Mitsubishi Laser Talon & Eclipse Workshop Service Manual 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999 (6525 pages

Includes Engine Transaxle Overhaul 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. WE SUPPORT VOLUNTARY TECHNICIAN CERTIFICATION THROUGH AUTOMOTIVE SERVICE EXCELLENCE 1996 Mitsubishi Motors Corporation Printed in U.S.A. ... General ...................... . Engine .............. ........... Engine Lubrication ........ . . Fuel ...................... .. Engine . .. ...... Intake and Exhaust, . . ............ . . Engine and Emission Control, ... Clutch ......................... Manual Transaxle .............. Automatic Transaxle ........... Propeller ................. Front Axle ..................... Rear Axle ...................... Wheel and Tire ................. Power Plant Mount ............. Front Suspension .............. Rear Suspension .............. Service Brakes ................ Parking Brakes ................ Steering ....................... Body .......................... Exterior ....................... Interior and Supplemental Restraint System (SRS) ........ Heater, Air Conditioning and Ventilation .................... Alphabetical Index .............. in Volume 2 “Electrical” of this paired Service Manu- al.

REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES WARNING! (1) Improper service or maintenance of any component of the SRS, or any component, can lead to personal injury or death to service personnel firing. of the bag) or to the driver and passenger (from rendering the SRS inoperative). (2) If it is possible that the SRS components are heat over baklng or in drying after painting, remove the SRS components (air bag module, beforehand. (3) Service or maintenance of any SRS component or SRS-related component be performed only at an authorized MITSUBISHI dealer. (4) MITSUBISHI dealer personnel must thoroughly review this manual, and Its GROUP 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

CONTENTS GENERAL DATA AND SPECIFICATIONS .. 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 .. 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 ......... Exhaust System ............................. 54 Fuel Hoses ................................. 38 Fuel System ................................ 38 Ignition Cables .............................. 40 Manual Transaxle Oil ........................ Rear Axle Oil ............................ 50 Rear Drum Brake Linings and Rear Wheel Cylinders ....................... Spark Plugs ................................ 40 SRS System ............................... 51 Timing Belt ................................. 40 Transfer Oil ................................ 48 PRECAUTIONS BEFORE SERVICE ........ 20 RECOMMENDED LUBRICANTS LUBRICANT CAPACITIES TABLE .......... 34 SCHEDULED MAINTENANCE TABLE ..... 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

GENERAL How to Use This HOW TO USE THIS MANUAL 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 10% except the following cases when the upper. and of tightening torque are given. (1) The tolerance of the ‘basic value 10%. (2) Special bolts or, the ‘like are (3) Special tightening methods are used. SPECIAL TOOL NOTE When the MMC special tool is described, please refer to the special tool is located at the beginning of each group, for a cross reference from the tool, number to the special tool number that available in your market. . 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 fuel injection, or engines equipped with the fuel injection. Turbo: Indicates the engine with turbocharger, or models equipped such an 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 braking

GENERAL How to Use This Manual EXPLANATION OF MANUAL CONTENTS Maintenance and Servicing Procedures l l Classifications of Major Maintenance Service points Symbols for Lubrication, Sealants and Adhesives a

GENERAL How to Use This Manual 1 STEERING Power Steering Gear BOX POWER STEERING GEAR BOX 6 gear . TIE-ROD END . Operating procedures, etc. on removal, assembly 1. sun tie the cord of the special tool described. 2. Loosen the nut but do not FOG LIGHT RELAY CHECK I indicates that there is 1 3 4 , continuity’ between the o---a nals. supplied indicates terminals‘ to which battery STEERING Power Steering Box

GENERAL How to Use Troubleshooting/Inspection Service Points Troubleshooting of electronic control systems for which the scan tool the basic outline described below. Furthermore, even in systems for which the scan tool cannot be used, part of these systems still follow this outline. TROUBLESHOOTING CONTENTS 1. STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING The main procedures for diagnostic troubleshooting are shown. 2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS If verification of the trouble symptoms is difficult, procedures for checking operation and verifying trouble symptoms are shown. 3. DIAGNOSTIC FUNCTION The following diagnostic functions are shown. l , Method of reading diagnostic trouble codes Method of erasing diagnostic trouble codes l Input inspection service points 4. INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES 5. INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES Indicates the inspection procedures corresponding to each diagnostic trouble code. (Refer to the next page on how to use the inspection procedures.) 6. INSPECTION CHART FOR TROUBLE SYMPTOMS If there are trouble symptoms, even though the scan tool displays no diagnostic inspection procedures 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 the Inspection Chart for Trouble Symptoms. (Refer to the next page on how to use the inspection procedures.) 8. DATA LIST REFERENCE TABLE Inspection items and normal judgement values have been provided in this chart as reference 9. CHECK AT ECU TERMINALS Terminal numbers for the ECU connectors, inspection items and standard values have been provided in this chart as reference information. Terminal Voltage Checks 1. 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 from the wire side, and measure the voltage while referring to the check chart. NOTE 1. 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 don’t have to be carried out in the order given in the chart. Short-circuiting the positive probe between a connector damage the vehicle wiring, the sensor, the ECU, or all three. Use care to prevent this 3. If voltage readings differ from Normal Condition values, related actuators, and wiring, then replace or repair. TSB Revision

GENERAL How to Use Troubleshooting/Inspection Service Points 4. After repair or replacement, recheck the voltmeter to confirm the repair the problem. Terminal Resistance and Continuity Checks 1. 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 connector while referring to the check chart. NOTE Checks don’t have to be carried out in the order given in the chart. Cautlon If resistance and continuity checks are performed the wrong terminals, damage vehicle wiring, sensors, ECU, and/or ohmmeter may occur. Use care to prevent this! 4. 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 the problem. 10. INSPECTION PROCEDURES USING AN OSCILLOSCOPE When there are inspection procedures using an oscilloscope, these are listed here. , TSB Revision

GENERAL How to Use Service HOW TO USE THE INSPECTION PROCEDURES . . , The causes of a high frequency of problems occurring in electronic circuitry are generally components, the ECU and the harnesses between in that These follow this order, and they first try to discover a problem with a connector or a 17 Check trouble I Caution After carrying out connector inspection, always be sure to the connector as it was before. so check the harness. and check HARNESS INSPECTION Check for an open or short circuit in the harness between the terminals which were defective according to 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 Blown Fuse”. MEASURES TO TAKE AFTER REPLACING THE ECU If the trouble symptoms have not disappeared even after replacing the ECU, repeat the inspection procedure from the beginning. TSB Revision ,

Mitsubishi Laser Talon & Eclipse Workshop Service Manual 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999 (6525 pages

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