MITSUBISHI ECLIPSE & ECLIPSE SPYDER Service & Repair Manual (1997 1998 1999) - !

BACKUP Service Manual’ ECIB’SE/ ECII’SE Volume 1 Chassis & Body Includes Engine & Transaxle Overhaul FOREWORD This 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 diagnostic, 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 reliability designed into these outstanding vehicles. This BACKUP DSM manual IS to be used ONLY as a BACKUP. Please DO NOT REDISTRIBUTE WHOLE SECTIONS. This BACKUP was sold to you under the fact that you do indeed OWN a GENUINE DSM MANUAL. It CANNOT BE considered a REPLACEMENT (Unless your original manual was lost or destroyed.) Please See README.N or README.HTML for additional Information. Thank you. G~mm~emymanual@hotma~l.com WE SUPPORT VOLUNTARY TECHNICIAN CERTIFICATION THROUGH National lnritlfulc for AUTOMOTIVE SERVICE EXCELLENCE MITSUBISHI MOTOR SALES OF AMERICA. Inc. Mitsubishi Motors Corporation reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obligations upon itself to install them on its products previously manufactured. @ 1996 Mitsubishi Motors Corporation Printed in U.S.A. -I GRWB ‘HVPEX. ’ ... “wy+ General ...................... ..?, . ,.,m Engine .............. .:. ........... “ mm Engine Lubrication ........ . :‘1.‘ J . “” m Fuel ...................... ..i .. I’ mm Engine Cooli.ng, . ‘. .. .,I ...... ; ; ;-I. * :m Intake and Exhaust, . . ............ . . ” :I- Engine and Emission Control, ... F ;im Clutch ......................... Manual Transaxle .............. Automatic Transaxle ........... Propeller Shaft ................. Front Axle ..................... ma Rear Axle ...................... ma Wheel and Tire ................. Power Plant Mount ............. m Front Suspension .............. Rear Suspension .............. m Service Brakes ................ Parking Brakes ................ mm Steering ....................... Body .......................... mm Exterior ....................... Interior and Supplemental Restraint System (SRS) ........ Heater, Air Conditioning and Ventilation .................... Alphabetical Index .............. NOTE: Electrical system information is contained in Volume 2 “Electrical” of this paired Service Manu- al.

WAR,NINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT 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 subjected’to heat over 93°C 4290 In baklng or in 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 performed only 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 component 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. .I __ I ., ‘\ , :j ‘( ‘ ‘_ <’ .a II I ,: i” *a ,” I. . . ._

f.)fJ$$ I” L ,, #_v,: .,,.,, 1/_ ?,.*A.- GENERAL CONTENTS oolo9ooo171 GENERAL DATA AND SPECIFICATIONS .. .28 HOW TO USE THIS MANUAL ............. 3 Explanation of Manual Contents .............. 4 Model Indications ........................... 3 Maintenance, Repair and Servicing Explanations. ...................... 3 Special Tool Note ........................... 3 Terms Definition ............................ 3 Tightening Torque Indication ................. 3 HOW TO USE TROUBLESHOOTING/ INSPECTION SERVICE POINTS ............ 6 Connector Inspection Service Points .......... 10 Connector Measurement Service Points ........ 9 How to Cope with Intermittent Malfunctions ... 11 How to Use the Inspection Procedures ....... 8 Inspection Service Points for a Blown Fuse ... 12 Troubleshooting Contents .................... 6 LUBRICATION AND MAINTENANCE ....... 33 MAIN SEALANT AND ADHESIVE TABLE .. .55 MAINTENANCE SERVICE .................. 38 Air Cleaner Element ........................ 39 Automatic Transaxle Fluid ................... 45 Ball Joint and Steering Linkage Seals ........ 50 Brake Hoses .. . ............................ 50 Disc Brake Pads ............................ 49 Drive Belt (For Generator, Water Pump, Power Steering Pump) ............................. 40 Drive Shaft Boots ........................... 50 Engine Coolant ............................. 48 Engine Oil .................................. 42 Engine Oil Filter ............................ 43 Evaporative Emission Control System ......... 39 Exhaust System ............................. 54 Fuel Hoses ................................. 38 Fuel System ................................ 38 Ignition Cables .............................. 40 Manual Transaxle Oil ........................ 44 Rear Axle Oil ............................ 50 Rear Drum Brake Linings and Rear Wheel Cylinders ....................... 49 Spark Plugs ................................ 40 SRS System ............................... 51 Timing Belt ................................. 40 Transfer Oil ................................ 48 PRECAUTIONS BEFORE SERVICE ........ 20 RECOMMENDED LUBRICANTS .AND LUBRICANT CAPACITIES TABLE .......... 34 SCHEDULED MAINTENANCE TABLE ..... .37 SPECIAL HANDLING INSTRUCTIONS FOR AWD MODELS ............................ 26 TIGHTENING TORQUE .................... 32 TOWING AND HOISTING .................. 22 VEHICLE IDENTIFICATION ................. 13 Engine Model Stamping ..................... 15 Theft Protection ............................. 18 Vehicle Identification Code Chart Plate ....... 13 Vehicle Identification Number List ............ 14 Vehicle Identification Number Location ........ 13 Vehicle Information Code Plate. .............. 15 Vehicle Safety Certification Label ............. 15

00-2 NOTES ‘Jp& “, / i ‘_ :.‘: .e” “. ,” ,/: 9, “I : I. I d: . ‘1 ,_ ,.“1, > : ,:, , ‘1.. < I,r : .I I,” * ,.. r ,L- ,: 1 .” p: ,%,“? : 4, Crr / :,.. ‘, ,, P i . ,. . . . itr ,/ : . . B I ,,, L. ;j ,, ‘r ..I : . a1 ,. (“2,. _, r I” ,; “” U’ c , ,, ‘i ., 1 : ” . _: ‘/ I- ,‘i I. “\al’? ;, : : .-, ,I. x i c ,‘” t, ,, .-I :, .! ‘T ,a / L _I L: i.. ,.* ,,C ; i . 7* _:

GENERAL - How to Use This Manual HOW TO USE THIS MANUAL ‘* 3 ” mu%& MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS This manual provides explanations, etc. concerning procedures for the inspection, maintenance, repair and servicing of the subject model. Unless other- wise specified, each service procedure covers all models. Procedures covering specific models are identified by the model codes, or similar designation (engine type, transaxle type, etc.). A description of these designations is covered in this manual under “VEHICLE IDENTIFICATION”. ON-VEHICLE SERVICE “On-vehicle Service” are procedures for performing inspections and adjustments of particularly impor- tant locations with regard to the construction and for maintenance and servicing, but other inspections (for looseness, play, cracking, damage, etc. ) must also be performed. SERVICE PROCEDURES The service steps are arranged in numerical order and attention must to be paid in performing vehicle service are described in detail in SERVICE POINTS. TERMS DEFINITION STANDARD VALUE Indicates the value used as the standard for judging the quality of a part or assembly on inspection or the value to which the part or assembly is cor- rected and adjusted. It is given by tolerance. LIMIT Indicates a maximum or minimum value, the part or assembly should be kept within, in order to be functional. This value is established outside the standard value range. REFERENCE VALUE Indicates the adjustment value prior to starting the work (presented in order to facilitate assembly and adjustment procedures, and so they can be com- pleted in a shorter time). CAUTION Indicates the presentation of information particularly vital to the worker during the performance of maintenance and servicing procedures in order to avoid the possibility of injury to the worker, or damage to component parts, or a reduction of component or vehicle function or performance, etc.. TIGHTENING TORQUE INDICATION The tightening torque shown in this manual is a basic value with a tolerance of f 10% except the following 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, please refer to the special tool cross~ referencechart, Which is located at the beginning of each group, for a cross reference from the MMGspecial tool, number to the special tool number that is available in your market. ,I “” . ,, ‘> MODEL INDICATIONS The 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 an engine. 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. ,( t,. ,*,, 2: .y; 3’

MITSUBISHI ECLIPSE & ECLIPSE SPYDER Service & Repair Manual (1997 1998 1999) - !

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