of the flange and then tighten it with the filter wrench:. . .etc. .

GENERAL - Maintenance, Service 0045L_

5. Tighten filler plug to specified torque.

Specified torque: 30 Nm (22 ft.lbs.)

32 Nm (24 ft.lbs.)

12. AUTOMATIC TRANSAXLE FLUID(Check fluid level)

00100290188

1. Position the vehicle on a level surface.2. Start engine and allow to idle in PARK for at least 60

seconds. The warmer the transaxle fluid, the moreaccurate the reading.

3. While sitting in driver seat, apply brakes and place gearselector in each position. Return gear selector to PARK.

4. Raise hood and remove transaxle fluid level indicator(dipstick) and wipe clean with a suitable shop towel.

5. Install dipstick and verify it is seated in fill tube.

CautionDo not overfill automatic transaxle, leakage or damagecan result.

6. Remove dipstick, with handle above tip, take fluid levelreading. If the vehicle has been driven for at feast 15minutes before inspecting fluid levef, transaxle can beconsidered hot and reading should be above the WARMmark. If vehicle has run for less than 15 minutes andmore than 60 seconds, transaxle can be considered warmand reading should be above ADD mark. Add fluid onlyif level is below ADD mark on dipstick when transaxleis warm.

1. Drive until the fluid temperature reaches the usual

, temperature [70-80C (158-176F)]2. Place vehicle on level floor.3. Move selector lever sequentially to every position to fill

torque converter and hydraulic circuit with fluid, then placelever, in N Neutral position. This operation is necessaryto be sure that fluid level check is accurate.

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TFA1069

4. Before removing dipstick, wipe all dirt from area arounddipstick. Then take out the dipstick and check the conditionof the fluid.Further investigation of the transaxle is necessary if,l the fluid smells burnt.l the fluid color is brown or black.l metal particles can be seen or felt on the dipstick.

5. Check to see if fluid level is in HOT range on dipstick.If fluid level is low, add ATF until level reaches HOTrange. Low fluid level can cause a variety of conditionsbecause it allows pump to take in air along with fluid.Air trapped in hydraulic circuit forms bubbles which makefluid spongy.Therefore, pressures will be erratic.Improper filling can also raise fluid level too high. Whentransaxle has too much fluid, gears churn up foam andcause same conditions which occur with low fluid level,resulting in accelerated deterioration of ATF.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 fluidescaping from transaxle vent where it may be mistakenfor a leak.

6. Be sure to examine fluid on dipstick closely.

(Change fluid)

1. Place a drain container with a large opening, under the

transaxle oil pan.2. Loosen the pan bolts and tap the .pan at one comer

to break it loose allowing fluid to drain, then remove theoil pan.

3. Install a new filter and O-ring on bottom of the valvebody.

4. Clean the oil pan and magnet.Apply the specified sealant to the oil pan.

Specified sealant:Loctite 18718 or equivalent

Tighten the oil pan mounting bolts to the specified torque:

Tightening torque:19 Nm (14 ft.lbs.)

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GENERAL - Maintenance Service O&47

5. Add 3.8 dm3 (4.0 qts.) of the specified transmission fluidthrough the filler tube.

Specified fluid:DIAMOND ATF SP II or equivalent

6. Start the engine and allow it to run at idle for at leastone minute. Then, with parking and service brake applied,move the selector lever momentarily to each position,ending in the park or neutral position.

7. Add sufficient fluid to bring lever to l/8 inch below theADD mark. ,A

8. Recheck fluid level after transaxfe is at normal operatingtemperature. The level should be in the HOT region.

Drain the fluid and check whether there is any evidence ofcontamination.Refill with new fluid after the cause of any contaminationhas 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 replace

if necessary.4. Clean the inside of oil pan and magnets.5. Attach the magnets to the concave part of the oil pan.

6. Clean both gasket surfaces of transaxle case and oil

7. p,,1all oil pan with new gasket and tighten oil pan bolts.

Oil pan bolt: 11 Nm (8.0 klbs.)

8. Tighten drain plug with gasket to specified torque.

Specified torque:

(A) 39 Nm (29 ft.lbs.)(B) 29-34 Nm (22-25 ft.lbs.)

(A) 39 Nm (29 ft.lbs.)(B) 39 Nm (29 klbs.)

9. Fill new ATF up to the COLD mark on the dipstick.

Transmission fluid:DIAMOND ATF SP II or equivalent

10. Start engine and allow to idle for at least two minutes.Then, with parking brake on, move selector lever momen-tarily to each position, ending in N Neutral Rosition.

11. Check if ATF is filled up to the HOT mark on the dipstick.

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- , m 09AOO24

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Drain Pluge

04FOOO4

13. TRANSFER OIL ooloowool0(Check oil level) ,.

Check each component for evidence of leakage, and-checkthe oil level by removing the filler plug:lf the oil is contammated,it is necessary to replace it with new oil.1. With the vehicle parked at a level place, remove tlie filler,

plug.

I

,I

2. Check that the transfer oil level is at the loti& portionof the filler plug hole.

3. Check to be sure that the transfer oil is not noticeably

14woo95

2. For non-turbo, remove the drain plug from thecyiinderblock to drain engine coolant.For turbo, remove the water hose from the water pipeassembly (C) to do so.

3.4.

5.

Remove the reserve tank to drain the @gine coolant.When the engine coolant has drained, pour in water fromthe cap to clean the engine coolant line.For non-turbo, install the drain plug to the cylinder block.For turbo, install the water hose to the..water pipe assemblyw

6.7.8.

Securely tighten the radiator drain plug.Install the reserve tank.

9.

Slowly pour the engine coolant into the mouth of theradiator until the radiator is full, and pour also into thereserve tank up to the FULL line.

Recommended antifreeze:DIA-QUEEN LONG-LIFE COOLANT (Part No. 0103044)or high quality ethylene-glycol antifreeze coolant)

Quantity 7.0 dm3 (7.4 qts.)

Install the cap securely.10.: Start the engine and warm the engine until the thermostat

opens. (Touch the radiator hose with your hand to checkthat warm water is flowing.)

11. After the thermostat opens, race the engine at 3,000r/min 3 times.

12. After the engine is stopped, wait until the engine hascooled down, and then remove the cap to check thelevel of the liquid. If the level is low, repeat the operationfrom step 9.Lastly, if the level does not drop, fill the condense tankwith coolant up to the FULL line.

15. DISC BRAKE PADS (Check for wear) 00100~20054Check for fluid contamination and wear. Replace completeset of pads if defective.

CautionThe pads for the right and left wheels should be replacedat, the same time. Never split or intermix brake padsets.All four pads must be replaced as a complete set.

Thickness of lining (A)Limit: 2.0 mm (.08 in.)

16. REAR DRUM BRAKE LININGS Ai@-Ri%3. WHEEL CYLINDERS (Check- for 8weai. andl e a k s ) jhdoo4o ;

1. Remove the brake drum and check the,thicknqbs of brakeshoe lining for wear. Check the automatic brake adjustingsystem by hand to see if it operates smoothly.Also see if the gears are in proper mesh with each other.To assure smooth operation, apply a vety thin coat ofmultipurpose grease to the friction surface of adjusterand link shaft.

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14WOOB6

2. Check the wheel cylinder boots for evidence, of, a brakefluid leak. Visually check the boots for cufs, tears or ii&tcracks. (A slight amount of fluid on the boot may notbe a leak, but may be preservative fluid,tisqd a? assembly.) :Caution v

The shoes for the right and left &h6els shyuld be,replaced at the same time.Never split or intermix brake shti sets. All four shoes must be replaced as a cdmljlete set.

Thickness of lining (A)Limit: 1.0 mm (.04 in.)

17. BRAKE HOSES (Check for deterio&tioh %wleaks) OOlW34OW

.,

Check of brake hoses and tubing should be inclt.@d iii alallbrake service operations.

The hoses should be checked for:1. Correct length, severe surface cracking, pulling, scuffing

or worn spots. (If the fabric casing of the hoses is exposedby cracks of abrasion in the rubber hose cover, the hosesshould be replaced. Eventual deterioration of boss mayoccur with possible bursting failure.)

2. Faulty installation, casing twisting or interference Withwheel, tire or chassis.

18. BALL JOINT AND STEERING LINKAGE SEALS(Check for grease leaks tind damage)

001OOSOO46

1. These components, which are permanently lubricatedat the factory, do not require periodic lubrication. Damagedseals and boots should be replaced to prevent leakageor contamination of the grease.

2. Check the dust cover and boots for proper sealing, leakageand damage. Replace them if defective.

19. DRIVE SHAFT BOOTS (Check for grease leaks and damage) 001ooa6oo4s

1. These components, which are permanently lubricatedat the factory, do not require periodic lubricstton. Damagedboots should be replaced to prevent leakage or contamina-tion of the grease.

2. Check the boots for proper sealing, leakage and damage.Replace it if defective.

20.REAR AXLE OIL (Check oil level)-AWD00100750011

Remove the filler plug and check the oil level at bottom offiller hole. If the oil level is slightly below the filler hole, itis in satisfactory condition.

GENERAL - Maintenance Setike oa43~~

21 SRS SYSTEM (SRS component check:damage, function, conn,ection to wiring,harness, etc.) imaa7oD66

Certification labelManufacture date

I

YII-lwl!:-w -23

00xm.3

oooo3e75

SRSlight

Insulating tape

AlQZ0001

The SRS must be inspected by an authorized-deater~gyea~safter the .car manufacture date shown,,.on the certificationlabel located on left center pillar.,. .: ,

. .

SRS WARNING LIGHT CHECK,

Turn the ignition key to the ON position. Does the SWwarning light illuminate for about 7 seconds, turn OFF andthen remain extinguished for at least 45 seconds? If yes,SRS system is functioning properly. If not, refer to GROUP528 - Troubleshooting.

SRS COMPONENTS VISUAL CHECK1. Turn the ignition key to L&K position, disconnect the

negative battery cable and tape the terminal..fCautionWait at least 60 seconds &ter disconnecting the bat-tery cable before doing any further tiork.The SRS system is designed to retain enough voltageto deploy the air bag for a short tirneeven after thebattery has been disconnected, so serlous fnjury mayresult from unintended air bag deployment ff workis done on the SRS system immediately tier the ,b&tery cable is disconnected. , 1.

2. Remove the floor console assembly. (Refer to, GROUP52A - Floor Console.) ~ :

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0 0 0 0 0 1 6 7

Inflator case

Connect&

SRS-ECU CHECKCheck SRS-ECU case and brackets for dents, cracks,deformities or rust.

CautionThe SRS may not activate if a front impact sensor Isnot installed properly, which could result In serious injuryor death to the driver and passenger.

,

AIR BAG MODULE, STEERING WHEFL AND CLOCKSPRING CHECK1. Remove the air bag module, .steering wheel and clock

spring. (Refer to GROUP 528 - .@ -l$ag,,Module andClock Spring.) ? ! ,. *CautionThe removed air bag module should be stored In aclean, dry place with the pad cover face up.

2. Check pad cover for dents, cracks of deformities.

3. Check connector for damage, terminals deformities, andharness for binds.

4. Check air bag inflator case for dents, cracks or deformities.5. Check harness (built into steering wheel) and connectors

for damage, and terminals for deformities.

19X0560

GENERAL - Maintenance Servide

Protective tube

A19X0554

harness

-I

6. Check clock spring connectors and protective tube fordamage, and terminals for deformities.

7. Visually check the clock spring case for damage.8. Align the mating mark of the clock spring and, after turning

the vehicles front wheels to straightahead position, installthe clock spring to the column switch.

Mating mark alignmentTurn the clock spring fully clockwise, and turn back itapprox. 3 and l/8 turns counterclockwise to align themating marks.

CautionIf the clock springs mating mark is not properlyaligned, the steering wheel may not be completelyrotational during a turn, or the flat cable within theclock spring may be severed, obstructing normal op-eration of the SRS and possibly leading to seriousinjury to the vehicles driver and passenger.

9. Install the steering column covers, steering wheel andthe air bag module.

10. Check steering wheel for noise, binds of difficult operation.11. Check steering wheel for excessive free play.

REPLACE ANY VISUALLY INSPECTED PART IF ITFAILS THAT INSPECTION.

(Refer to GROUP 528 -Air Bag Module and Clock Spring.)

CautionThe SRS may not activate if any of the above compo-nents is not installed properly, which could resultin serious injury or death to the vehicles driver andpassenger.

INSTRUMENT PANEL WIRING HARNESS AND BODYWIRING HARNESS1. Check connector for poor connection.2. Check harnesses for binds, connectors for damage, and

terminals for deformations.REPLACE ANY CONNECTORS OR HARNESS THATFAIL THE VISUAL INSPECTION.(Refer to GROUP 528 - SRS Service Precautios.)

CautionThe SRS may not activate if SRS harnesses or connec-tors are damaged or improperly connected, whichcould result in serious injury or death to the vehiclesdriver and passenger.

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00-54 GENERAL - Maintenance Service;

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22. EXHAUST SYSTEM (CONNECTION PORTION;OF MUFFLER, PIPINGS AND, CONVERTERHEAT SHIELDS) (Check anti I Feryice as

required) I omo5800491. Check for holes and gas leaksdwe to damage; &orrosion,

etc.2. Check the joints and connections for looseness and gas

leaks. /3. Check the hanger rubber and brackets for damage.

GENERAL - Main Sealant and Adhesive Table

MAIN SEALANT AND ADHESIVE TABLESEALANTS FOR ENGINE ACCESSORIES

00-55

0016dssoo52

Application Recommended brand

Sealing between rocker cover and camshaft bearing cap (4G6 DOHC 3M ATD Part No. 8680 or equivalentand 6G7 engines only)

1Sealing between semi-circular packing and rocker cover and betweensemi-circular packing and cylinder head

Oil pressure switch (except 4Gl and 6G7 engines). . . ,.

Engine coolant temperature switch, Engine coolant temperature sensor,3M Nut Locking Part No. 4171 or equiva-Therm0 valve, Therm0 switch, Joints, Engine coolant temperature lent ,. 8

gauge unit (large size),

Engine coolant temperature gauge unit (small size, MD091056 only) 3M ATD Part No. 8660 or equivalent

Oil pan (except 4G5 engine) MITSUBISHI GENUINE Part No.*MD99711 0 or equivalent ,I

SEALING BETWEEN GLASS AND WEATHERSTRIP

Application

Sealing between tempered glass and weatherstrip

Sealing between body flange and weatherstrip

Sealing between laminated glass and weatherstrip

Recommended brand

3M ATD Part No. 8513 or equivalent

3M ATD Part No. 8509 or equivalent

ADHESION WITH RIBBON SEALER

Application Recommended brand

Waterproof film for door, Fender panel, Splash shield, Mud guard, Rear3M ATD Part No. 8625 or equivalentcombination light

Mitsubishi Eclipse Service Manual 1995-1999

Documents

Transcript of Mitsubishi Eclipse Service Manual 1995-1999