Mitsubishi Eclipse 2000, Eclipse 2001, Eclipse 2002 User Manual

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GROUP 00

GENERAL

CONTENTS

GENERAL <BODY AND CHASSIS> . . . . . . . . . . . . . . . . . . . . . 00

GENERAL <ELECTRICAL> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00E

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Page 2

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GROUP 00

GENERAL

CONTENTS

HOW TO USE THIS MANUAL. . . . . . 00-3

TROUBLESHOOTING GUIDELINES 00-6

HOW TO USE TROUBLESHOOTING/

INSPECTION SERVICE POINTS. . . . 00-6

VEHICLE IDENTIFICATION . . . . . . . 00-15

VEHICLE IDENTIFICATION. . . . . . . . . . . . 00-15

VEHICLE IDENTIFICATION CODE PLATE 00-17

PRECAUTIONS BEFORE SERVICE. 00-21

TOWING AND HOISTING . . . . . . . . . 00-23

GENERAL DATA AND

SPECIFICATIONS . . . . . . . . . . . . . . . 00-27

TIGHTENING TORQUE . . . . . . . . . . . 00-30

LUBRICATION AND MAINTENANCE 00-31

RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE . . 00-32

SCHEDULED MAINTENANCE TABLE 00-35

MAINTENANCE SERVICE . . . . . . . . 00-38

FUEL SYSTEM (TANK, PIPE LINE AND CONNECTION, AND FUEL TANK FILLER

TUBE CAP) (CHECK FOR LEAKS) . . . . . . 00-38

FUEL HOSES (CHECK CONDITION) . . . . 00-38

AIR CLEANER ELEMENT (REPLACE) . . . 00-38

EVAPORATIVE EMISSION CONTROL SYSTEM (EXCEPT EVAPORATIVE EMISSION CANISTER)

(CHECK FOR LEAKS AND CLOGGING) . . 00-38

SPARK PLUGS (REPLACE). . . . . . . . . . . . 00-39

IGNITION CABLES (REPLACE) . . . . . . . . . 00-39

DISTRIBUTOR CAP AND ROTOR (CHECK)

<3.0L ENGINE>. . . . . . . . . . . . . . . . . . . . . . 00-40

TIMING BELT (REPLACE) . . . . . . . . . . . . . 00-40

DRIVE BELT (FOR GENERATOR, WATER PUMP, A/C COMPRESSOR AND POWER STEERING PUMP)

(CHECK CONDITION) . . . . . . . . . . . . . . . . 00-40

ENGINE OIL (CHANGE) . . . . . . . . . . . . . . . 00-47

ENGINE OIL FILTER (REPLACE) . . . . . . . 00-48

MANUAL TRANSMISSION OIL . . . . . . . . . 00-49

AUTOMATIC TRANSMISSION FLUID . . . . 00-49

ENGINE COOLANT (CHANGE) . . . . . . . . . 00-52

DISC BRAKE PADS (INSPECT FOR WEAR) 00-53

REAR DRUM BRAKE LININGS AND REAR WHEEL CYLINDERS

(INSPECT FOR WEAR AND LEAKS). . . . . 00-53

BRAKE HOSES (CHECK FOR DETERIORATION

OR LEAKS) . . . . . . . . . . . . . . . . . . . . . . . . . 00-54

BALL JOINT AND STEERING LINKAGE SEALS (INSPECT FOR GREASE LEAKS

AND DAMAGE) . . . . . . . . . . . . . . . . . . . . . . 00-54

DRIVE SHAFT BOOTS (INSPECT FOR

GREASE LEAKS AND DAMAGE). . . . . . . . 00-54

SRS AIR BAG

(INSPECT FOR SRS SYSTEM) . . . . . . . . . 00-55

EXHAUST SYSTEM (CONNECTION PORTION OF MUFFLER, PIPINGS AND CONVERTER HEAT SHIELDS) (CHECK AND SERVICE AS

REQUIRED) . . . . . . . . . . . . . . . . . . . . . . . . 00-60

TIRES (ROTATE) . . . . . . . . . . . . . . . . . . . . 00-60

AIR PURIFIER FILTER (REPLACE) . . . . . . 00-60

MAIN SEALANT AND ADHESIVE TABLE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-61

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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GENERAL <BODY AND CHASSIS>

HOW TO USE THIS MANUAL

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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 otherwise 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 important 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. Attention must to be paid in performing vehicle service are described in detail in SERVICE POINTS.

DEFINITION OF TERMS

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 corrected and adjusted. It is given by tolerance.

LIMIT

Shows the standard for judging the quality of a part or assembly on inspection and means the maximum or minimum value within which the part or assembly must be kept functionally or in strength. It is a value established outside the range of standard value.

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 completed in a shorter time).

M1001000100110

DANGER, WARNING, AND CAUTION

DANGER, WARNING, and CAUTION call special attention to a necessary action or to an action that must be avoided. The differences among DANGER, WARNING, and CAUTION are as follows:

• If a DANGER is not followed, the result is severe bodily harm or even death.

• If a WARNING is not followed, the result could be bodily injury.

• If a CAUTION is not followed, the result could be damage to the vehicle, vehicle components or service equipment.

TIGHTENING TORQUE INDICATION

The tightening torque indicates a median and its tolerance by a unit of N⋅m (in-lb) or N⋅m (ft-lb). For fasteners with no assigned torque value, refer to

P.00-30.

SPECIAL TOOL NOTE

Only MMC special tool part numbers are called out in the repair sections of this manual. Please refer to the special tool cross reference chart, which is located in the service manual at the beginning of each group, for a cross reference from the MMC special tool number to the special tool number that is available in your market.

MODEL INDICATIONS

The following abbreviations are used in this manual for classification of model types. M/T:Indicates manual transaxle, or models equipped

with manual transaxle.

A/T: Indicates automatic transaxle, or models

equipped with automatic transaxle.

MFI: Indicates multiport fuel injection, or engines

equipped with multiport fuel injection.

A/C: Indicates air conditioning.

2.4L Engine: Indicates the 2.4 liter <4G64> engine, or a model equipped with such an engine.

3.0L Engine: Indicates the 3.0 liter <6G72> engine, or a model equipped with such an engine.

PCM: Powertrain control module ECM: Engine control module SWS: Simplified Wiring System

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GENERAL <BODY AND CHASSIS>

HOW TO USE THIS MANUAL

<<A>>

>>A<<

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ACX00859

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GENERAL <BODY AND CHASSIS>

HOW TO USE THIS MANUAL

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(continued)

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ACX00860

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GENERAL <BODY AND CHASSIS>

TROUBLESHOOTING GUIDELINES

VERIFY THE COMPLAINT

• Make sure the customer's complaint and the service writer's work order description are understood before starting work.

• Make sure the correct operation of the system is understood. Read the service manual description to verify any aspect of normal system operation.

• Operate the system to see the symptoms. Look for other symptoms that were not reported by the customer, or on the work order, that may be related to the problem.

DETERMINE POSSIBLE CAUSES

Compare the confirmed symptoms to the diagnostic symptom indexes to get to the right diagnosis procedure. If the confirmed symptoms can not be found on any symptom index, determine other possible causes.

• Analyze the system diagrams and list all possible causes for the problem symptoms.

• Rank all these possible causes in order of probability, based on how much of the system they cover, how likely they are to be the cause, and how easy they will be to check. Be sure to take experience into account. Consider the causes of similar problems seen in the past. The list of causes should be ranked in order from general to specific, from most-likely to least-likely, and from easy-to-check to hard-to-check.

M1001008800102

FIND THE PROBLEM

After the symptoms have been confirmed, and probable causes have been identified, the next step is to make step-by-step checks of the suspected system components, junctions, and links in logical order. Use the diagnostic procedures in the service manual whenever possible. Follow these procedures carefully to avoid missing an important step in the diagnosis sequence. It might be the skipped step that leads to the solution of the problem. If the service manual doesn't have step-by-step procedures to help diagnose the problem, come up with a series of checks based on the ranked list of probable causes. Troubleshooting checks should be made in the order that the list of causes was ranked:

• general to specific

• most-likely to least-likely

• easy-to-check to hard-to-check

REPAIR THE PROBLEM

When the step-by-step troubleshooting checks find a fault, perform the proper repairs. Make sure to fix the root cause of the problem, not just the symptom. Just fixing the symptom, without fixing the root cause, will cause the symptom to eventually return.

VERIFY THE REPAIR

After repairs are made, recheck the operation of the system to confirm that the problem is eliminated. Make sure to check the system thoroughly. Sometimes new problems are revealed after repairs have been made.

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE

POINTS

M1001000200098

Troubleshooting of electronic control systems for which the scan tool can be used follows the basic outline described below. 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

Troubleshooting strategy are shown.

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2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS

If verification of the symptoms is difficult, procedures for checking operation and verifying symptoms are shown.

3. DIAGNOSTIC FUNCTION

The following trouble code diagnosis are shown.

• How to read diagnostic trouble codes

• How to erase diagnostic trouble codes

• Input inspection service points

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GENERAL <BODY AND CHASSIS>

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

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4. DIAGNOSTIC TROUBLE CODE CHART

5. SYMPTOM CHART

If there are symptoms, even though the results of inspection using the scan tool show that all diagnostic trouble codes are normal, inspection procedures for each symptom will be found by using this chart.

6. DIAGNOSTIC TROUBLE CODE PROCEDURES

Indicates the inspection procedures corresponding to each diagnostic trouble code. (Refer to P.00-7.)

7. SYMPTOM PROCEDURES

Indicates the inspection procedures corresponding to each symptoms classified in the Symptom Chart. (Refer to P.00-7.)

8. SERVICE DATA REFERENCE TABLE

Inspection items and normal judgement values have been provided in this chart as reference information.

9. CHECK AT ECU TERMINALS

Ter mi nal n um be rs f or t he E CU c on ne ct or s, inspection items and standard values have been provided in this chart as reference information.

Termin a l Vo l tage Ch e ck s

1. Connect a needle-nosed wire probe to a voltmeter probe.

CAUTION

Short-circuiting the positive (+) probe between a connector terminal and ground could damage the vehicle wiring, the sensor, the ECU, or all three. Use care to prevent this!

2. Insert the needle-nosed wire probe into each of the ECU connector terminals from the wire side, and measure the voltage while referring to the check chart.

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

Checks don't have to be carried out in the order given in the chart.

3. If voltage readings differ from normal condition values, check related sensors, actuators, and wiring, then replace or repair.

4. After repair or replacement, recheck with the voltmeter to confirm that the repair has corrected the problem.

Termin a l Re s ist a nce a nd C ontinu i ty C heck s

1. Turn the ignition switch to "LOCK" (OFF) position.

2. Disconnect the ECU connector.

CAUTION

If resistance and continuity checks are performed on the wrong terminals, damage to the vehicle wiring, sensors, ECU, and/or ohmmeter may occur. Use care to prevent this!

3. Measure the resistance and check for continuity between the terminals of the ECU harness-side connector while referring to the check chart.

NOTE: Checks don't have to be carried out in the order given in the chart.

4. If the ohmmeter shows any deviation from the Normal Condition value, check the corresponding sensor, actuator and related electrical wiring, then repair or replace.

5. After repair or replacement, recheck with the ohmmeter to confirm that the repair has corrected the problem.

10. INSPECTION PROCEDURES USING AN

OSCILLOSCOPE

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

HOW TO USE THE INSPECTION PROCEDURES

The causes of many of problems occurring in electric circuitry are generally the connectors, components, the ECU and the harnesses between connectors, in that order. These inspection procedures follow this order. They first try to discover a problem with a connector or a defective component.

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GENERAL <BODY AND CHASSIS>

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

(1) Relevanta circuit(s) of the component which the DTC indicates are described.

(2) Shows the position of the connector(s) which are referred to in the above circuit(s).

(3) Explains about the operation principle of the component or its relevant parts in that circuit.

ACX00861

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GENERAL <BODY AND CHASSIS>

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

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(4) Explains about technicai details.

lower

(5) Describes the conditions for that DTC being set (stored).

(6) Describes possible cause(s)for that DTC.

(7) Describes the diagnosis procedure for that DTC.

(8) Describes the special tool(s) necessary for that DTC.

(9) Describes the inspection procedure for that DTC step by step.

HARNESS INSPECTION

Check for an open or short circuit in the harness between the terminals which were faulty according to the connector measurements. Carry out this inspection while referring to GROUP 00E, Harness Connector Inspection P.00E-2. Here, "Check

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ACX00862

harness between power supply and terminal xx" also includes checking for blown fuse. For inspection service points when there is a blown fuse, refer to "Inspection Service Points for a Blown Fuse P.00-

15."

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HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

GENERAL <BODY AND CHASSIS>

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.

CONNECTOR MEASUREMENT SERVICE POINTS

Turn the ignition switch to the "LOCK" (OFF) position when connecting and disconnecting the connectors. Turn the ignition switch to "ON" when measuring if there are no instructions to the contrary.

IF INSPECTING WITH THE CONNECTOR CONNECTED (WITH CIRCUIT IN A CONDITION OF CONTINUITY)

Required Special Tool:

MD998459: Test Harness

Waterproof Connectors

MD998459

Be sure to use special tool, MB998459. Never insert a test probe from the harness side, as this so will reduce the waterproof performance and result in corrosion.

CONNECTOR

ACX00863

AC001606

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 to permit insertion of the test probe, it should not be forced; use the backprobing tool for this purpose.

IF INSPECTING WITH THE CONNECTOR DISCONNECTED

• From front side of the connector

Required Special Tool:

MB991219:

Inspection Harness (Included in MB991223, Harness

Set)

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MB991219

GENERAL <BODY AND CHASSIS>

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

The inspection harness for connector pin contact pressure should be used. The test probe should never be forcibly inserted, as it may cause a defective contact.

• From back side of the connector (SRS-ECU harness side connector)

00-11

SRS-ECU HARNESS CONNECTOR

ACX00865

AC001607

Since the SRS-ECU harness connector is plated to improve conductivity, observe the warning below when checking this connector.

WARNING

Insert the backprobing tool into connector from harness side, and connect the tester to the backprobing tool. If any tool other than the backprobing tool is used, it may cause damage to the harness and other components. Furthermore, measurement should not be carried out by touching the backprobing tool directly against the terminals from the front of the connector. The terminals are plated to increase their conductivity, so that if they are touched directly by the backprobing tool, the plating may break, which will decrease reliability.

CAUTION

At this time, be careful not to short the connector pins with the test probes. To do so may damage the circuits inside the ECU.

To uc h t he p in d i re c tl y w i th t h e te st b a r.

ACX00867

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CONNECTOR DISCONNECTED OR IMPROPERLY CONNECTED

DEFECTIVE CONNECTOR CONTACT

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

GENERAL <BODY AND CHASSIS>

CONNECTOR INSPECTION SERVICE POINTS

VISUAL INSPECTION

• Connector is disconnected or improperly connected

• Connector pins are pulled out

• Due to harness tension at terminal section

• Low contact pressure between male and female terminals

• Low connection pressure due to rusted terminals or foreign

matter lodged in terminals

HARNESS WIRE BREAKAGE AT TERMINAL SECTION

LOW CONTACT PRESSURE

GOOD

BAD

ACX00868

ACX00869

CONNECTOR PIN INSPECTION

If the connector pin stopper is damaged, the terminal connections (male and female pins) will not be perfect even when the connector body is connected, because the pins may pull out of the back side of the connector. Therefore, gently pull the wires one by one to make sure that no pins pull out of the connector.

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GENERAL <BODY AND CHASSIS>

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

CONNECTOR ENGAGEMENT INSPECTION

Required Special Tool:

MB991219: Inspection Harness (contained in MB991223 Test

Harness)

Use special tool, MB991219 to inspect the engagement of the male pins and female pins. [Pin drawing force: 1 N (0.2 pound)

MB991219

or more]

00-13

ACX00870

HOW TO COPE WITH INTERMITTENT MALFUNCTIONS

Most intermittent malfunctions occur under certain conditions. If those conditions can be identified, the 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 driving conditions, weather, frequency of occurrence, and so on.

2. Determine the conditions from the customer's responses

Typically, almost all intermittent malfunctions occur from conditions like vibration, temperature and/or moisture change, poor connections. From the customer's responses, it should be reasoned which condition is influenced.

SIMULATION TESTS

NOTE: In case of difficulty in finding the cause of the intermittent malfunction, the data recorder function in the scan tool is effective.

3. Use simulation test

In the cases of vibration or poor connections, use the simulation tests below to attempt to duplicate the customer's complaint. Determine the most likely circuit(s) and perform the simulation tests on the connectors and parts of that circuit(s). Be sure to use the inspection procedures provided for diagnostic trouble codes and trouble symptoms. For temperature and/or moisture conditions related intermittent malfunctions try to change the conditions of the suspected circuit components, then use the simulation tests below.

4. Verify the intermittent malfunction is eliminated

Repair the malfunctioning part and try to duplicate the condition(s) again to verify the intermittent malfunction has been eliminated.

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GENERAL <BODY AND CHASSIS>

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

For these simulation tests, shake, then gently bend, pull, and twist the wiring of each of these examples to duplicate the intermittent malfunction.

• Shake the connector up-and-down, and right-and-left.

• Shake the wiring harness up-and-down, and right-and-left.

• Vibrate the part or sensor.

ACX00871

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BATTERY

LOAD SWITCH

FUSE

SHORTCIRCUIT OCCURRENCE SECTION

GENERAL <BODY AND CHASSIS>

VEHICLE IDENTIFICATION

INSPECTION SERVICE POINTS FOR A BLOWN FUSE

Remove the fuse and measure the resistance between the load side of the fuse and ground. Set the switches of all circuits which are connected to this fuse to a condition of continuity. If the resistance is almost 0 Ω at this time, there is a short somewhere between these switches and the load. If the resistance is not 0 Ω, there is no short at the present time, but a momentary short has probably caused the fuse to blow. The main causes of a short circuit are the following.

• Harness being clamped by the vehicle body

• Damage to the outer casing of the harness due to wear or

heat

• Water getting into the connector or circuitry

• Human error (mistakenly shorting a circuit, etc.)

00-15

LOAD

ACX00872

VEHICLE IDENTIFICATION

VEHICLES IDENTIFICATION NUMBER LOCATION

The vehicle identification number (VIN) is located on a plate attached to the left top side of the instrument panel.

AC000051

M1001000400122

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00-16

GENERAL <BODY AND CHASSIS>

VEHICLE IDENTIFICATION

VEHICLE IDENTIFICATION CODE CHART PLATE

All vehicle identification numbers contain 17 digits. The vehicle number is a code which tells country, make, vehicle type, etc.

NO. ITEMS CONTENTS

4A3AC33G11E 000001

1 2 3 4 5 6 7 8 9 10 11

AC002701

1Country 4: USA

2Make A: Mitsubishi

3Vehicle type 3: Passenger car

4Others A: Driver and passenger air bags

5Line C: ECLIPSE

E: ECLIPSE SPYDER

6Price class 3: Medium

4: High

5: Premium

8: Sports

7Body 4: 3-door hatch back

5: 2-door convertible

8Engine G: 2.4L

H: 3.0L

9Check digits* 0, 1, 2, 3, -----------9, X

10 Model year 1: 2001 year

11 Plant E: M i tsu b ishi Motor Manufacturing

of America, Inc.

12 Serial number 000001 to 999999

NOTE: *: Check digit means a singles number or letter X used to verify the accuracy of transcription of vehicle identification number.

VEHICLE IDENTIFICATION NUMBER LIST

ECLIPSE

VIN (EXCEPT SEQUENCE NUMBER)

4A3AC34G_1E MITSUBISHI ECLIPSE 2.4L D52AMNJEL4M

4A3AC44G_1E D52AMNHEL4M

4A3AC84H_1E 3.0L D53AMNXEL4M

4A3AC54H_1E D53AMNGEL4M

BRAND ENGINE

DISPLACEMENT

MODEL CODE

D52AMRJEL4M

D52AMRHEL4M

D53AMRXEL4M

D53AMRGEL4M

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ECLIPSE SPYDER

GENERAL <BODY AND CHASSIS>

VEHICLE IDENTIFICATION

00-17

VIN (EXCEPT SEQUENCE NUMBER)

4A3AE45G_1E MITSUBISHI ECLIPSE

BRAND ENGINE

DISPLACEMENT

2.4L D52ABNHEL4M

SPYDER

MODEL CODE

D52ABRHEL4M

4A3AE85H_1E 3.0L D53ABNXEL4M

D53ABRXEL4M

VEHICLE IDENTIFICATION CODE PLATE

The vehicle information code plate is riveted onto the cowl top

outer panel in the engine compartment. The plate shows model code, engine model, transmission model and body color code.

NO. ITEMS CONTENTS

1MODEL D53AMRG

EL4M

D53A: Vehicle model

MRGEL4M; Model series

2ENGINE6G72 Engine model

3EXT W69A Exterior code

4TRANS F4A51 F4A51:Transaxle model

M1001005400105

AC000053

AC000054

5COLOR W69 W69: Body color code

6TRIM 71H 71H: Interior code

7OPT Z31 Z31: Equipment code

For monotone color vehicles, the body color code shall be indicated.

VEHICLE SAFETY CERTIFICATION LABEL

The vehicle safety certification label is attached to the face of the left door sill. This label indicates the month and year of manufacture, Gross Vehicle Weight Rating (GVWR), front and rear G ross A xle Weight Rating (GAWR), and Vehicle Identification Number (VIN).

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2.4L ENGINE

3.0L ENGINE

GENERAL <BODY AND CHASSIS>

VEHICLE IDENTIFICATION

ENGINE MODEL STAMPING

The engine model is stamped on the cylinder block. These engine model numbers are as shown as follows.

ENGINE MODEL ENGINE DISPLACEMENT

4G64 2.4L

6G72 3.0L

The engine serial number is stamped near the engine model number.

AC000055

THEFT PROTECTION LABEL

FOR ORIGINAL PARTS

FOR REPLACEMENT PARTS

AC000056

AC000057

THEFT PROTECTION

In order to protect against theft, a Vehicle Identification Number (VIN) is attached as a plate or label to the following major parts of the engine and transmission, as well as main outer panels: Engine cylinder block, Transmission housing. Fender, Doors, Liftgate, Quarter panel, Hood, Bumpers. In addition, a theft-protection label is attached to replacement parts for the body outer panel main components, and the same data are stamped into replacement parts for the engine and the transmission.

CAUTION

Cautions regarding panel repairs:

1. When repainting original parts, do so after first masking the theft-protection label. After painting, be sure to peel off the masking tape.

2. The theft-protection label for replacement parts is covered by masking tape, so such parts can be painted as is. The masking tape should be removed after painting is finished.

3. The theft-protection label should not be removed from original parts or replacement parts.

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GENERAL <BODY AND CHASSIS>

VEHICLE IDENTIFICATION

LOCATIONS

TARGET ARE A (A : FO R OR IGIN A L E QUI PME N T PA RTS , B: F OR REP L AC E ME N T PA R TS )

00-19

ENGINE <4G64>

MANUAL TRANSAXLE <F5M42>

ENGINE <6G72>

AC000058

AC000061

MANUAL TRANSAXLE <F5M51>

AUTOMATIC TRANSAXLE

AC000059

AC000062

FENDER

THE ILLUSTRATION INDICATOR LEFT OUER SIDE. RIGHT

AC000060

SIDE IS SYMMETRICALLY OPPOSITE.

AC000063

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GENERAL <BODY AND CHASSIS>

VEHICLE IDENTIFICATION

TARGET ARE A (A : FO R OR IGIN A L E QUI PME N T PA RTS , B: F OR REP L AC E ME N T PA R TS )

QUARTER PANEL OUTER

AC000064

THE ILLUSTRATION INDICATOR LEFT OUER SIDE. RIGHT SIDE IS SYMMETRICALLY OPPOSITE.

HOOD

DOOR

AC000067

THE ILLUSTRATION INDICATOR LEFT OUER SIDE. RIGHT SIDE IS SYMMETRICALLY OPPOSITE.

LIFTGATE <ECLIPSE>

TRUNK LID <ECLIPSE SPYDER>

AC000065

AC004278

FRONT BUMPER

AC000068

AC000066

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GENERAL <BODY AND CHASSIS>

PRECAUTIONS BEFORE SERVICE

TARGET ARE A (A : FO R OR IGIN A L E QUI PME N T PA RTS , B: F OR REP L AC E ME N T PA R TS )

REAR BUMPER

00-21

AC000069

PRECAUTIONS BEFORE SERVICE

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

1. Items to follow when servicing SRS (1) Be sure to read GROUP 52B, Supplemental

Restraint System (SRS). For safe operation, please follow the directions and heed all warnings.

(2) Wait at least 60 seconds after disconnecting

the battery cable before doing any further work. The SRS system is designed to retain enough voltage to deploy the air bag even after the battery has been disconnected. Serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cable is disconnected.

(3) Warning labels must be heeded when

servicing or handling SRS components. Warning labels can be found in the following locations.

• Hood

• Sun visor

• Glove box

• SRS-ECU

• Steering wheel

• Air bag module (Driver's side or front

passenger's side)

• Side air bag module

• Clock spring

• Steering gear box

M1001000500088

(4) Always use the designated special tools and

test equipment.

(5) 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 is facing upward.

(6) Never attempt to disassemble or repair the

SRS components (SRS-ECU, air bag module and clock spring). If there is a defect, replace the defective part.

(7) Whenever you finish servicing the SRS, check

the SRS warning light operation to make sure that the system functions properly.

(8) Be sure to deploy the air bag before disposing

of the air bag module or disposing of a vehicle equipped with an air bag. (Refer to GROUP 52B P.52B-80, Air Bag Module Disposal Procedures.)

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

temperatures of over 93°C (200°F), so remove the SRS components before drying or baking the vehicle after painting. After re-installing them, check the SRS warning light operation to make sure that the system functions properly.

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00-22

GENERAL <BODY AND CHASSIS>

PRECAUTIONS BEFORE SERVICE

SERVICING ELECTRICAL SYSTEM

WARNING

Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING.

1. Note the following before proceeding with working on the electrical system.

Never perform unauthorized modifications to any electrical device or wiring. Such modifications might lead to a vehicle malfunction, over-capacity or short-circuit that could result in a fire in the vehicle.

CAUTION

• Before connecting or disconnecting the negative battery cable, be sure to turn off the ignition switch and

ACX00880

the lights. (If this is not done, there is the possibility of semiconductor parts being damaged.)

• After completion of the work steps (when the negative battery terminal is connected), warm up the engine and allow it to idle for approximately 10 minutes under the conditions described below in order to stabilize engine control conditions, and then check to be sure that the idling is satisfactory.

2. When servicing the electrical system, disconnect the negative cable terminal from the battery.

Engine coolant temperature: 85 − 95°C (185 − 203°F)

Lights and all accessories: OFF

Transmission: "N" or "P" position

Steering wheel: straight-forward position

APPROXIMATELY 40 cm (16 in)

ACX00881

VEHICLE WASHING

If high-pressure car-washing equipment or steam car-washing equipment is used to wash the vehicle, be sure to maintain the spray nozzle at a distance of at least approximately 40cm (16 inches) from any plastic parts and all opening parts (doors, luggage compartment, etc.).

APPLYING ANTI-CORROSION AGENT OR OTHER UNDERCOAT AGENTS

Be careful not to adhere oil or grease to the heated oxygen sensor. If adhered, the sensor may malfunction. Protect the heated oxygen sensor with a cover before applying anticorrosion agent, etc.

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Page 23

SCAN TOOL (MUT-II)

ROM PACK

GENERAL <BODY AND CHASSIS>

TOWING AND HOISTING

SCAN TOOL (MUT-II)

CAUTION

Turn the ign itio n s w itc h to " LO C K" ( OFF ) po s iti o n b efor e disconnecting or connecting the scan tool.

To o pe r at e th e s ca n to o l, re fe r t o " M UT -I I Op e ra ti ng Instructions."

00-23

SLIDING TYPE

WHEEL LIFE TYPE

ACX00882

TOWING AND HOISTING

WRECKER TOWING RECOMMENDATION

FRONT TOWING PICKUP

CAUTION

This vehicle cannot be towed by a wrercker using slingtype equipment to prevent the bumper from deformation. If this vehicle is towed, use wheel lift or flat bed equipment.

The vehicle may be towed on its rear wheels for extended distances provided the parking brake is released. It is recommended that vehicles be towed using the front pickup whenever possible.

M1001000800090

FLAT BED TYPE

AC000070

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Page 24

00-24

SLIDING TYPE

WHEEL LIFE TYPE

GENERAL <BODY AND CHASSIS>

TOWING AND HOISTING

REAR TOWING PICKUP

CAUTION

• This vehicle cannot be towed by a wrecker using slingtype equipment to prevent the lower arm from deformation.If this vehicle is towed, use a wheel lift or flat bed equipment.

• Do not use the steering column lock to secure the front wheel for towing.

• Make sure the transaxle is in Neutral if vehicle will have drive wheels on the ground.

• If these limits cannot be met, the front wheels must be placed on a tow dolly.

Automatic transmission vehicle may be towed on the front wheels at speeds not to exceed 50 km/h (30 mph) for distances not to exceed 30 km (18 miles).

FLAT BED TYPE

AC000071

TOWING WHEN KEYS ARE NOT AVAILABLE

When a locked vehicle must be towed and keys are not available, the vehicle may be lifted and towed from the front, provided the parking brake is released. If not released, the rear wheels should be placed on a tow dolly.

SAFETY PRECAUTIONS

The following precautions should be taken when towing the vehicle:

1. DO NOT LIFT OR TOW THE VEHICLE BY ATTACHING TO OR WRAPPING AROUND THE BUMPER.

2. Any loose or protruding parts or damaged vehicle such as hoods, doors, fenders, trim, etc. should be secured or removed prior to moving the vehicle.

3. Operator should refrain from going under a vehicle it is lifted by the towing equipment, unless the vehicle is 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.

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GENERAL <BODY AND CHASSIS>

TOWING AND HOISTING

LIFTING，，，， JACKINGSUPPORT LOCATION

FLOOR JACK

CAUTION

• Never support any point other than the specified one, or it will be deformed.

• For lifting, put rubber or similar material between the side sill and rigid rack, or the side sill area will be damaged.

00-25

RIGID RACK

NOTCH NOTCH

RUBBER

POST TYPE

Special care should be taken when raising the vehicle on a frame contact type hoist. The hoist must be equipped with the proper adapters in order to support the vehicle at the proper locations.

AC00 007 2

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00-26

GENERAL <BODY AND CHASSIS>

TOWING AND HOISTING

CAUTION

When service procedures require removing rear suspension, fuel tank and spare tire, place additional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping of center of gravity changes.

NOTCHNOTCH

AC000073

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Page 27

GENERAL <BODY AND CHASSIS>

GENERAL DATA AND SPECIFICATIONS

00-27

GENERAL DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS (Model with 2.4L Engine)

ITEMS RS

Vehicle dimension mm (in)

Overall length 1 4,455 (175.4) 4,455 (175.4) 4,455 (175.4) 4,455 (175.4)

Overall width 2 1,750 (68.9) 1,750 (68.9) 1,750 (68.9) 1,750 (68.9)

Overall height (unladen)

Wheelbase 4 2,560 (100.8) 2,560 (100.8) 2,560 (100.8) 2,560 (100.8)

MNJEL4M

31,310 (51.6)1,310 (51.6)1,310 (51.6) 1,310 (51.6)

RS MRJEL4M

GS MNHEL4M

M1001000900097

AC002714

RS MRHEL4M

Tread-front 5 1,510 (59.4) 1,510 (59.4) 1,510 (59.4) 1,510 (59.4)

Tread-rear 6 1,510 (59.4) 1,510 (59.4) 1,510 (59.4) 1,510 (59.4)

Overhang-front 7 975 (38.4) 975 (38.4) 975 (38.4) 975 (38.4)

Overhang-rear 8 920 (36.2) 920 (36.2) 920 (36.2) 920 (36.2)

Minimum running

9148 (5.8) 148 (5.8) 148 (5.8) 148 (5.8) ground clearance

Vehicle weight kg (lb)

Curb weight 1,295 (2,855) 1,325 (2,922) 1,335 (2,944) 1,365 (3,010)

Gross vehicle weight

1,750 (3,859) 1,750 (3,859) 1,750 (3,859) 1,750 (3,859)

rating

Gross axle weight

1,005 (2,216) 1,005 (2,216) 1,065 (2,348) 1,065 (2,348)

rating-front

Gross axle weight

795 (1,753) 795 (1,753) 795 (1,753) 795 (1,753)

rating-rear

Seating capacity 4

Engine Model No. 4G64

Piston displacement 2.4L

Transaxle Model No. F5M42 F4A42 F5M42 F4A42

Type 5-speed

manual

4-speed automatic

5-speed manual

4-speed automatic

Fuel system Fuel supply system Electronic controlled multiport fuel injection

GENERAL SPECIFICATIONS (Model with 3.0L Engine)

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00-28

GENERAL <BODY AND CHASSIS>

GENERAL DATA AND SPECIFICATIONS

ITEMS GT

MNXEL4M

Vehicle dimension mm (in)

Vehicle weight kg (lb)

Seating capacity 4

Overall length 1 4,455 (175.4) 4,455 (175.4) 4,455 (175.4) 4,455 (175.4)

Overall width 2 1,750 (68.9) 1,750 (68.9) 1,750 (68.9) 1,750 (68.9)

Overall height (unladen)

Wheelbase 4 2,560 (100.8) 2,560 (100.8) 2,560 (100.8) 2,560 (100.8)

Tread-front 5 1,510 (59.4) 1,510 (59.4) 1,510 (59.4) 1,510 (59.4)

Tread-rear 6 1,510 (59.4) 1,510 (59.4) 1,510 (59.4) 1,510 (59.4)

Overhang-front 7 975 (38.4) 975 (38.4) 975 (38.4) 975 (38.4)

Overhang-rear 8 920 (36.2) 920 (36.2) 920 (36.2) 920 (36.2)

Minimum running ground clearance

Curb weight 1,415 (3,120) 1,445 (3,186) 1,460 (3,219) 1,460 (3,219)

Gross vehicle weight rating

Gross axle weight rating-front

Gross axle weight rating-rear

31,310 (51.6)1,310 (51.6)1,310 (51.6) 1,310 (51.6)

9150 (5.9) 150 (5.9) 150 (5.9) 150 (5.9)

1,810 (3,991) 1,810 (3,991) 1,810 (3,991) 1,810 (3,991)

1,065 (2,345) 1,065 (2,345) 1,065 (2,345) 1,065 (2,345)

795 (1,753) 795 (1,753) 795 (1,753) 795 (1,753)

GT MRXEL4M

GT MNGEL4M

GT MRGEL4M

Engine Model No. 6G72

Piston displacement 3.0L

Transaxle Model No. F5M51 F4A52 F5M51 F4A51

Type 5-speed

manual

Fuel system Fuel supply system Electronic controlled multiport fuel injection

4-speed automatic

5-speed manual

4-speed automatic

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GENERAL <BODY AND CHASSIS>

GENERAL DATA AND SPECIFICATIONS

00-29

GENERAL SPECIFICATIONS

ITEMS GS

HNHEL 4D

Vehicle dimension mm

Overall length 1 4,455 (175.4) 4,455 (175.4) 4,455 (175.4) 4,455 (175.4)

Overall width 2 1,750 (68.9) 1,750 (68.9) 1,750 (68.9) 1,750 (68.9)

(in)

Overall height

31,340 (52.8) 1,340 (52.8) 1,340 (52.8) 1,340 (52.8)

(unladen)

Wheelbase 4 2,560 (100.8) 2,560 (100.8) 2,560 (100.8) 2,560 (100.8)

Tread-front 5 1,510 (59.4) 1,510 (59.4) 1,510 (59.4) 1,510 (59.4)

Tread-rear 6 1,510 (59.4) 1,510 (59.4) 1,510 (59.4) 1,510 (59.4)

Overhang-front 7 975 (38.4) 975 (38.4) 975 (38.4) 975 (38.4)

Overhang-rear 8 920 (36.2) 920 (36.2) 920 (36.2) 920 (36.2)

Minimum running

9163 (6.4) 163 (6.4) 165 (6.5) 165 (6.5)

ground clearance

Vehicle weight kg (lb)

Curb weight 1,395 (3,075) 1,425 (3,142) 1485 (3,274) 1515 (3,340)

Gross vehicle weight

1,770 (3,903) 1,770 (3,903) 1,855 (4,090) 1,855 (4,090)

rating

4 1

GS HRHEL 4D

GT NGEL4M

AC002712

GT RGEL4M

Gross axle weight

1,010 (2,227) 1,010 (2,227) 1,085 (2,392) 1,085 (2,392)

rating-front

Gross axle weight

810 (1,786) 810 (1,786) 820 (1,808) 820 (1,808)

rating-rear

Seating capacity 4

Engine Model No. 4G64 6G72

Piston displacement 2.4L 3.0L

Transaxle Model No. F5M42 F4A42 F5M51 F4A51

Type 5-sp e e d

manual

4-speed automatic

5-speed manual

4-speed automatic

Fuel system Fuel supply system Electronic controlled multiport fuel injection

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00-30

GENERAL <BODY AND CHASSIS>

TIGHTENING TORQUE

Each torque value in the table is a standard value for 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 are not applicable:

Standard bolt and nut tightening torque

THREAD SIZE STANDARD TIGHTENING TORQUE

NOMINAL BOLT DIAMETER (mm)

M5 0.8 2.5±0.5 N⋅m

M6 1.0 5.0±1.0 N⋅m

M8 1.25 12±2 N⋅m

M10 1.25 24±4 N⋅m

M12 1.25 41±8 N⋅m

M14 1.5 73±12 N⋅m

M16 1.5 110±20 N⋅m

M18 1.5 165±25 N⋅m

M20 1.5 225±35 N⋅m

M22 1.5 300±40 N⋅m

M24 1.5 395±55 N⋅m

PITCH (mm)

HEAD MARK "4" HEAD MARK "7" HEAD MARK "8"

(23±4 in-lb)

(44±9 in-lb)

(107±17 in-lb)

(18±3 ft-lb)

(30±6 ft-lb)

(54±9 ft-lb)

(81±15 ft-lb)

(122±18 ft-lb)

(166±26 ft-lb)

(222±29 ft-lb)

(292±40 ft-lb)

1. If toothed washers are inserted.

2. If plastic parts are fastened.

3. If bolts are tightened to plastic or die-cast inserted nuts.

4. If self-tapping screws or self-locking nuts are used

5.0±1.0 N⋅m (44±9 in-lb)

9.0±2.0 N⋅m (79±18 in-lb)

22±4 N⋅m (16±3 ft-lb)

44±10 N⋅m (33±7 ft-lb)

83±12 N⋅m (61±9 ft-lb)

140±20 N⋅m (104±14 ft-lb)

210±30 N⋅m (155±22 ft-lb)

300±40 N⋅m (222±29 ft-lb)

410±60 N⋅m (303±44 ft-lb)

555±85 N⋅m (410±62 ft-lb)

735±105 N⋅m (543±77 ft-lb)

M1001001100094

6.0±1.0 N⋅m (53±9 in-lb)

10±2 N⋅m (89±17 in-lb)

25±4 N⋅m (18±3 ft-lb)

53±7 N⋅m (39±5 ft-lb)

98±12 N⋅m (72±9 ft-lb)

155±25 N⋅m (115±18 ft-lb)

235±35 N⋅m (174±25 ft-lb)

340±50 N⋅m (251±37 ft-lb)

480±70 N⋅m (354±52 ft-lb)

645±95 N⋅m (476±70 ft-lb)

855±125 N⋅m (631±92 ft-lb)

Flange bolt and nut tightening torque

THREAD SIZE STANDARD TIGHTENING TORQUE

NOMINAL BOLT DIAMETER (mm)

M6 1.0 5.0±1.0 N⋅m

M8 1.25 13±2 N⋅m

M10 1.25 26±4 N⋅m

PITCH (mm)

HEAD MARK "4" HEAD MARK "7" HEAD MARK "8"

10±2 N⋅m

(44±9 in-lb)

(111±22 in-lb)

(19±3 ft-lb)

(89±17 in-lb)

24±4 N⋅m (18±3 ft-lb)

49±9 N⋅m (36±7 ft-lb)

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12±2 N⋅m (107±17 in-lb)

27±5 N⋅m (20±4 ft-lb)

58±7 N⋅m (43±5 ft-lb)

Page 31

GENERAL <BODY AND CHASSIS>

LUBRICATION AND MAINTENANCE

THREAD SIZE STANDARD TIGHTENING TORQUE

NOMINAL BOLT DIAMETER (mm)

M10 1.5 24±4 N⋅m

M12 1.25 46±8 N⋅m

M12 1.75 43±8 N⋅m

PITCH (mm)

HEAD MARK "4" HEAD MARK "7" HEAD MARK "8"

45±8 N⋅m

(18±3 ft-lb)

(34±6 ft-lb)

(32±6 ft-lb)

(33±6 ft-lb)

95±15 N⋅m (70±11 f t - lb)

83±12 N⋅m (61±9 ft-lb)

00-31

55±10 N⋅m (41±7 ft-lb)

105±15 N⋅m (78±11 ft-l b)

98±12 N⋅m (72±9 ft-lb)

LUBRICATION AND MAINTENANCE

Maintenance and lubrication service recommendations have been compiled to provide maximum protection for the vehicle owner's investment against all reasonable types of driving conditions. Since these conditions vary with the individual vehicle owner's driving habits, the area in which the vehicle is operated and the type of driving to which the vehicle is subjected, it is necessary to prescribe lubrication and maintenance service on a time frequency as well as mileage interval basis. Oils, lubricants and greases are classified and graded according to standards recommended by the Society of Automotive Engineers (SAE), the American Petroleum Institute (API) and the National Lubricating Grease Institute (NLGI).

MAINTENANCE SCHEDULES

Information for service maintenance is provided in the "SCHEDULED MAINTENANCE TABLE." Three schedules are provided; one for "Required Maintenance." one for "General Maintenance and " and one for "Severe Usage Service." The item numbers in "SCHEDULED MAINTENANCE TABLE" cor r esp o nd t o th e se cti o n nu mbe r s i n "MAINTENANCE SERVICE."

SEVERE SERVICE

Vehicles operating under severe service conditions will require more frequent service. Component service information is included in appropriate units for vehicles operating under one or more of the following conditions:

1. Trailer towing or police, taxi or commercial type operation.

2. Operation of Vehicle (1) Short-trip operation at freezing temperature

(engine not thoroughly warmed up)

M1001001200091

(2) More than 50% operation in heavy city traffic

during hot weather above 32°C (90°F) (3) Extensive idling (4) Driving in sandy areas (5) Driving in salty areas (6) Driving in dusty conditions (7) Driving off-road

ENGINE OIL

CAUTION

Test re sult s su b m itted t o E PA ha v e s h ow n th a t laboratory animals develop skin cancer after prolonged contact with used engine oil. Accordingly, the potential exists for humans to develop a number of skin disorders, including cancer, from such exposure to used engine oil. Therefore, when changing engine oil, be careful not to touch it as much as possible. Protective clothing and gloves, that cannot be penetrated by oil, should be worn. The skin should be thoroughly washed with soap and water, or use waterless hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents.

Either of the following engine oils should be used:

1. Engine oil displaying ILSAC certification mark.

2. Engine oil conforming to the API classification SJ EC or SJ/CD EC.

For further details, refer to "LUBRICANTS SELECTION."

LUBRICANTS AND GREASES

Semi-solid lubricants bear the NLGI designation and are further classified as grades 0, 1, 2, 3, etc. Whenever "Chassis Lubricant" is specified, Multipurpose Grease, NLGI grade Number 2, should be used.

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00-32

GENERAL <BODY AND CHASSIS>

RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE

FUEL USAGE STATEMENT

CAUTION

Using leaded gasoline in your car will damage the catalytic converters and heated oxygen sensors, and affect the warranty coverage validity.

This vehicle must use unleaded gasoline only. This vehicle has a fuel filler tube which is especially designed to accept only the smaller-diameter unleaded gasoline dispensing nozzle.

2.4L model is designed to operate on unleaded gasoline having a minimum octane rating of 87 [(MON + RON)/2], or 91 RON.

3.0L model is designed to operate on premium grade unleaded gasoline having a minimum octane rating of 91 [(MON + RON)/2], or 95 RON. If premium grade unleaded gasoline is not available, unleaded gasoline having an octane rating of 87 [(MON + RON)/2], or 91 RON may be used. However, the performance level may be reduced. MON: Motor Octane Number RON: Research Octane Number

GASOLINE CONTAINING ALCOHOL

Some gasoline sold at service stations contain alcohol although they may not be so identified. Using fuels containing alcohol is not recommended unless the nature of the blend can be determined as being satisfactory.

Gasohol: A mixture of 10% ethanol (grain alcohol) and 90% unleaded gasoline may be used in your vehicle. If driveability problems are experienced as a result of using gasohol, it is recommended that the vehicle be operated on gasoline. Methanol: Do not use gasoline containing methanol (wood alcohol). Using this type of alcohol can result in vehicle performance deterioration and damage critical parts in the fuel system components. Fuel system damage and performance problems resulting from the use of gasoline containing methanol may not be covered by the new vehicle warranty.

GASOLINE CONTAINING METHY TERTIARY BUTYL ETHER (MTBE)

Unleaded gasoline containing 15% or less MTBE may be used in your vehicle. (Fuel containing MTBE over 15% in volume may cause reduced engine performance and produce vapor lock or hard starting.

MATERIALS ADDED TO FUEL

Indiscriminate use of fuel system cleaning agents should be avoided. Many of these materials intended for gum and varnish removal may contain highly active solvents or similar ingredients that can be harmful to gasket and diaphragm materials used in fuel system component parts.

RECOMMENDED LUBRICANTS AND LUBRICANT

CAPACITIES TABLE

M1001001300098

RECOMMENDED LUBRICANTS

PARTS SPECI F ICAT ION S REMARK S

Engine oil Engine oil displaying ILSAC

certification mark ("Starburst" symbol) conforming the API classification SJ EC or SJ/CD EC

Manual transaxle API classification GL-4 SAE grade number:SAE75W-90

Automatic transaxle - -

Power steering MITSUBISHI POWER STEERING

FLUID

Brakes Conforming to DOT 3 or DOT 4

Engine coolant MITSUBISHI genuine coolant or

an equivalent

Door hinges, back door hinges Engine oil -

For further details, refer to "LUBRICANTS SELECTION" section.

or 75W/85W

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GENERAL <BODY AND CHASSIS>

RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE

LUBRICANT CAPACITY TABLE

DESCRIPTION SPECIFICATIONS

Engine oil dm

(qt)

Oil pan (excluding oil filter) 4.0 (4.2)

Oil filter 0.3 (0.32)

Engine coolant dm

Manual transaxle dm

(qt)

Automatic transmission dm

Power steering dm

Fuel tank dm

(qt)

(gal)

(qt)

2.4L engine 7.0 (7.4)

3.0L engine 8.0 (8.5)

2.4L engine 2.2 (2.3)

3.0L engine 2.8 (3.0)

2.4L engine 7.7 (8.1)

3.0L engine 8.4 (8.5)

1.2 (1.3)

62 (16.4)

LUBRICANT SELECTION

ENGINE OIL

00-33

ILSAC CERTIFICATION MARK ("STARBURST" SYMBOL)

API SERVICE SYMBOL

ACX00394

ACX00886

CAUTION

Never use nondetergent or straight mineral oil. Oil Identification Symbol

Use only engine oils displaying the ILSAC certification mark ("Starburst" symbol) on the container.

If these oils are not available, an API classification SJ EC or SJ/ CD EC can be used.

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00-34

GENERAL <BODY AND CHASSIS>

RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE

Oil Viscosity

The SAE grade number indicates the viscosity of the oil. A proper SAE grade number should be selected according to ambient temperature.

ACX00887

SELECTION OF COOLANT

COOLANT

Relationship between Coolant Concentration and Specific Gravity

CAUTION

• If the concentration of the coolant is below 30%, the anti-corrosion property will be adversely affected. In addition, if the concentration is above 60%, both the anti-freeze and engine cooling properties will decrease, affecting the engine adversely. For these reasons, be sure to maintain the concentration level within the specified range.

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

COOLANT TEMPERATURE °C (°F) AND SPECIFIC GRAVITY

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

(104)

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

50 (122)

FREEZING TEMPERATURE

°C (°F) °C (°F)

−16 (3.2) −11 (1 2 .2)

−20 (−4) −15 (5)

−25 (−13) −20 (−4)

SAFE OPERATING TEMPERATURE

COOLANT CONCENTRATION (SPECIFIC VOLUME)

1.079 1.074 1.069 1.064 1.058

1.087 1.082 1.076 1.070 1.064

1.095 1.090 1.084 1.077 1.070

1.103 1.098 1.092 1.084 1.076

Example

The safe operating temperature is −15°C (5° F) when the specific gravity is 1.058 at the coolant temperature of 20°C (68°F).

−30 (−22) −25 (−13)

−36 (−32.8) − 31 (−23.8)

−42 (−44) −37 (−35)

−50 (−58) −45 (−49)

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GENERAL <BODY AND CHASSIS>

SCHEDULED MAINTENANCE TABLE

00-35

SCHEDULED MAINTENANCE TABLE

M1001001400103

SCHEDULED MAINTENANCE SERVICE FOR EMISSION CONTROL AND PROPER VEHICLE PERFORMANCE

Inspection and service should be performed any time a malfunction is observed or suspected.

NO. EMISSION

CONTROL SYSTEM MAINTENANCE

1Fuel system (tank,

pipe line and connection, and fuel tank filler tube cap)

2Fuel hoses Check condition every 2 years or X X X

3Air cleaner elementReplace at X X X

4Evaporative emission

control system (except evaporative emission canister)

5Spark plugs Replace at Except platinum

SERVICE INTERVALS

Check for leaks every 5 years or X

Check for leaks and clogging every 5 years or

KILOMETERS IN THOUSANDS

MILEAGE IN THOUSANDS

plugs at

24 48 72 96 120 144 168

15 30 45 60 75 90 105

XXX

Platinum plugs only at

6Ignition cables Replace every 5 years or X

7Distributor cap and

rotor

GENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE PERFORMANCE

NO. GENERAL

MAINTENANCE

8Timing belt Replace at

9Drive belt (for generator,

water pump, A/C compressor and power steering pump)

Check every 5 years X

SERVICE INTERVALS

Check condition at X X X

KILOMETERS IN THOUSANDS

MILEAGE IN THOUSANDS

24 48 72 96 120 144 168

15 30 45 60 75 90 105

At 160,000

km (100,000 miles)

10 Engine oil Change oil every 12 months or Every 12,000 km (7,500 miles)

11 Eng i ne o il f i lte r

12 Manual transmission oil Check oil level every at X X X

Replace every 12 months or

XXXXXXX

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00-36

GENERAL <BODY AND CHASSIS>

SCHEDULED MAINTENANCE TABLE

NO. GENERAL

MAINTENANCE

SERVICE INTERVALS

KILOMETERS IN

24 48 72 96 120 144 168

THOUSANDS

MILEAGE IN

15 30 45 60 75 90 105

THOUSANDS

13 Automatic transmission

fluid

Check A/T fluid level every 12 months or

XXXXXXX

14 Engine coolant Change at first 4 years or X

After that every 2 years or

15 Disc brake pads Inspect for wear every 12

XXXXXXX

months or

16 Rear drum brake linings

and rear wheel cylinders

17 Brake hoses Check for deterioration or leaks

Inspect for wear and leaks every 2 years or

XXX

XXXXXXX

every 12 months or

Every 48,000km /h (30,000 miles)

18 Ball joint and steering

linkage seals

19 Drive shaft boots Inspect for grease leaks and

Inspect for grease leaks and damage every 2 years or

XXX

XXXXXXX

damage every 12 months or

20 SRS air bag Inspect the SRS system at 10 years

21 Exhaust system

(connection portion of

Check and service as required every 2 years or

XXX

muffler, piping and converter heat shields)

22 Tires Rotate every 12 months or Every 12,000 km (7,500 miles)

23 Air purifier filter Replace every 12 mouths or Every 12,000 km (7,500 miles)

NOTE: .

: For California, this maintenance is recommended but not required

: Not required if belt was previously changed

: If the mileage is less than 12,000 km (7,500 miles) each year, the oil filter should be replaced at every oil

change.

: Change fluid under severe usage conditions only.

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GENERAL <BODY AND CHASSIS>

SCHEDULED MAINTENANCE TABLE

SCHEDULED MAINTENANCE UNDER SEVERE USAGE CONDITIONS

Maintenance should be carried out according to the following table:

00-37

NO. MAINTENANC

E ITEM

3Air cleaner

element

5Spark plugs Replace at XXXXXXXB and D

10 Engine oil Change every 3 months or Every 4,800 km (3,000 miles) A, B, C, D

11 En g ine oil filte r Replac e ev e ry 6 mo nths or E v ery 9 ,6 0 0 km (6 , 0 00 m ile s ) A, B, C , D

12 Manual

transmission oil

13 Automatic

transmission fluid

15 Disc brake

pads

16 Rear drum

brake linings and rear wheel cylinders

22 Tires Rotate every 6 months or Every 9,600 km (6,000 miles) B, C, E, G

SERVICE INTERVALS

Replace at X X X X X X X A and E

Change oil at X X X B, G and H

Change A/T fluid at X X X B, G and H

Inspect for wear every 6 months or

Inspect for wear every 12 months or

KILOMETERS IN THOUSANDS

MILEAGE IN THOUSANDS

24 48 72 96 120 144 168 SEVERE

USAGE CONDITION

15 30 45 60 75 90 105

Every 9,600 km (6,000 miles) A and F

Every 2,400 km (15,000 miles) A and F

and G

and H

Sever usage conditions:

A: Driving in dusty conditions

B: Trailer towing, or police, taxi, or commercial type operation

C: Extensive idling, driving in stop and go traffic

D: Short-trip operation at freezing temperatures (engine not thoroughly warmed up)

E: Driving in sandy areas

F: Driving in salty areas

G: More than 50% operation in heavy city traffic or at sustained high speeds during hot weather above 32°C

(90°F)

H: Driving off-road

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00-38

GENERAL <BODY AND CHASSIS>

MAINTENANCE SERVICE

1. FUEL SYSTEM (TANK, PIPE LINE AND CONNECTION, AND FUEL TANK FILLER TUBE CAP) (CHECK FOR LEAKS)

1. Check for damage or leakage in the fuel lines and connections.

2. Inspect the surface of fuel hoses for heat and mechanical damage. Hard and brittle rubber, cracking, checking, tears, cuts, abrasions and excessive swelling indicate deterioration of the rubber.

3. If the fabric casing of the rubber hose is exposed by cracks and abrasions in the fuel system, the hoses should be replaced.

M1001001600099

AC000074

2. FUEL HOSES (CHECK CONDITION)

1. Inspect the surface of fuel hoses for heat and mechanical damage.Hard and brittle rubber, cracking, tears, cuts, abrasions and excessive swelling indicate deterioration of the rubber.

2. If the fabric casing of the rubber hose is exposed by cracks and abrasions in the fuel system, the hoses should be replaced.

3. AIR CLEANER ELEMENT (REPLACE)

The air cleaner element will become dirty during use, reducing its effect. Replace it with a new one.

REPLACEMENT OF AIR CLEANER ELEMENT

1. Unclamp the air cleaner cover.

2. Remove the air cleaner element and install a new one.

3. When clamping the air cleaner cover in place, be sure that the cover is completed closed.

M1001001700096

M1001001800093

4. EVAPORATIVE EMISSION CONTROL SYSTEM

(EXCEPT EVAPORATIVE EMISSION CANISTER) (CHECK FOR LEAKS AND CLOGGING)

If the fuel-vapor vent line is clogged or damaged, the fuel vapor mixture will escape into the atmosphere causing excessive emissions. Disconnect the line at both ends, and blow it clean with compressed air. Remove the fuel tank filler tube cap from the filler tube and check to see if there is evidence that the packing makes improper contact to the filler tube.

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M1001001900090

Page 39

GENERAL <BODY AND CHASSIS>

AKX00434

MAINTENANCE SERVICE

00-39

<3.0L ENGINE>

<2.4L ENGINE>

PLATINUM TIPS

AKX00383AKX00383

PLUG GAP GAUGE

5. SPARK PLUGS (REPLACE)

M1001002000078

CAUTION

Platinum plugs are used on 3.0L engine.Use care not to damage the platinum tips of the platinum plugs.Do not attempt to adjust the gap on these plugs.

1. Spark plugs must spark properly to assure proper engine performance and reduce exhaust emission level.

Therefore, they should be replaced periodically with new ones.

Spark plug type

MAKER 2.4L ENGINE 3.0L ENGINE

NGK BKR5E-11 PFR6G-11

DENSO K16PR-U11 PK20PR11

CHAMPION RC10YC4 RC8PYP4

2. The new plugs should be checked for the proper gap.

Spark plug gap: 1.0 − 1.1 mm (0.039 − 0.043 inch)

3. Install the spark plugs and tighten to 25 ± 4 N⋅m (18 ± 4 ft-lb)

INCORRECT

MEASUREMENT DIRECTION

CORRECT

AKX01272AKX01272

6. IGNITION CABLES (REPLACE)

M1001002100064

CAUTION

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

The ignition cables should be replaced periodically with new ones. After replacing, make sure that the ignition cables are routed properly and fully seated.

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00-40

GENERAL <BODY AND CHASSIS>

MAINTENANCE SERVICE

7. DISTRIBUTOR CAP AND ROTOR (CHECK)

<3.0L ENGINE>

Check the distributor cap and rotor to maintain driveability and reduce exhaust emissions.

DISTRIBUTOR CAP AND ROTOR INSPECTION

Inspect in accordance with the following procedure. Repair or replace as necessary.

• Check the cap for cracks.

• Check the cap and rotor electrodes for damage.

• Wipe clean the cap and rotor.

• Clean the corrosion off the terminals inside the distributor

AKX01147

cap.

M1001002200050

8. TIMING BELT (REPLACE)

Replace the belt with a new one according to the maintenance schedule on P.00-35 to assure proper engine performance. For removal and installation procedures, refer to GROUP 11A, Timing Belt P.11A-35 or 11C, Timing Belt P.11A-31.

M1001002300091

9. DRIVE BELT (FOR GENERATOR, WATER PUMP,

A/C COMPRESSOR AND POWER STEERING PUMP) (CHECK CONDITION)

M1001002500073

Water Pump <2.4L ENGINE>, A/C Compressor <3.0L ENGINE> and Generator Drive Belt Tension Check and Adjustment

Required Special Tools:

• MB991502: Scan Tool (MUT-II)

• MB991668: Belt Tension Meter Set

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<2.4L ENGINE>

MB991668 (MICROPHONE)

GENERATOR PULLEY

<3.0L ENGINE>

TENSIONER PULLEY

CRANK SHAFT PULLEY

15˚

TAP L I G HT LY WITH A FINGER

GENERATOR PULLEY

TAP L I G HT LY WITH A FINGER

15˚

16 PIN

MB991502

AKX01177

10 – 20mm (0.4 – 0.8in)

AKX01149

A/C COMPRESSOR PULLEY

10 – 20mm (0.4 – 0.8in)

MB991668 (MICROPHONE)

GENERAL <BODY AND CHASSIS>

MAINTENANCE SERVICE

CAUTION

To p r e ven t da m age to scan too l MB 9 9 150 2 , always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502.

1. Connect special tool MB991668 to the scan tool MB991502.

2. Connect scan tool MB991502 to the data link connector.

3. Turn the ignition switch to the "ON" and select scan tool MB991502 "Belt Tension Measurement" from the menu screen.

4. Hold special tool MB991668 (microphone) to the middle of the drive belt between the pulleys (at the place indicated by the arrow), about 10 − 20 mm (0.4 − 0.8 inch) away from the rear surface of the belt and so that it is perpendicular to the

WATER PUMP PULLEY

CRANK SHAFT PULLEY

belt (within an angle of ± 15 degree angle).

CAUTION

• The temperature of the surface of the belt should be as close as possible to underhood temperature.

• Do not let any contaminants such as water or oil get onto the microphone.

• If strong gusts of wind blow against the microphone or

if there are any loud sources of noise nearby, the values measured by the microphone may not correspond to actual values.

• If the microphone is touching the belt while the measurement is being made, the values measured by the microphone may not correspond to actual values.

• Do not take the measurement while the vehicle's engine is running.

IDLER PULLEY

5. Gently tap the middle of the belt between the pulleys (the place indicated by the arrow) with your finger as shown in the illustration, and check that the vibration frequency of the belt is within the standard value.

Standard value:

ITEM 2.4L ENGINE 3.0L ENGINE

Vibration frequency Hz189 − 232 134 − 159

00-41

AKX01150

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00-42

<2.4L ENGINE>

GENERATOR PULLEY

TENSION GAUGE

WATER PUMP PULLEY

GENERAL <BODY AND CHASSIS>

MAINTENANCE SERVICE

Use a belt tension gauge to check that the belt tension is within the standard value.

Standard value:

ITEM 2.4L ENGINE 3.0L ENGINE

<3.0L ENGINE>

TENSIONER PULLEY

CRANK SHAFT PULLEY

TENSION GAUGE

GENERATOR PULLEY

CRANKSHAFT PULLEY

AKX01151AKX01151

A/C COMPRESSOR PULLEY

IDLER PULLEY

Ten si on N (l b) 3 92 − 588

(88 − 132)

490 − 686 (110 − 154)

AKX01152AKX01152 AB

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<2.4L ENGINE>

98 N (22 lb)

GENERAL <BODY AND CHASSIS>

WATER PUMP PULLEY

MAINTENANCE SERVICE

Apply 98 N (22 pound) of force to the middle of the drive belt between the pulleys (at the place indicated by the arrow) and check that the amount of deflection in within the standard value.

Standard value:

00-43

GENERATOR PULLEY

<3.0L ENGINE>

TENSIONER PULLEY

CRANK SHAFT PULLEY

GENERATOR PULLEY

98 N (22 lb)

CRANKSHAFT PULLEY

AKX01153AKX01153

IDLER PULLEY

A/C COMPRESSOR PULLEY

ITEM 2.4L ENGINE 3.0L ENGINE

Deflection (Reference value) mm (in)

6.7 − 9.0 (0.26 − 0.35)

8.5 − 10.9 (0.33 − 0.43)

<2.4L ENGINE>

ADJUSTING BOLT

LOCK BOLT

AKX01154AKX01154 AB

PIVOT BOLT

AKX01155AKX01155

Generator Drive Belt Tension Adjustment <2.4L ENGINE>

1. Loosen the nut of the generator pivot bolt.

2. Loosen the lock bolt.

3. Turn the adjusting bolt to adjust the belt vibration frequency, belt tension or deflection to the standard value.

Standard value:

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Page 44

00-44

GENERAL <BODY AND CHASSIS>

MAINTENANCE SERVICE

TENSIONER PULLEY

ITEMS DURING

ADJUSTMENT

Vibration

201 − 222 267 − 299

DURING REPLACEMENT

frequency Hz

Ten si on N (l b) 4 41 − 539

(99 − 121)

Deflection (Reference value)

7.2 − 8.4 (0.28 − 0.33)

785 − 981 (176 − 220)

4.4 − 5.3 (0.17 − 0.21)

mm (in)

4. Tighten the lock bolt.

Tightening torque: 23 ± 2 N⋅m (16 ± 2 ft-lb)

5. Tighten the nut of the generator pivot bolt.

Tightening torque: 44 ± 10 N⋅m (33 ± 7 ft-lb)

6. Tighten the adjusting bolt.

Tightening torque: 4.9 ± 1.0 N⋅m (44 ± 8 in-lb)

Generator and A/C Comressor Drive Belt Tension Adjustment<3.0L ENGINE>

1. Loosen the tensioner pulley fixing nut.

2. With the tensioner pulley fixing nut temporarily tightened to 15 ± 5 N⋅m (11 ± 4 ft-lb), set the belt tension or defection amount to the standard value using the adjusting bolt.

Standard value:

FIXING NUT

ADJUSTING BOLT

AKX01156AKX01156

ITEMS DURING

ADJUSTMENT

Vibration

141 − 153 170 − 190

frequency Hz

Ten si on N (l b) 5 39 − 637

(121 − 143)

Deflection (Reference value)

9.0 − 10.1 (0.35 − 0.40)

mm (in)

3. Tighten the tension pulley fixing nut.

Tightening torque: 49 ± 10 N⋅m (36 ± 7 ft-lb)

DURING REPLACEMENT

785 − 981 (176 − 221)

6.2 − 7.6 (0.24 − 0.30)

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<2.4L ENGINE>

(VEHICLES WITHOUT A/C)

GENERAL <BODY AND CHASSIS>

MAINTENANCE SERVICE

Power Steering Oil Pump and A/C Compressor <2.4L ENGINE> Drive Belt Tension Check and Adjustment

Check the drive belt tension by the following procedure.

00-45

OIL PUMP PULLEY

CRANKSHAFT PULLEY

(VEHICLES WITH A/C)

OIL PUMP PULLEY

CRANKSHAFT PULLEY

<3.0L ENGINE>

POWER STEERING OIL PUMP PULLEY

A/C COMPRESSOR PULLEY

AC000087

Required Special Tools:

• MB991502: Scan Tool (MUT-II)

• MB991668: Belt Tension Meter Set

Gently tap the middle of the belt between the pulleys (the location indicated by the arrow) with your finger as shown in the illustration, and check that the vibration frequency of the belt is within the standard value range.

NOTE: Refer to P.00-40 for details on the method of measuring the vibration frequency using the scan tool.

Use a belt tension gauge to check that the belt tension is within the standard value.

Apply 98 N (22 pound) of force to the middle of the drive belt between the pulleys (at the place indicated by the arrow) and check that the amount of deflection is within the standard value.

Standard value:

<2.4L ENGINE>

ITEMS WHEN

CHECKED

DURING ADJUSTMENT

DURING REPLACEM ENT

ADJUSTING BOLT

CRANKSHAFT PULLEY

AC000088

Vibration frequency Hz

Ten si on N (lb)

Deflection (Reference value) mm (in)

108 − 132 114 − 126 137 − 157

392 − 588 (88 − 132)

11.7 − 15.3 (0.46 − 0.60)

441 − 539 (99 − 121)

12.5 − 14.3 (0.49 − 0.56)

637 − 834 (143 − 187)

8.8 − 11.0 (0.35 − 0.43)

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00-46

GENERAL <BODY AND CHASSIS>

MAINTENANCE SERVICE

<3.0L ENGINE>

ITEMS WHEN

CHECKED

DURING ADJUSTMENT

DURING REPLACEM ENT

<2.4L ENGINE>

(VEHICLES WITHOUT A/C)

OIL PUMP PULLEY

CRANKSHAFT PULLEY

44 ± 10 N·m 33 ± 7 ft-lb

TENSIONER PULLEY

Vibration

125 − 154 133 − 148 160 − 183 frequency Hz

Te ns io n N (lb)

Deflection (Reference

373 − 569

(84 − 128)

11.0 − 14.2

(0.43 − 0.56)

422 − 520 (95 − 117)

11.7 − 13.4 (0.46 − 0.53)

608 − 804 (137 − 181)

8.4 − 9.3

(0.33 − 0.37) value) mm (in)

if the tension or deflection is outside the standard value, adjust by the following procedure.

<2.4L ENGINE>

1. Loosen the tension pulley fixing nut A behind the tension pulley.

2. Adjust the belt deflection amount using the adjusting bolt B.

3. Tighten the fixing nut A.

Tightening torque: 44 ± 10 N⋅m (33 ± 7 ft-lb)

CAUTION

Check after turning the crankshaft once or more clockwise.

4. Check the belt deflection amount and tension, and readjust if necessary.

(VEHICLES WITH A/C)

OIL PUMP PULLEY

CRANKSHAFT PULLEY

44 ± 10 N·m 33 ± 7 ft-lb

TENSIONER PULLEY

A/C COMPRESSOR PULLEY

AC000089

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<3.0L ENGINE>

POWER STEERING OIL PUMP PULLEY

44 ± 10 N·m 33 ± 7 ft-lb

ADJUSTING BOLT

FIXING BOLT

TENSION PULLEY

FIXING NUT

CRANKSHAFT PULLEY

AC000090

GENERAL <BODY AND CHASSIS>

MAINTENANCE SERVICE

<3.0L ENGINE>

1. Loosen the tension pulley fixing nut and bolt.

2. Adjust the belt tension using the adjusting bolt.

3. Tighten the fixing nut and bolt.

Tightening torque: 44 ± 10 N⋅m (33 ± 7 ft-lb)

CAUTION

Check after turning the crankshaft once or more clockwise.

4. Check the belt deflection amount and tension, and readjust

if necessary.

00-47

<2.4L ENGINE>

39 ± 5 N·m 29 ± 4 ft-lb

<3.0L ENGINE>

DRAIN PLUG GASKET

OIL PAN SIDE

DRAIN PLUG GASKET

OIL PAN SIDE

DRAIN PLUG

10. ENGINE OIL (CHANGE)

M1001002600092

Use the specified oil. (Refer to P.00-32.)

1. After warming up the engine, remove the oil filler cap.

WARNING

Use care as oil could be hot.

2. Remove the drain plug to allow the engine oil to drain.

3. Replace the drain plug gasket with a new one, and then tighten the drain plug to the specified torque.

Tightening torque: 39 ± 5 N⋅m (29 ± 4 ft-lb)

NOTE: Install the drain plug gasket so it faces in the direction shown in the illustration.

4. Pour new engine oil in through the oil filler.

Engine oil capacity:

•••• 4.0 dm3 (4.5 quart)

[excluding oil filter 0.3 dm

5. Start the engine and run it at idle for a few minutes.

(0.32 quart)]

39 ± 5 N·m 29 ± 4 ft-lb

MAXIMUM

GOOD

DRAIN PLUG

AC000092

MINIMUM

ACX00892

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6. Stop the engine and check to ensure that the engine oil level is within the level range indicated on the dip stick.

Page 48

00-48

GENERAL <BODY AND CHASSIS>

MAINTENANCE SERVICE

O-RING

MB991396 OR MB991610

AC000093

ACX00893

11. ENGINE OIL FILTER (REPLACE)

M1001002700099

The quality of replacement filters varies considerably. Only high quality filters should be used to assure most efficient service. Genuine oil filters require that the filter is capable of withstanding a pressure of 1,765 kPa (256 psi) are high quality filters and are recommended as follows:

Mitsubishi Oil Filter Part Number:

<2.4L Engine> MD136466, MD322508, MD325714, MD332687 MD360935, MD365876 or equivalent <3.0L Engine> MD352626 or equivalent

Engine Oil Filter Selection

This vehicle is equipped with a full-flow, throw-away oil filter. The same type of filter is recommended as a replacement filter for this vehicle. It is possible, particularly in cold weather, that this vehicle may develop high oil pressure for a short duration. Make sure that any replacement filter used on this vehicle is a high-quality filter. The filter can withstand a pressure of 1,765 kPa (256 psi) [manufacturer's specifications] to avoid the filter and engine damage. The following is a high-quality filter and is strongly recommended for use on this vehicle: Mitsubishi Engine Oil Filter Part number MD136466, MD322508, MD325714, MD332687, MD352626, MD360935 and MD365876. Any replacement oil filter should be installed in accordance with the oil filter manufacturer's installation instructions.

1. Drain the engine oil by removing the oil drain plug.

2. Use an oil filter wrench to remove the engine oil filter.

3. Clean the contacting surface of the filter bracket.

4. Lubricate the O-ring of the new oil filter with a small amount of new engine oil.

5. Screw on the oil filter by hand until it touches the surface of the flange and then tighten it with the oil filter wrench: etc.

NUMBER ENGINE SPECIAL TOOL TIGHTENING TORQUE

MD360935 2.4L MB991396 or equivalent Approximately one turn [14 ± 2 N⋅m (124 ± 18 in-lb)]

MD325714

MB991396 or equivalent Approximately 3/4 turn [16 ± 4 N⋅m (12 ± 3 ft-lb)] MD332687 MD365876

MD136466

General service tool Approximately 3/4 turn [17 ± 3 N⋅m (34 ± 2 ft-lb)] MD322508

MD352626 3.0L MB991610 or equivalent Approximately one turn [14 ± 2 N⋅m (124 ± 18 in-lb)]

6. Add new engine oil through the oil filter.

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GENERAL <BODY AND CHASSIS>

MAINTENANCE SERVICE

00-49

TRANSMISSION OIL

DRIVE SHAFT <LH>

FILLER PLUG

AC000094

12. MANUAL TRANSMISSION OIL

M1001002800074

Check oil level

Inspect each component for evidence of leakage, and check the oil level by removing the filler plug. If the oil is contaminated, replace with new oil.

1. Remove the filler plug.

2. Check that the oil is not noticeably dirty, and that it has a suitable viscosity.

3. Tighten the filler plug to the specified torque.

Tightening torque: 32 ± 2 N⋅m (24 ± 1 ft-lb)

Change oil

1. Remove the filler plug.

2. Remove the drain plug and drain the oil.

3. Tighten the drain plug to the specified torque.

Tightening torque: 32 ± 2 N⋅m (24 ± 1 ft-lb)

FLUID LEVEL [mm (in)]

10 (0.4)

0 (0)

– 10 (– 0.4)

– 20 (– 0.8)

– 30 (– 1.2)

(104)

FLUID TEMPERATURE [˚C (˚F)]

6040

(140)

DRAIN PLUG

AC000095

DIPSTICK

(176)

AC002477

4. Fill with Hypoid gear oil SAE 75W-90 or 75W-85W conforming to API classification GL-4 until the level comes to the lower portion of filler plug hole.

Quantity:

<2.4L Engine> 2.2 dm

<3.0L Engine> 2.8 dm

(2.3 quarts)

(3.0 quarts)

5. Tighten the filler plug to the specified torque.

Tightening torque: 32 ± 2 Nm (24 ± 1 ft-lb)

13. AUTOMATIC TRANSMISSION FLUID

M1001002900093

Checking A/T fluid level

1. Drive the vehicle until the A/T fluid temperature rises to the normal temperature [70 − 80°C (158 − 176°F)].

NOTE: The A/T fluid temperature is measured with MUT-II.

NOTE: If it takes some amount of time until the A/T fluid reaches its normal operating temperature [70 − 80°C (158 − 176°F)], check the A/T fluid level by referring to the left diagram.

2. Park the vehicle on a level surface.

3. Move the selector lever through all positions to fill the torque converter and the hydraulic circuits with A/T fluid, and then move the selector lever to the "N" position.

4. After wiping off any dirt around the dipstick, remove the dipstick and check the condition of the A/T fluid.

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00-50

<2.4L ENGINE>

<3.0L ENGINE>

GENERAL <BODY AND CHASSIS>

MAINTENANCE SERVICE

NOTE: If the fluid smells as if it is burnt, it means that the A/ T fluid has been contaminated by fine particles from the bushings and friction materials, a transaxle overhaul and flashing the cooler line flushing may be necessary.

5. Check that the A/T fluid level is at the "HOT" mark on the dipstick. If the A/T fluid level is lower than this, pour in more DIAMOND ATF SP-II M or SP-III or equivalent until the level reaches the "HOT" mark.

NOTE: If the A/T fluid level is too low, the oil pump will draw in air along with the A/T fluid, which will cause bubbles to form. This will in turn cause the hydraulic pressure to drop, which will result in late shifting and slipping of the clutches and brakes. In either case, air bubbles can interfere with normal valve, clutch, and brake operation. Foaming can cause A/T fluid to escape from the transaxle vent, in which case it may be mistaken for a leak.

6. Securely insert the dipstick.

NOTE: The A/T fluid should always be replaced when:

When trouble shooting the transaxle

AC000098

•

When overhauling the transaxle

•

When the oil is noticeably dirty or burnt (vehicle was

•

driven under severe conditions)

AC000099

Change A/T fluid

If you have a A/T fluid changer, use this changer to replace the A/T fluid. If you do not have a A/T fluid changer, replace the A/T fluid by the following procedure.

1. Disconnect the hose shown in the illustration which connects the transaxle and the oil cooler (inside the radiator). Place a container under the hose to collect the discharge.

CAUTION

The engine should be stopped within one minute after it is started. If the A/T fluid has all drained out before then, the engine should be stopped at that point. Discharge volume:

Approximately 3.5 dm

2. Start the engine and let the A/T fluid drain out.

Running conditions: "N" range with engine idling

3. Remove the drain plug from the bottom of the transaxle case to drain the A/T fluid.

Discharge volume: Approximately 2.0 dm

4. Install the drain plug with a new gasket, and tighten it to the specified torque.

Tightening torque: 32 ± 2 N⋅m (24 ± 1 ft-lb)

(3.7 quarts)

(2.1 quarts)

AC000100

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5. Pour new AT fluid in through the oil filler tube.

Adding volume: Approximately 5.5 dm

(5.8 quarts)

Page 51

GENERAL <BODY AND CHASSIS>

MAINTENANCE SERVICE

CAUTION

Stop pouring if the full volume of A/T fluid cannot be poured in.

6. Repeat the procedure in Step 2. (to pump out the rest of the contaminated A/T fluid)

7. Pour the new A/T fluid in through the oil filler tube.

NOTE: Check the A/T fluid for contamination or burnt smell. If A/T fluid is still contaminated or burnt, repeat Steps 6 and 7 before proceeding to Step 8.

8. Reconnect the hose which was disconnected in step 1 above, and firmly replace the dipstick.

9. Start the engine and run it at idle for 1 − 2 minutes.

10. Move the selector lever through all positions, and then move it to the "N" position.

AC000101

00-51

<2.4L ENGINE>

<3.0L ENGINE>

FLUID LEVEL [mm (in)]

10 (0.4)

0 (0)

– 10 (– 0.4)

AC000098

11.Chec k tha t th e A / T fl u id l evel is a t th e "C O LD " ma r k o n the dipstick. If the level is lower than this, pour in more A/T fluid.

12.Drive the vehicle until the A/T fluid temperature rises to the normal temperature [70 − 80°C (158 − 176°F)], and then check the A/T fluid level again. If it takes some amount of time until the A/T fluid reaches its normal operating temperature [70 − 80°C (158 − 176°F)], check the A/T fluid level by referring to the diagram at left. The A/T fluid level must be at the "HOT" mark.

NOTE: The A/T fluid temperature is measured with scan tool (MUT-II). The "COLD" level is for reference only; the "HOT" level should be regarded as the standard level.

NOTE: If it takes some amount of time until the A/T fluid reaches its normal operating temperature [70 − 80°C (158 176°F)], check the A/T fluid level by referring to the left diagram.

13. Firmly insert the dipstick into the oil filler tube.

– 20 (– 0.8)

– 30 (– 1.2)

(104)

FLUID TEMPERATURE [˚C (˚F)]

6040

(140)

(176)

DIPSTICK

AC002477

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00-52

GENERAL <BODY AND CHASSIS>

MAINTENANCE SERVICE

DRAIN PLUG

AC000106

14. ENGINE COOLANT (CHANGE)

M1001003100090

Check the cooling system parts such as the radiator, heater and oil cooler hoses, thermostat and the connections for leakage and damage.

Changing Coolant

1. Set the temperature control knob to the "HOT" position.

2. Let the engine operate until the engine coolant warms, and then stop the engine.

CAUTION

When removing the radiator cap, use care to avoid contact with hot coolant or steam. Place a shop towel over the cap and turn the cap counterclockwise a little to let the pressure escape through the vinyl tube. After relieving the steam pressure, remove the cap by slowly turning it counterclockwise.

3. Remove the radiator cap, radiator drain plug and engine drain plug to drain the coolant.

4. Remove the reserve tank and drain the coolant.

5. After completely draining the coolant, reinstall the drain plugs and flush the engine and radiator using a radiator cleaning fluid.

6. After the flushing is completed, completely drain the cleaning fluid and install the radiator and engine drain plugs.

7. By referring to the section on coolant, select an appropriate concentration for safe operation for safe operating temperature within the range of 30 to 60%. Refill the coolant at the selected concentration. A convenient mixture is a 50% water and 50% antifreeze solution [freezing point: −31°C (−

32.8 °F)].

Recommended antifreeze:

MITSUBISI GENUINE Part NO.MD970389 or equivalent

Quantity:

<2.4L Engine> 7.0 dm

<3.0L Engine> 8.0 dm

(7.4 quarts)

(8.5 quarts)

AIR BLEED BOLT

CAUTION LABEL

14 ±1 N·m 120 ± 13 in-lb

ACX01422

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CAUTION

Do not use alcohol or methanol anti-freeze or any engine coolants mixed with alcohol or methanol anti-freeze. The use of an improper anti-freeze can cause the corrosion of the aluminum components.

8. Reinstall the radiator cap.

9. Start the engine and let it warm up until the thermostat opens.

10.After repeatedly revving the engine up to 3,000 r/min several times, then stop the engine.

11.Remo v e t h e r a dia t or c a p a f ter t he e ngi n e h a s b e co m e c o ld, and pour in coolant up to the brim. Reinstall the cap.

Page 53

GENERAL <BODY AND CHASSIS>

MAINTENANCE SERVICE

CAUTION

Do not overfill the reserve tank.

12.Add coolant to the reserve tank between the "FULL" and "LOW" mark if necessary.

00-53

ACX00898

15. DISC BRAKE PADS (INSPECT FOR WEAR)

M1001003200097

Check for fluid contamination and wear. Replace the complete set of pads if defective.

Thickness of lining Minimum limit: 2.0 mm (0.08 inch)

CAUTION

The pads for the right and left wheels should be replaced at the same time. Never split or intermix brake pad sets. All four pads must be replaced as a complete set.

16. REAR DRUM BRAKE LININGS AND REAR

WHEEL CYLINDERS (INSPECT FOR WEAR AND LEAKS)

1. Remove the brake drum and check the thickness of brake shoe lining for wear. Check the automatic brake adjusting system 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 very thin coat of multipurpose grease to the friction surface of the adjuster and link shaft.

CAUTION

The shoes for the right and left wheels should be replaced at the same time. Never split or intermix brake shoe seats. All four shoes must be replaced as a complete set.

2. Inspect the wheel cylinder boot for evidence of a brake fluid leak. Visually check the boot for cuts, tears or heat cracks. (A slight amount of fluid on the boot may not be a leak, but may be preservative fluid used at assembly.) Check the Brake Shoes for Wear.

Thickness of lining

Minimum limit: 1.0 mm (0.04 inch)

M1001003300083

AC002717

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00-54

BRAKE HOSE

BOOT

BRAKE TUBE

AC000107AB

DUST COVER

GENERAL <BODY AND CHASSIS>

MAINTENANCE SERVICE

17. BRAKE HOSES (CHECK FOR

DETERIORATION OR LEAKS)

Inspection of brake hoses and tubing should be included in all brake 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 exposed by cracks or abrasion in the rubber hose cover, the hoses should be replaced. Eventual deterioration of the hose and possible bursting failure may occur.)

2. Incorrect installation, casing twisting or interference with wheel, tire or chassis.

18. BALL JOINT AND STEERING LINKAGE

SEALS (INSPECT FOR GREASE LEAKS AND DAMAGE)

1. These components, which are permanently lubricated at the factory, do not require periodic lubrication. Damaged seals and boots should be replaced to prevent leakage or contamination of the grease.

2. Inspect the dust cover and boots for proper sealing, leakage and damage, and replace them if defective.

M1001003400091

M1001003500098

BOOTS

AC000108

AC000109

19. DRIVE SHAFT BOOTS (INSPECT FOR

GREASE LEAKS AND DAMAGE)

2. Inspect the dust cover and boots for proper sealing, leakage and damage, and replace them if defective.

M1001003600095

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GENERAL <BODY AND CHASSIS>

MAINTENANCE SERVICE

00-55

CERTIFICATION LABEL

DATE OF MANUFACTURE

AC000111

20. SRS AIR BAG (INSPECT FOR SRS SYSTEM)

M1001003700092

The SRS must be inspected by an authorized dealer 10 years after the car manufacture date shown on the certification label located on the left center sill.

SRS WARNING LIGHT

AC000112

SRS Warning Light Check

Turn the ignition key to the "ON" position. Does the "SRS" warning light illuminate for about seven seconds, and then remain off for at least five seconds after turning OFF? If yes, the SRS system is functioning properly. If no, refer to GROUP 52B, Diagnosis P.52B-20.

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00-56

TAPE

BATTERY CABLE

GENERAL <BODY AND CHASSIS>

MAINTENANCE SERVICE

SRS Component Visual Check

DANGER

Wait at least 60 seconds after disconnecting the

BATTERY

ACX00902

battery cable before doing any further work. The SRS system is designed to retain enough voltage to deploy the air bag for a short time even after the battery has been disconnected, so serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cable is disconnected.

WARNING

Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING.

1. Turn the ignition switch to the "LOCK" (OFF) position, disconnect the negative battery cable and tape the terminal.

2. Remove the floor console assembly. (Refer to GROUP 52A, Floor Console P.52A-9.)

3. Disconnect a connector from the SRS-ECU.

< ECLIPSE >

REAR SPEAKER (LH)

REAR SPEAKER(LH)

SIDE IMPACT SENSOR

FRONT OF VEHICLE

SIDE IMPACT SENSOR

AC000113

Side Impact Sensors

WARNING

• If the side impact sensor is not installed securely

and correctly, the side air bag may not operate normally.

• If a dent, crack, deformation or rust is detected,

replace with a new sensor.

1. Check the side impact sensor and bracket for dents, cracks or deformation.

2. Check the connector for damage, and terminal for deformation.

3. Check that there is no bending or corrosion in the side outer panel (ECLIPSE) or quarter panel (ECLIPSE SPYDER).

FRONT VEHICLE

AC002718

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SRS-ECU

CENTER REINFORCEMENT (RH)

GENERAL <BODY AND CHASSIS>

MAINTENANCE SERVICE

Replace The Side Impact Sensor If It Fals The Visual Check

Refer to GROUP 52B, Side Impact Sensor P.52B-76.

NOTE: The illustration at left shows the left side impact sensor (LH). The position of the side impact sensor (RH) is symmetrical to this.

SRS Air Bag Control Unit (SRS-ECU)

WARNING

The SRS may not activate if the SRS-ECU (with builtin safing G-sensor and analog G-sensor) is not installed properly, which could result in serious injury or death to the vehicle's driver and passenger.

1. Check the SRS-ECU case and brackets for dents, cracks, deformation or rust.

2. Check the connector for damage, and check the terminals for deformation or rust.

AC000114

Replace the SRS-ECU if it fails the visual check. (Refer to GROUP 52B, SRS Air bag Control Unit P.52B-66.)

00-57

Air Bag Module, Steering Wheel and Clock Spring

WARNING

The removed air bag module should be stored in a clean, dry place with the pad cover face up.

1. Remove the air bag module, steering wheel and clock spring.

(Refer to GROUP 52B, Air Bag Module and Clock Spring

P.52B-69.)

2. Check the pad cover for dents, cracks or deformation.

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00-58

GENERAL <BODY AND CHASSIS>

MAINTENANCE SERVICE

<DRIVER'S SIDE>

CONNECTOR

CONNECTOR

INFLATOR CASE

COVER

INFLATOR CASE

AC000116

3. Check the connector for damage and deformed terminals, and check the harness for binds.

4. Check the air bag inflator case for dents, cracks or deformation.

5. Check the harness (built into the steering wheel) and connectors for damage, and check the terminals for deformation.

PROTECTIVE TUBES

CASE

ACX01302

MATING MARK

ACX00602

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

7. Visually check the case for damage.

WARNING

If the clock spring's mating mark is not properly aligned, the steering wheel may not completely rotate during a turn, or the flat cable within the clock spring may be severed, obstructing normal operation of the SRS and possibly leading to serious injury to the vehicle's driver and passenger.

8. Align the mating marks of the clock spring, and after turning the front wheels to the straight-ahead position, install the clock spring to the column switch.

Mating marks alignment

After turning the clock spring fully clockwise, turn it

approximately 3 4/5 turns counterclockwise until the mating marks are aligned.

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GENERAL <BODY AND CHASSIS>

MAINTENANCE SERVICE

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

10.Check the steering wheel for noise, binds or difficult operation.

00-59

AIR BAG MODULE

AC000118

INSTRUMENT PANEL WIRING HARNESS

DANGER

The SRS may not activate if any of the above components are not installed properly, which could result in serious injury or death to the vehicle's driver and passenger.

11.Chec k the ste e rin g w h eel for e xce s siv e fr e e p l ay. REPLACE ANY VISUALLY INSPECTED PART IF IT FAILS

THAT INSPECTION. (Refer to GROUP 52B, Air Bag Module and Clock Spring P.52B-69.)

Wiring Harness

SIDE AIR BAG WIRING HARNESS (ECLIPSE ONLY)

FRONT WIRING HARNESS (LH)

AC00 011 9

1. Check the connector for poor connection.

DANGER

The SRS system may not operate if SRS harnesses or connectors are damaged or improperly connected, which could result in serious injury or death to the vehicle's driver and passenger.

2. Check the harness for binds, the connectors for damage, and the terminals for deformation. REPLACE ANY CONNECTORS OR HARNESS THAT FAIL THE VISUAL INSPECTION. (Refer to GROUP 52B, SRS Service Precaution P.52B-69.)

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00-60

GENERAL <BODY AND CHASSIS>

MAINTENANCE SERVICE

21. EXHAUST SYSTEM (CONNECTION PORTION

OF MUFFLER, PIPINGS AND CONVERTER HEAT SHIELDS) (CHECK AND SERVICE AS REQUIRED)

1. Check for holes and gas leaks due to damage, corrosion, etc.

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

3. Check the hanger rubber and brackets for damage.

M1001005800073

AC000120

22. TIRES (ROTATE)

M1001008900080

Rotate tires regularly to equalize tire wear and help extend tire life. Recommended tire rotation is every 7,500 miles (12,000 km) under normal driving conditions and every 6,000 miles (9,600 km) in severe driving conditions. Timing for the rotation may vary according to vehicle condition, road surface conditions, and individual driver's habits. When rotating tires, check for uneven wear, damage, and wheel alignment. Abnormal wear is usually caused by incorrect tire pressure, improper wheel alignment, out-of balance wheels, or severe braking. The first rotation is the most important to achieve more uniform wear for all tires on the vehicle.

23. AIR PURIFIER FILTER (REPLACE)

M1001009000013

1. Remove the glove box inner and outer (Refer to P.52A-4.)

2. Pull the air purifier filter cut of the blower assembly.

3. Insert a new air purifier into the glove box inner and outer.

AIR PURIFIER FILTER

AC004883

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GENERAL <BODY AND CHASSIS>

MAIN SEALANT AND ADHESIVE TABLE

00-61

MAIN SEALANT AND ADHESIVE TABLE

APPLICATION 3M NO. LOCTITE/

PERMATEXNO.

ENGINE AND DRIVETRAIN

WEATHERSTRI PPING FOR GLASS

Between rocker cover and camshaft bearing cap. Between rocker cover, semicircular packing and cylinder head. Between oil pressure switch and engine.

Between engine coolant temperature switch, engine coolant temperature sensor, thermo valve, thermo switch, joint, engine coolant temperature gauge unit (large-size) and engine

Between oil pan and engine block

Between tempered glass, body flanges, and weatherstrip

Between laminated glass and weatherstrip

3M AAD Part No. 8660 Ultrapro High Temp.Silicone Gasket or 3M AAD Part No. 8679 Black/8678 Black Press-InPlace Silicone gasket strips

3M AAD Part No. 8731 Medium Strength Blue Threadlocker

3M AAD Part No. 8672, 3M AAD Part No. 8704 or 3M AAD Part No. 8679/ 3M AAD Part No. 8678 or

3M AAD Part No. 8509 Auto Bedding and Glazing Compound or 3M AAD Part No. 8633 Windo-weld Resealant

3M AAD Part No. 8633

Permatex Ultra Black 598, No.82180

Loctite242 Blue Service Too l Re mo va ble 2 42 00

Permatex Ultra Gray 599, No.82194

−

M1001003800107

INTERIORS Adhesive of vinyl chloride

cloth

Adhesion of door weatherstrip

Sealing of various grommets and packing

Adhesion of headliners and various interior decorative materials

3M AAD Part No. 8088 General Trim Adhesive or 3M AAD Part No. 8064 Vinyl Trim Adhesive

3M AAD Part No. 8001 (yellow) or 3M AAD Part No. 8008 (black) Super Weatherstrip Adhesive or 3M AAD Part No. 8011 Black Weatherstrip Adhesive

3M AAD Part No. 8509 or 3M AAD Part No. 8678

3M AAD Part No. 8088 General Trim Adhesive or 3M AAD Part No. 8090 Super Trim Adhesive

Permatex Vinyl Repair Kit No.81786

Permatex Super Black Weatherstrip Adhesive No.82, 81850

−

Permatex Spray Adhesive No.82019

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00-62

APPLICATION 3M NO. LOCTITE/

GENERAL <BODY AND CHASSIS>

MAIN SEALANT AND ADHESIVE TABLE

PERMATEXNO.

BODY SEALANTS

CHASSIS SEALANT

Sealing of sheet metal joints, drip rail, floor, side panels, trunk, front panel, tail gate hinge

Miscellaneous body sealants (original mounted w/adhesive tape)

• Waterproof door film

• Fender panel

• Splash shield

• Mud guard

• Rear combination lamp

Fuel Tank and Pad 3M AAD Part No. 8088

Sealant of various flange faces and threaded parts. Packing of fuel gauge unit

3M AAD Part No. 8531 Heavy Drip-Check Sealer (gray) or 3M AAD Part No. 8302 Ultrapro Autobody Sealant (clear) or 3M AAD Part No. 8361 Urethane A/B Sealant (gray or white)

3M AAD Part No. 8633 Windo-weld Resealant

General Trim Adhesive or 3M AAD Part No. 8090 Super Trim Adhesive

3M AAD Part No. 8730 High Strength Red Thread lock or 3M AAD Part No. 8731 Medium Strength Blue Threadlocker

−

Permatex Spray Adhesive No.82019

Loctite272 High Strength and High Temperature 27200

Sealing of various threaded parts, dust covers. Differential carrier packing, dust covers and ball joint and linkage. Packing and shims of steering box, sealing of rack support cover and top cover of steering box housing, seal of junction face of knuckle arm flange

Seal of brake shoe hold down pin and wheel cylinder of drum brakes

3M AAD Part No. 8672 Ultrapro High Temp.Silicone Gasket or 3M AAD Part No. 8679 (black) or 3M AAD Part No. 8678 (black) Press-In-Place Silicone gasket strips 3M AAD Part No. 8661 or 3M AAD Part No. 8663 Super Silicone sealant

3M AAD Part No. 8633 Windo-weld Resealant

Permatex The Right Stuff No.25223

−

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GENERAL <BODY AND CHASSIS>

MAIN SEALANT AND ADHESIVE TABLE

APPLICATION 3M NO. LOCTITE/

PERMATEXNO.

00-63

QUICK FIX ADHESIVE

ANAEROBIC STRONG SEALING AGENT

UNDERCOATING AGENT

−

Fixing of various threads, bolts, screws. Fixing of differential drive gear bolt, Connecting of tilt steering bolt. Fan, pulley, gear Sealing of small gaps and flange faces

-3M AAD Part No. 8883

3M AAD Part No. 8155 Quick Fix Adhesive

3M AAD Part No. 8730 High Strength Threadlocker or 3M AAD Part No. 8731 Medium Strength ThreadlockerThreadlocker

Rubberized Undercoating Aerosol or 3M AAD Part No. 8864 Body Schutz Undercoating (qt)

LoctiteQuicktite Super Glue 21309

Loctite271, HighStrength Threadlocker 27100 or 27200

Permatex Heavy-Duty Undercoating 81833

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NOTES

Page 65

GROUP 00E

GENERAL

CONTENTS

00E-1

HARNESS CONNECTOR

INSPECTION . . . . . . . . . . . . . . . . . . . 00E-2

HOW TO DIAGNOSE. . . . . . . . . . . . . 00E-5

HOW TO DIAGNOSE . . . . . . . . . . . . . . . . . 00E-5

TROUBLESHOOTING STEPS . . . . . . . . . . 00E-5

INFORMATION FOR DIAGNOSIS . . . . . . . 00E-6

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 00E-7

INSPECTION INSTRUMENTS . . . . . . . . . . 00E-7

CHECKING SWITCHES . . . . . . . . . . . . . . . 00E-8

CHECKING RELAYS . . . . . . . . . . . . . . . . . 00E-10

CHECKING FUSES. . . . . . . . . . . . . . . . . . . 00E-11

CABLES AND WIRES CHECK . . . . . . . . . . 00E-12

BATTERY HANDLING . . . . . . . . . . . . . . . . 00E-12

GENERAL ELECTRICAL SYSTEM

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00E-13

Page 66

00E-2

GENERAL <ELECTRICAL>

HARNESS CONNECTOR INSPECTION

MB991219

HARNESS CONNECTOR INSPECTION

CONNECTOR CONTINUITY AND VOLTAGE TEST

Required Special Tools:

• MB991219: Test Harness Set

• MD998459: Test Harness

Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at connectors of waterproof connectors.

CAUTION

MD998459

AC000014

AC000015

Never backprobing a waterproof connector. Backprobing a connector may cause the terminals to corrode, deteriorating circuit performance.

1. If checking is performed with the circuit in the state of continuity, to use special tool MD998459.

CAUTION

Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit.

2. If the connector is disconnected for checking and the facing part is the female pin side, the harness for checking the contact pressure of connector pins (MB991219) should be used.

CAUTION

Do not simultaneously contact more than one terminal with the probe. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire.

3. If the facing part is the male pin side, contact the test probe directly at the pins.

M1001003900030

AC000016

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IMPROPER TERMINAL ENGAGEMENT CHECK

Te rm in a ls i ns id e a co n ne ct or m a y no t en g ag e pr o pe r ly ev en i f the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the connector.

Page 67

FRONT HOLDER

HARNESS CONNECTOR INSPECTION

FRONT HOLDER

ACX00904

GENERAL <ELECTRICAL>

CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT

Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuit can be done in the following manner.

COMPUTER CONNECTOR

1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage front holder, and remove it.

2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there.

00E-3

HOUSING LANCE

NEEDLE

ACX00905

ACX00906

NEEDLE

ACX00907

3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal.

4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom.

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00E-4

GENERAL <ELECTRICAL>

HARNESS CONNECTOR INSPECTION

ROUND WATERPROOF CONNECTOR

1. Remove the waterproof cap by using a screwdriver.

2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal.

HOUSING LANCE

FRONT HOLDER

ACX00908

ACX00909

FRONT HOLDER

ACX00910

3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom.

RECTANGULAR WATERPROOF CONNECTOR

1. Disengage the front holder with a screwdriver and remove it.

HOUSING LANCE

ACX00911

ACX00912

2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal.

3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom.

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WATERPROOF CAP

GENERAL <ELECTRICAL>

HOW TO DIAGNOSE

INJECTOR CONNECTOR

1. Remove the waterproof cap.

00E-5

ACX00913

2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal.

CAUTION

Make sure the lance is pressed in before the terminal is inserted into the connector.

3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the

TERMINAL LANCE

ACX00914

figure.

HOW TO DIAGNOSE

The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only.

M1001004300064

TROUBLESHOOTING STEPS

M1001004400038

If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting.

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00E-6

Observation of Problem Symptoms

Determination of Probable Causes

GENERAL <ELECTRICAL>

HOW TO DIAGNOSE

Observe the symptom carefully. Check if there are also other problems.

In determining the probable causes, it is necessary to study the wiring diagram to understand the circuit as a system. Knowledge of switches, relays and other parts is necessary for accurate analysis. The causes of similar problems in the past must be taken into account.

Checking of Parts Associated with Plobable Causes and Determination

Troubleshooting is carried out by making step-by-step checks until the cause is found.

of Faulty Parts

After the problems are corrected, be sure to check that the

Repair and Confirmation

INFORMATION FOR DIAGNOSIS

system operates correctly. Also check that new problems have not been caused by the repair.

ACX00915

M1001004500035

This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner:

1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path.

2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions.

3. Operational explanations include circuit drawings

4. Troubleshooting hints include numerous examples of problems which might occur, traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits.

of voltage flow when the switch is operated and how the component operates in reaction.

NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant group which includes details of these components.

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GENERAL <ELECTRICAL>

HOW TO DIAGNOSE

00E-7

CLICK

ACX00936

ACX00937

INSPECTION

M1001004600032

1. Sight and sound checks Check relay operation, blower motor rotation, light

illumination, etc. Listen for a "click" when a relay cover is pushed down.

2. Simple checks For example, if a headlight does not come on and a faulty

fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem.

SELECTOR KNOB

POINTER

ACX00938

3. Checking with instruments Use an appropriate instrument in an adequate range and

read the indication correctly.

INSPECTION INSTRUMENTS

M1001004700039

For inspection, use the following instruments:

1. Test lights A test light consists of a 12V bulb and lead wires. It is used

to check voltages or short circuits.

ACX00939

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00E-8

GENERAL <ELECTRICAL>

HOW TO DIAGNOSE

2. Self-powered test light A self-powered test light consists of a bulb, battery and lead

wires connected in series. It is used to check continuity or grounding.

ACX00940

3. Jumper wire A jumper wire is used to close an open circuit.

CAUTION

Never use a jumper wire to connect a power supply directly to a load.

POWER LINE

RED LEAD WIRE

ACX00941

BLACK LEAD WIRE

GROUND

ACX00942

ACX00943

4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally,

the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop before or after a component.

5. Ohmmeter An ohmmeter is used to check continuity or measure

resistance of a switch or coil. If the measuring range has been changed, the zero point must be adjusted before measurement.

CHECKING SWITCHES

In a circuit diagram, a switch is shown in the idle state.

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M1001004800036

Page 73

GENERAL <ELECTRICAL>

HOW TO DIAGNOSE

00E-9

NORMAL OPEN (NO) TYPE

OFF

CURRENT DOES NOT FLOW

NORMAL CLOSED (NC) TYPE

OFF

CURRENT FLOWS

CURRENT DOES NOT FLOW

1. Normally open or normally closed switch Switches are classified into those which open the circuit and

those which close the circuit when off.

ACX00944AB

2. Switch connection This figure illustrates a complex switch. The continuity

between terminals at each position is as indicated in the table below.

OFF

1ST 2ND 3RD

4TH

STAGE

SWITCH POSITION

OFF

TESTER CONNECTION

SPECIFIED CONNECTION

−−

1st stage 1−5−6Continuity

2nd stage 1−4−6Continuity

3rd stage 1−3−6Continuity

4th stage 1−2−6Continuity

ACX00945

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00E-10

GENERAL <ELECTRICAL>

HOW TO DIAGNOSE

NORMAL CLOSED (NC) TYPE

DEENERGIZED STATE

321

CURRENT FLOWS CURRENT DOES

COIL

IRON PIECE

ENERGIZED STATE

321

NOT FLOW

ACX00946

COVER

ACX00947

SPRING

IRON CORE

CONTACT

CHECKING RELAYS

M1001004900033

NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. When a normal closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when the battery voltage and ground are applied to terminals 1 and 2.

1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF).

POWER SUPPLY

OFF

FUSE

LIGHT

OFF

RELAY

SWITCH ON

ACX00948

2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light.

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Page 75

GENERAL <ELECTRICAL>

HOW TO DIAGNOSE

00E-11

NORMAL OPEN (NO) TYPE

DEENERGIZED STATE ENERGIZED STATE

CURRENT DOES NOT FLOW

NORMAL CLOSED (NC) TYPE

DEENERGIZED STATE

CURRENT FLOWS

ACX00949

ENERGIZED STATE

CURRENT DOES NOT FLOW

ACX00950

3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction.

FUSE BLOCK

TEST TAPS

STATE OF FUSE BLOWN DUE TO OVERCURRENT

ACX00951

ACX00952

CHECKING FUSES

M1001005000033

A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live.

CAUTIONS IN EVENT OF BLOWN FUSE

When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below.

1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this

cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged.

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00E-12

STATE OF FUSE BLOWN DUE TO THERMAL FATIGUE

GENERAL <ELECTRICAL>

HOW TO DIAGNOSE

2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to

repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than the above. In this case, simply replace with a new fuse of the same capacity.

ACX00953

ACX00954

ACX00955

CABLES AND WIRES CHECK

M1001005100030

1. Check connections for looseness, rust, and stains.

2. Check terminals and wires for corrosion by battery electrolyte, etc.

3. Check terminals and wires for open circuit or impending open circuit.

4. Check wire insulation and coating for damage, cracks and wear.

5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts).

6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body.

7. Check for incorrect wiring.

8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.).

9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts.

10.Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement.

AC000017

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BATTERY HANDLING

M1001005200037

WARNING

Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING.

When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last.

Page 77

GENERAL <ELECTRICAL>

HOW TO DIAGNOSE

00E-13

(1)

POWER SUPPLY

ON (2)

OFF

TEST LIGHT (OR VOLTMETER)

(3)

FUSE

SWITCH

MOTOR

ACX00956AB

GENERAL ELECTRICAL SYSTEM CHECK

M1001005300034

A circuit consists of the power supply, switch, relay, load, ground, etc. There are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration.

1. VOLTAGE CHECK

(1) Ground one lead wire of the test light. If a voltmeter is

used instead of the test light, ground the grounding side lead wire.

(2) Connect the other lead wire of the test light to the power

side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage.

(3) Then, connect the test light or voltmeter to the motor

connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned on in this state, the test light should come on, or the voltmeter should indicate a voltage, with motor starting to run.

(4) The circuit illustrated here is normal. If there is any

problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified.

2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a

short circuit. Follow the procedures below to narrow down the short-circuit location.

TEST LIGHT

POWER SUPPLY

OFF

ILLUMINATION LIGHT

FUSE BLOCK (REMOVE THE FUSE)

SHORT-CIRCUIT LOCATION

SWITCH

STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Switch: OFF). Q: Does the test light illuminate?

YES : Short-circuit exists between the fuse block and the

switch.Repair the harness between the fuse block and the switch.

NO : Go to Step 2.

ACX00957

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00E-14

TEST LIGHT

POWER SUPPLY

SWITCH

SHORT-CIRCUIT LOCATION

DISCONNECT THE LOAD

FUSE BLOCK (REMOVE THE FUSE)

GENERAL <ELECTRICAL>

HOW TO DIAGNOSE

STEP 2. Switch on the switch and disconnect the illumination light connector. Q: Does the test light illuminate?

YES : Short-circuit exists between the switch and the

connector. Repair the harness between the switch and the connector.

NO : Short-circuit exists between the connector and the

illumination light. Repair the harness between the switch and the connector.

TEST LIGHT

ILLUMINATION LIGHT

POWER SUPPLY

FUSE BLOCK (REMOVE THE FUSE)

SWITCH

DISCONNECT THE LOAD

SHORT-CIRCUIT LOCATION

ACX00958

ILLUMINATION LIGHT

ACX00959

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SELF POWER TEST LIGHT (OR OHMMETER)

OFF

ACX00960

OFF

GENERAL <ELECTRICAL>

HOW TO DIAGNOSE

3. CONTINUITY CHECK

(1) When the switch is in the "OFF" position, the self-

powered test light should illuminate or the ohmmeter should read 0 ohm, only when the contact points of terminals 1 and 2 are connected.

(2) When the switch is the "ON" position, the self-powered

test light should come on or the ohmmeter should read 0 ohm, only when the contact points of terminals 3 and 4 are connected.

00E-15

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Page 80

NOTES

Page 81

GROUP 11

ENGINE

CONTENTS

ENGINE MECHANICAL <2.4L ENGINE>. . . . . . . . . . . . . . . . . . 11A

ENGINE OVERHAUL <2.4L ENGINE> . . . . . . . . . . . . . . . . . . . . 11B

11-1

ENGINE MECHANICAL <3.0L ENGINE>. . . . . . . . . . . . . . . . . . 11C

ENGINE OVERHAUL <3.0L ENGINE> . . . . . . . . . . . . . . . . . . . . 11D

Page 82

11A-2

GROUP 11A

ENGINE

MECHANICAL

<2.4L ENGINE>

CONTENTS

GENERAL DESCRIPTION. . . . . . . . . 11A-3

ENGINE DIAGNOSIS. . . . . . . . . . . . . 11A-3

SPECIAL TOOLS. . . . . . . . . . . . . . . . 11A-4

ON-VEHICLE SERVICE. . . . . . . . . . . 11A-6

DRIVE BELT TENSION CHECK AND

ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 11A-6

IGNITION TIMING CHECK . . . . . . . . . . . . . 11A-6

IDLE MIXTURE CHECK . . . . . . . . . . . . . . . 11A-7

CURB IDLE SPEED CHECK . . . . . . . . . . . 11A-8

COMPRESSION PRESSURE CHECK. . . . 11A-8

MANIFOLD VACUUM CHECK . . . . . . . . . . 11A-9

LASH ADJUSTER CHECK . . . . . . . . . . . . . 11A-10

ENGINE ASSEMBLY. . . . . . . . . . . . . 11A-12

REMOVAL AND INSTALLATION . . . . . . . . 11A-12

CAMSHAFT AND CAMSHAFT

OIL SEAL . . . . . . . . . . . . . . . . . . . . . . 11A-17

REMOVAL AND INSTALLATION . . . . . . . . 11A-17

OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 11A-20

REMOVAL AND INSTALLATION . . . . . . . . 11A-20

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11A-22

CRANKSHAFT FRONT OIL SEAL. . . 11A-22

REMOVAL AND INSTALLATION . . . . . . . . 11A-22

CRANKSHAFT REAR OIL SEAL. . . . 11A-24

REMOVAL AND INSTALLATION . . . . . . . . 11A-24

CYLINDER HEAD GASKET . . . . . . . . 11A-26

REMOVAL AND INSTALLATION . . . . . . . . 11A-26

TIMING BELT . . . . . . . . . . . . . . . . . . . 11A-31

REMOVAL AND INSTALLATION . . . . . . . . 11A-31

TIMING BELT B . . . . . . . . . . . . . . . . . 11A-35

REMOVAL AND INSTALLATION . . . . . . . . 11A-35

SPECIFICATIONS . . . . . . . . . . . . . . . 11A-38

FASTENER TIGHTENING

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 11A-38

SERVICE SPECIFICATIONS . . . . . . . . . . . 11A-39

SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-39

Page 83

ENGINE MECHANICAL <2.4L ENGINE>

GENERAL DESCRIPTION

11A-3

GENERAL DESCRIPTION

M1111000100099

The 4G64 (2.4L) engine is an in-line four cylinder engine. The cylinder numbers are assigned as 1-2-3-4 from the front of the engine (timing belt side). This engine is fired in the order of the 1, 3, 4 and 2 cylinders.

ITEMS SPECIFICATIONS

Type In-line SOHC

Number of cylinders 4

Bore mm (in) 86.5 (3.41)

Stroke mm (in) 100.0 (3.94)

Piston displacement cm

Compression ratio 9.0

Firing order 1-3-4-2

Counterbalance shaft Equipped

Valve t i mi n g I n tak e va l ve Opens (BT D C) 16°

(cu in)

Closes (ABDC) 60° <M/T>

Exhaust valve Opens (BBDC) 60° <M/T>

Closes (ATDC) 16°

2,351 (143.4)

53° <A/T>

50° <A/T>

Lubrication Pressure feed-full flow filtration

Oil pump type Involute gear type

ENGINE DIAGNOSIS

SYMPTOMS PROBABLE CAUSE REMEDY

Compression is too low

Drop in oil pressure Engine oil level is too low Check the engine oil level

Blown cylinder head gasket Replace the gasket

Worn or damaged piston rings Replace the rings

Worn piston or cylinder Repair or replace the piston and/or the

cylinder block

Worn or damaged valve seat Repair or replace the valve and/or the

seat ring

Malfunction of oil pressure switch Replace the oil pressure switch

Clogged oil filter Install a new filter

Worn oil pump gears or cover Replace the gears and/or the cover

Thin or diluted engine oil Change the engine oil to correct viscosity

M1111000700109

Stuck (opened) oil relief valve Repair the relief valve

Excessive bearing clearance Replace the bearings

Oil pressure too high stuck (closed) oil relief valve Repair the relief valve

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11A-4

ENGINE MECHANICAL <2.4L ENGINE>

SPECIAL TOOLS

SYMPTOMS PROBABLE CAUSE REMEDY

Noisy valves Malfunction of lash adjuster (including

Check the lash adjuster

entry of air into high pressure chamber)

Thin or diluted engine oil (low oil

Change the engine oil

pressure)

Worn or damaged valve stem or valve

Replace the valve and/or the guide

guide

Connecting rod noise/ main bearing noise

Insufficient oil supply Check the engine oil level

Low oil pressure Refer to oil pressure drop symptoms

above

Thin or diluted engine oil Change the engine oil

Excessive bearing clearance Replace the bearings

SPECIAL TOOLS

TOOL TOOL NUMBER AND

NAME

MB991502 Scan tool (MUT-II)

B991502

MB991453 Engine hanger assembly

MB991453

GENERAL SERVICE TOOL MZ203827 Engine lifter

MZ203827

MB990767 End yoke holder

M1111000600168

SUPERSESSION APPLICATION

MB991496-OD • Ignition timing check

• Idle speed check

MZ203827-01 Supporting the engine

assembly during removal and installation of the transaxle

MZ203827-01

MB990767-01 Holding the camshaft

sprocket when loosening and tightening bolt

MB990767

MD998719

MD998719 Crankshaft pulley holder pin

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MT308239

Page 85

ENGINE MECHANICAL <2.4L ENGINE>

SPECIAL TOOLS

11A-5

TOOL TOOL NUMBER AND

NAME

MD998443 Lash adjuster holder (8)

D998443

MD998713 Camshaft oil seal installer

D998713

MD998727 Oil pan remover

MB991367 Special spanner

SUPERSESSION APPLICATION

MD998443-01 Supporting of the auto-lash

adjuster to prevent it from falling when rocker shaft assembly is removed or installed

MD998713-01 Camshaft oil seal

installation

MD998727-01 Oil pan removal

MB991367-01 Holding the crankshaft

sprocket

B991367

D998781

MD998375 Crankshaft oil seal installer

MD998781 Flywheel stopper

MD998776 Crankshaft rear oil seal installer

MB990938 Handle

MD998375-01 Crankshaft front oil seal

installation

General service tool Flywheel <M/T> or Drive

plate <A/T> supporting

MD998776-01 Crankshaft rear oil seal

installation

MB990938-01

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Page 86

11A-6

ENGINE MECHANICAL <2.4L ENGINE>

ON-VEHICLE SERVICE

TOOL TOOL NUMBER AND

NAME

MB991654 Cylinder head bolt wrench (12)

MD998738 Adjusting screw

MD998767 Te ns io n er p ul le y s o c ke t wrench

D998767

SUPERSESSION APPLICATION

General service tool Removal and installation of

cylinder head bolt

General service tool • Holding the auto-

tensioner

• Timing belt tension adjustment

MD998752-01 Timing belt tension

adjustment

16 PIN

MB991502

ON-VEHICLE SERVICE

DRIVE BELT TENSION CHECK AND ADJUSTMENT

Refer to GROUP 00, Maintenance Service − Drive Belts (Check Condition) P.00-40.

IGNITION TIMING CHECK

Required Special Tool:

MB991502: Scan Tool (MUT-II)

1. Before inspection, set vehicles in the following condition:

• Engine coolant temperature: 80 − 95°C (176 − 203°F)

• Lights and all accessories: OFF

• Transaxle: Neutral (P range on vehicles with A/T)

CAUTION

To p r e ven t da m age to scan too l MB 9 9 150 2 , always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502.

2. Connect scan tool MB991502 to the data link connector.

3. Set up a timing light.

4. Start the engine and run it at idle.

5. Check that the idle speed is approximately 700 r/min.

6. Select scan tool MB991502 actuator test "item number 17."

AKX01177

7. Check that basic ignition timing is within the standard value.

Standard value: 5° BTDC ± 3°

M1111003100106

M1111001700061

8. If the basic ignition timing is not within the standard value,

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check the following items:

Page 87

ENGINE MECHANICAL <2.4L ENGINE>

ON-VEHICLE SERVICE

• Diagnosis output

• Timing belt cover and crankshaft position sensor installation

conditions

• Crankshaft sensing blade condition

CAUTION

If the actuator test is not canceled, the forced drive will continue for 27 minutes. Driving in this state could lead to engine failure.

9. Press the clear key on scan tool MB991502 (select forced drive stop mode), and cancel the actuator test.

10.Check that the actual ignition timing is at the standard value.

Standard value: Approximately 10° BTDC

NOTE: Ignition timing fluctuates about ± 7° Before Top Dead Center, even under normal operating condition.

NOTE: It is automatically further advanced by about 5° to 10° Before Top Dead Center at higher altitudes.

11A-7

16 PIN

MB991502

AKX01177

IDLE MIXTURE CHECK

M1111002100062

Required Special Tool:

MB991502: Scan Tool (MUT-II)

1. Before inspection, set vehicles in the following condition:

• Engine coolant temperature: 80 − 95°C (176 - 203°F)

• Lights and all accessories: OFF

• Transaxle: Neutral (P range on vehicles with A/T)

CAUTION

To p r e ven t da m age to scan too l MB 9 9 150 2 , always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502.

2. Connect scan tool MB991502 to the data link connector.

3. Check that the basic ignition timing is within the standard value.

Standard value: 5° BTDC ± 3°

4. Start the engine and increase the engine speed to 2,500 r/ min for 2 minutes.

5. Set the CO, HC tester.

6. Check the CO contents and the HC contents at idle.

Standard value:

CO contents: 0.5% or less HC contents: 100 ppm or less

7. If the CO and HC contents do not remain inside the standard

• Diagnosis output

• Closed-loop control (When the closed-loop control is carried

• Fuel pressures

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value, check the following items:

NOTE: Replace the catalytic converter when the CO and HC contents do not remain inside the standard value, even though the result of the inspection is normal for all items.

out normally, the output signal of the heated oxygen sensor changes between 0 − 400 mV and 600 − 1,000 mV at idle.)

Page 88

11A-8

ENGINE MECHANICAL <2.4L ENGINE>

ON-VEHICLE SERVICE

• Injector

• Ignition coil, spark plug cable, spark plug

• EGR system and EGR valve leak

• Evaporative emission control system

• Compression pressure

16 PIN

MB991502

AKX01177

CURB IDLE SPEED CHECK

M1111003500096

Required Special Tool:

MB991502: Scan Tool (MUT-II)

1. Before inspection and adjustment set vehicles in the following condition.

• Engine coolant temperature: 80 − 95°C (176 - 203°F)

• Lights and all accessories: OFF

• Transaxle: Neutral (P range on vehicles with A/T)

CAUTION

To p r e ven t da m age to scan too l MB 9 9 150 2 , always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502.

2. Connect scan tool MB991502 to the data link connector.

3. Check the basic ignition timing.

Standard value: 5° BTDC ± 3°

4. Start the engine.

5. Run the engine at idle for 2 minutes.

6. Check the idle speed. Select item number 22 and take a reading of the idle speed.

Curb idle speed: 700 ± 100 r/min

NOTE: The idle speed is controlled automatically by the idle air control system.

7. If the idle speed is outside the standard value, refer to GROUP 13A, Diagnosis − Symptom Chart P.13A-22.

COMPRESSION PRESSURE CHECK

1. Before inspection, check that the engine oil, starter and

• Engine coolant temperature: 80 − 95°C (176 − 203°F)

• Lights, and all accessories: OFF

• Transaxle: Neutral (P range on vehicles with A/T)

2. Disconnect the spark plug cables.

3. Remove all of the spark plugs.

4. Disconnect the crankshaft position sensor connector.

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M1111002600056

battery are normal. Also, set the vehicle in the following condition:

NOTE: Doing this will prevent the engine control module from carrying out ignition and fuel injection.

Page 89

COMPRESSION GAUGE

ENGINE MECHANICAL <2.4L ENGINE>

ON-VEHICLE SERVICE

WARNING

Keep your distance from the spark plug hole when cranking. Oil, fuel, etc., may spray out from the spark plug hole and may cause serious injury.

5. Cover the spark plug hole with a shop towel etc., during cranking. After the engine has been cranked, check for foreign material adhering to the shop towel.

6. Set compression gauge to one of the spark plug holes.

7. Crank the engine with the throttle valve fully open and measure the compression pressure.

Standard value (at engine speed of 250 − 400 r/min): 1,275 kPa (185 psi)

Minimum limit (at engine speed of 250 − 400 r/min): 959 kPa (139 psi)

8. Measure the compression pressure for all the cylinders, and

AKX01178

check that the pressure differences of the cylinders are below the limit.

Limit: 98 kPa (14 psi)

11A-9

VACUUM GAUGE

AKX01179

9. If there is a cylinder with compression or a compression difference that is outside the limit, pour a small amount of engine oil through the spark plug hole, and repeat the operations in steps 6 to 8.

(1) If the compression increases after oil is added, the cause

of the malfunction is a worn or damaged piston ring and/ or cylinder inner surface.

(2) If the compression does not rise after oil is added, the

cause is a burnt or defective valve seat, or pressure is leaking from the gasket.

10.Connect the crankshaft position sensor connector.

11.Inst a ll th e sp ark plu g s a n d s p ark plu g ca b les .

12.Use the scan tool to erase the diagnostic trouble codes.

NOTE: This will erase the diagnostic trouble code resulting from the crankshaft position sensor connector being disconnected.

MANIFOLD VACUUM CHECK

M1111002700064

1. Start the engine and allow it to warm up until the temperature of the engine coolant reaches 80 − 95°C (176 − 203°F).

2. Connect a tachometer.

3. Attach a tee-fitting union to the vacuum hose between the fuel pressure regulator and the intake manifold plenum, and connect a vacuum gauge.

4. Start the engine and check that idle speed is within specification. Then check the vacuum gauge reading.

Idle speed: 700 ± 100 r/min

Minimum limit: 60 kPa (18 in Hg)

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Page 90

11A-10

ENGINE MECHANICAL <2.4L ENGINE>

ON-VEHICLE SERVICE

LASH ADJUSTER CHECK

If an abnormal noise (chattering noise) suspected to be caused by malfunction of the lash adjuster is produced immediately after starting the engine and does not disappear, perform the following check.

NOTE: An abnormal noise due to malfunction of the lash adjuster is produced immediately after starting the engine and changes with the engine speed, irrespective of the engine load. If, the abnormal noise is not produced immediately after starting the engine or does not change with the engine speed, or it changes with the engine load, the lash adjuster is not the cause for the abnormal noise.

NOTE: When the lash adjuster is malfunctioning, the abnormal noise is rarely eliminated by continuing the warming-up of the engine at idle speed. However, the abnormal noise may disappear only when seizure is caused by oil sludge in the engine whose oil is not maintained properly.

1. Start the engine.

2. Check if the abnormal noise produced immediately after starting the engine, changes with the change in the engine speed.

If the abnormal noise is not produced immediately after starting the engine or it does not change with the engine speed, the lash adjuster is not the cause for the noise. Therefore, investigate other causes. The abnormal noise is probably caused by some other parts than the engine proper if it does not change with the engine speed. (In this case, the lash adjuster is in good condition.)

3. With the engine idling, change the engine load (shift from N to D range, for example) to make sure that there is no change in the level of abnormal noise.

If there is a change in the level of abnormal noise, suspect a tapping noise due to worn crankshaft bearing or connecting rod bearing. (In this case, the lash adjuster is in good condition.)

4. After completion of warm-up, run the engine at idle to check for abnormal noise.

If the noise is reduced or disappears, clean the lash adjuster (Refer to GROUP 11B-Engine overhaul − Rocker Arms and Camshaft − Inspection P.11B-28.) As it is suspected that the noise is due to seizure of the lash adjuster. If there is no change in the level of the abnormal noise, proceed to step 5.

5. Run the engine to bleed the lash adjuster system. (Refer to

P.11A-11.)

6. If the abnormal noise does not disappear after air bleeding operation, clean the lash adjuster (Refer to GROUP 11BEngine overhaul − Rocker Arms and Camshaft − Inspection

P.11B-28.)

M1111002900121

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GOOD

MINIMUM

MAXIMUM

ENGINE MECHANICAL <2.4L ENGINE>

ON-VEHICLE SERVICE

Bleeding lash adjuster system

NOTE: Parking the vehicle on a grade for a long time may decrease oil in the lash adjuster, causing air to enter the high pressure chamber when starting the engine.

NOTE: After parking for many hours, oil may run out from the oil passage and take time before oil is supplied to the lash adjuster, causing air to enter the high pressure chamber.

NOTE: In the above cases, abnormal noise can be eliminated by bleeding the lash adjuster system.

1. Check engine oil and add or change oil if required.

NOTE: If the engine oil level is low, air is sucked from the oil screen, causing air to enter the oil passage.

NOTE: If the engine oil level is higher than specification, oil may be stirred by the crankshaft, causing oil to be mixed with a large quantity of air.

NOTE: If oil is deteriorated, air is not easily separated from oil, increasing the quantity of air contained in oil.

AKX00328

11A-11

AIR BLEEDING OPERATION PATTERN

OPEN THROTTLE VALVE GRADUALLY

APPROXIMATELY 3,000 r/min

IDLING OPERATION

15s 15s

ONCE

CLOSE THROTTLE VALVE

HIGHPRESSURE CHAMBER

AKX00329

AKX00330

NOTE: If air mixed with oil enters the high pressure chamber inside the lash adjuster from the above causes, air in the high pressure chamber is compressed excessively while the valve is opened, resulting in an abnormal noise when the valve closes. This is the same phenomenon as that observed when the valve clearance has become excessive. The lash adjuster can resume normal function when air entered the lash adjuster is removed.

2. Idle the engine for one to three minutes to warm it up.

3. Repeat the operation pattern, shown in left figure, at no load to check for abnormal noise. (Usually the abnormal noise is eliminated after repetition of the operation 10 to 30 times. If, however, no change is observed in the level of abnormal noise after repeating the operation more than 30 times, suspect that the abnormal noise is due to some other factors.)

4. After elimination of abnormal noise, repeat the operation shown in left figure five more times.

5. Run the engine at idle for one to three minutes to make sure that the abnormal noise has been eliminated.

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11A-12

ENGINE MECHANICAL <2.4L ENGINE>

ENGINE ASSEMBLY

REMOVAL AND INSTALLATION

M1112001000184

CAUTION

*: Indicates parts which should be temporarily tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body.

Pre-removal Operation

• Hood Removal (Refer to GROUP 42, Hood P.42-7.)

• Fuel Line Pressure Reduction [Refer to GROUP 13A, On-

vehicle Service − Fuel Pump Relay Disconnection (How to Reduce Pressurized Fuel Lines) P.13A-478.]

• Engine Oil Draining (Refer to GROUP 12, On-vehicle Service − Engine Oil Replacement P.12-3.)

• Engine Coolant Draining [Refer to GROUP 00, Maintenance Service − Engine Coolant (Change) P.00-52.]

• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner

P.15-5.)

• Reserve Tank and Radiator Removal (Refer to GROUP 14, Radiator P.14-19.)

• Front Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler P.15-19.)

Post-installation Operation

• Front Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler P.15-19.)

• Reserve Tank and Radiator Installation (Refer to GROUP 14, Radiator P.14-19.)

• Air Cleaner Installation (Refer to GROUP 15, Air Cleaner

P.15-5.)

• Drive Belt Tension Adjustment [Refer to GROUP 00, Maintenance Service − Drive Belts (Check Condition)

P.00-40.]

• Engine Oil Refilling (Refer to GROUP 12, On-vehicle Service − Engine Oil Replacement P.12-3.)

• Engine Coolant Refilling [Refer to GROUP 00, Maintenance Service − Engine Coolant (Change) P.00-52.]

• Accelerator Cable Adjustment (Refer to GROUP 17, Onvehicle Service − Accelerator Cable Check and Adjust- ment P.17-4.)

• Hood Installation (Refer to GROUP42, Hood P.42-7.)

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ENGINE MECHANICAL <2.4L ENGINE>

ENGINE ASSEMBLY

11A-13

4.8 ± 1.0 N·m 44 ± 8 in-lb

FUEL RAIL

O-RING

ENGINE OIL

12 ± 2 N·m 100 ± 22 in-lb

REMOVAL STEPS

1. ACCELERATOR CABLE CONNECTION

2. PURGE HOSE CONNECTION

3. BRAKE BOOSTER VACUUM HOSE CONNECTION

4. VACUUM HOSE CONNECTION

5. IGNITION COIL CONNECTOR

6. INJECTOR CONNECTOR

7. IGNITION FAILURE SENSOR CONNECTOR

8. MANIFOLD DIFFERENTIAL PRESSURE SENSOR CONNECTOR

9. THROTTLE POSITION SENSOR CONNECTOR

10. HEATED OXYGEN SENSOR (FRONT) CONNECTOR

11. CAPACITOR CON N E C TO R

12. ENGINE COOLANT TEMPERATURE SENSOR CONNECTOR

>>D<<

AC001692

REMOVAL STEPS (Continued)

13. CAMSHAFT POSITION SENSOR CONNECTOR

14. KNOCK SENSOR CONNECTOR

15. ENGINE COOLANT TEMPERATURE GAUGE UNIT CONNECTOR

16. IDLE AIR CONTROL MOTOR CONNECTOR

17. EVAPORATIVE EMISSION PURGE SOLENOID VALVE CONNECTOR

18. EGR SOLENOID VALVE CONNECTOR

19. HIGH-PRESSURE FUEL HOSE CONNECTION

20. FUEL RETURN HOSE CONNECTION

21. PRESSURE HOSE CONNECTION

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11A-14

ENGINE MECHANICAL <2.4L ENGINE>

ENGINE ASSEMBLY

29 ± 3 N·m 21 ± 3 ft-lb

49 ± 10 N·m 36 ± 7 ft-lb

29 ± 3 N·m 21 ± 3 ft-lb

11 ± 1 N·m 96 ± 8 in-lb

49 ± 10 N·m 36 ± 7 ft-lb

14 ± 1 N·m 117 ± 13 in-lb

12 ± 2 N·m 100 ± 22 in-lb

(ENGINE OIL)

22. OIL DIPSTICK AND DIPSTICK GUIDE

23. PRESSURE HOSE CONNECTION

24. HEATER HOSE CONNECTION

25. GENERATOR CONNECTOR

26. OIL PRESSURE SWITCH CONNECTOR

27. DRIVE BELT (POWER STEERING OIL PUMP AND A/C COMPRESSOR)

28. DRIVE BELT (GENERATOR)

29. CRANKSHAFT POSITION SENSOR CONNECTOR

<<A>>

<<B>> <<C>> <<D>> >>C<<

>>B<<

<<E>> >>A<<

86 ± 12 N·m 64 ± 8 ft-lb

81 ± 12 N·m* 60 ± 9 ft-lb*

30. POWER STEERING PRESSURE SWITCH CONNECTOR

31. POWER STEERING OIL PUMP AND BRACKET ASSEMBLY

32. A/C COMPRESSOR ASSEMBLY CONNECTOR

33. A/C COMPRESSOR TRANSAXLE ASSEMBLY

•

34. ENGINE MOUNT BRACKET

35. ENGINE MOUNT STOPPER

36. ENGINE ASSEMBLY

AC001694

Required Special Tools:

• MB991453: Engine Hanger Assembly

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• MZ203827: Engine Lifter

Page 95

<M/T>

FLYWHEEL

ENGINE MECHANICAL <2.4L ENGINE>

ENGINE ASSEMBLY

REMOVAL SERVICE POINTS

<<A>> POWER STEERING OIL PUMP AND BRACKET ASSEMBLY REMOVAL

Remove the power steering oil pump and bracket assembly from the engine with the hose attached.

NOTE: Place the removed power steering oil pump in a place where it will not be a hindrance when removing and installing the engine assembly, and secure it with a cord or wire.

<<B>> A/C COMPRESSOR REMOVAL

Remove the compressor from the compressor bracket with the hose still attached.

NOTE: Place the removed A/C compressor where it will not be a hindrance when removing and installing the engine assembly, and secure it with a cord or wire.

<<C>> TRANSAXLE ASSEMBLY REMOVAL

CAUTION

Do not remove the flywheel mounting bolt shown by the arrow. If this bolt Is removed, the flywheel will become out of balance and damaged.

<M/T>: Refer to GROUP 22A, Transaxle Assembly P.22A-14. <A/T>: Refer to GROUP 23A, Transaxle Assembly P.23A-353.

11A-15

MZ203827

MB991453

BOLT

AC000126

AC000127

<<D>> ENGINE MOUNT BRACKET REMOVAL

1. Support the engine with a garage jack.

2. Remove special tools MB991453 and MZ203827 which was attached when the transaxle assembly was removed.

3. Hold the engine assembly with a chain block or similar tool.

4. Place a garage jack against the engine oil pan with a piece of wood in between, jack up the engine so that the weight of the engine is no longer being applied to the engine mount bracket, and then remove the engine mount bracket.

<<E>> ENGINE ASSEMBLY REMOVAL

After checking that all cables, hoses and harness connectors, etc., are disconnected from the engine, lift the chain block slowly to remove the engine assembly upward from the engine compartment.

INSTALLATION SERVICE POINTS

>>A<< ENGINE ASSEMBLY INSTALLATION

Install the engine assembly, checking that the cables, hoses, and harness connectors are not clamped.

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11A-16

ENGINE SIDE

ENGINE MOUNT BRACKET

ENGINE MECHANICAL <2.4L ENGINE>

ENGINE MOUNT STOPPER

ENGINE ASSEMBLY

>>B<< ENGINE MOUNT STOPPER INSTALLATION

Clamp the engine mount stopper so that the arrow points in the direction as shown in the diagram.

ARROW

MZ203827

MB991453

HIGH-PRESSURE FUEL HOSE

O-RING

AC000128

AC000127

FUEL RAIL

AC000129

>>C<< ENGINE MOUNT BRACKET INSTALLATION

1. Place a garage jack against the engine oil pan with a piece of wood in between, and install the engine mount bracket while adjusting the position of the engine.

2. Support the engine with the garage jack.

3. Remove the chain block and support the engine assembly with special tools MB991453 and MZ203827.

>>D<< HIGH-PRESSURE FUEL HOSE INSTALLATION

CAUTION

Do not allow any engine oil to enter the fuel rail.

1. Apply a small amount of new engine oil to the O-ring.

2. While turning the high-pressure fuel hose to the right and left, install it to the fuel rail, while being careful not to damage the O-ring. After installing, check that the hose turns smoothly.

3. If the hose does not turn smoothly, the O-ring is probably being clamped. Disconnect the high-pressure fuel hose and check the O-ring for damage. Replace if necessary.

4. Re-insert the fuel rail and confirm the hose turns smoothly.

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ENGINE MECHANICAL <2.4L ENGINE>

CAMSHAFT AND CAMSHAFT OIL SEAL

11A-17

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

• Air Cleaner Removal and Installation (Refer to GROUP 15, Air Cleaner P.15-5.)

• Timing Belt Removal and Installation (Refer to P.11A-31.)

14 ± 1 N·m 117 ± 13 in-lb

21 ± 4 N·m 16 ± 3 ft-lb

9.8 ± 2.0 N·m 87 ± 17 in-lb

3.4 ± 0.5 N·m 31 ± 4 in-lb

31 ± 3 N·m 23 ± 2 ft-lb

M1112001900154

Ø 3 mm (0.1 in)

SEALANT: MITUBISHI GENUINE PART NO.MD970389OR EQUIVALENT

LIP SECTION

CAM SECTION AND JOURNAL SECTION

CAMSHAFT REMOVAL STEPS

1. SPARK PLUG CABLE

2. IGNITION COIL

3. PCV HOSE

4. BREATHER HOSE

5. ROCKER COVER

6. CAMSHAFT POSITION SENSOR SUPPORT

7. CAMSHAFT POSITION SENSING CYLINDER

<<A>> >>C<<

8. CAMSHAFT SPROCKET

Required Special Tools:

• MB990767: End Yoke Holder

• MB998713: Crankshaft Oil Seal Installer

88 ± 10 N·m 65 ± 7 ft-lb

<<B>> >>A<<

<<A>> >>C<<

>>B<<

ENGINE OIL

CAMSHAFT REMOVAL STEPS

10. SPARK PLUG GUIDE OIL SEAL

11. ROC KE R A RM AND SHAFT ASSEMBLY (INTAKE SIDE)

12. ROCKER ARM AND SHAFT ASSEMBLY (EXHAUST SIDE)

13. CAMSHAFT

CAMSHAFT OIL SEAL REMOVAL STEPS

8. CAMSHAFT SPROCKET

9. CAMSHAFT OIL SEAL

AC00 013 0

• MD998443: Auto-lash Adjuster Holder

• MD998719: Crankshaft Pulley Holder Pin

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11A-18

MB990767

ENGINE MECHANICAL <2.4L ENGINE>

CAMSHAFT AND CAMSHAFT OIL SEAL

REMOVAL SERVICE POINTS

<<A>> CAMSHAFT SPROCKET REMOVAL

1. Use special tools MB990767 and MD998719 to loosen the camshaft sprocket securing bolt.

2. Remove the camshaft sprocket.

MD998715

PLUG GUIDE

ROCKER SHAFT SPRING

MB998443

ACX00301

ACX00331AB

<<B>> ROCKER ARM AND SHAFT ASSEMBLY REMOVAL

1. Install special tool MD998443 as shown in the illustration so that the lash adjusters will not fall out.

CAUTION

Never disassemble the rocker arm and shaft assembly.

2. Loosen the rocker arm and shaft assembly mounting bolt, and then remove the rocker arm and shaft assembly with the bolt still attached.

INSTALLATION SERVICE POINTS

>>A<< ROCKER ARM AND SHAFT ASSEMBLY INSTALLATION

1. Temporarily tighten the rocker shaft with the bolt so that all rocker arms do not push the valves.

2. Fit the rocker shaft spring from the above and position it so that it is right angles to the plug guide.

NOTE: Install the rocker shaft spring before installing the rocker arm and rocker arm shaft on the exhaust side.

3. Tighten the rocker arm and shaft assembly mounting bolt to the specified torque.

Tightening torque: 31 ± 3 N⋅m (23 ± 2 ft-lb)

4. Remove special tool MD998443.

ROCKER SHAFT SPRING

PLUG GUIDE

ACX00378

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NOTCH

ENGINE MECHANICAL <2.4L ENGINE>

CAMSHAFT AND CAMSHAFT OIL SEAL

5. Make sure that the notch in the end of the rocker arm shaft is facing the direction shown.

11A-19

MD998713

MB990767

AC00 0131

ACX00372

>>B<< CAMSHAFT OIL SEAL INSTALLATION

1. Apply engine oil to the camshaft oil seal lip.

2. Use special tool MD998713 to press-fit the camshaft oil seal.

>>C<< CAMSHAFT SPROCKET INSTALLATION

1. Install the camshaft sprocket.

2. Use special tools MB990767 and MD998719 to tighten the camshaft sprocket securing bolt to the specified torque.

Tightening torque: 88 ± 10 N⋅m (65 ± 7 ft-lb)

MD998715

ACX00301

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11A-20

ENGINE MECHANICAL <2.4L ENGINE>

OIL PAN

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

• Engine Oil Draining and Refilling (Refer to GROUP 12, On-vehicle Service − Engine Oil Replacement P.12-3.)

• Oil Dipstick Removal and Installation

• Front Exhaust Pipe Removal and Installation (Refer to

GROUP 15, Exhaust Pipe and Main Muffler P.15-19.)

Ø 4 mm (0.2 in)

GROOVE

M1112002800116

BOLT HOLE

SEALANT: MITSUBISHI GENUINE PART NO.MD970389 OR EQUIVALENT

REMOVAL STEPS

1. DRAIN PLUG

>>B<<

2. DRAIN PLUG GASKET

Required Special Tool:

• MD998727: Oil Pan Remover

39 ± 5 N·m 29 ± 4 ft-lb

<<A>> >>A<<

26 ± 4 N·m 19 ± 3 ft-lb

6.9 ± 0.9 N·m 61 ± 8 in-lb

AC000132

REMOVAL STEPS (Continued)

3. BELL HOUSING COVER

4. OIL PAN

8.8 ± 1.0 N·m 78 ± 9 in-lb

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Mitsubishi Eclipse 2000, Eclipse 2001, Eclipse 2002 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual