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P.00-6 - Tearstone

1. Automatic transaxle an equivalent Door hinges back door hinges Engine oil LUBRICANT CAPACITY TABLE DESCRIPTION SPECIFICATIONS Engmeol m qt 01 pan excluding often 0 2 03 032 Engine coolant dm qt 7 0 7 4 Engine coolant dm qt 8 0 8 5 Manual transaxle dm qt 2 2 2 3 Manual transaxle dm qt 2 8 3 0 Automatic transaxle dm qt 7 7 8 1 Automatic transaxle dm qt 8 4 8 5 Power steering dm qt 1 2 1 3 3 gal 62 16 4 Fuel tank dm TSB Revision GENERAL BODY AND CHASSIS 00 37 RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE ILSAC CERTIFICATION MARK STARBURST SYMBOL ACX003944AI SAE 5W 30 PREFERRED ACX00887AB LUBRICANT SELECTION ENGINE OIL A 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 Oil Viscosity The SAE grade number indicates the viscosity of the oil A proper SAE grade number should be selected according to ambient temperature TSB Revision 00 38 GENERAL BODY AND CHASSIS RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE SELECTION OF COOLANT COOLANT Relationship between Coolant Concentration and Specific Gravity N CAUTION If
2. X0012AW NO ITEMS CONTENTS MODEL D53AMRG D53A Vehicle model FM MRGEL4M Model series 2 ENGINE 6G72 Engine model 3 EXT W69A Exterior code 4 TRANS F4A51 F4A51 Transaxle model 5 COLOR W69 W69 Body color code 6 TRIM 71H 71H Interior code 7 OPT Z31 Z31 Equipment code For monotone color vehicles the body color code shall be indi cated VEHICLE SAFETY CERTIFICATION LABEL ACO000054 TSB Revision 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 Gross Axle Weight Rating GAWR and Vehicle Identification Number VIN 3 0L ENGINE GENERAL BODY AND CHASSIS VEHICLE IDENTIFICATION THEFT PROTECTION LABEL FOR ORIGINAL PARTS VN yo nop my AUAA nua m Ah ARUM MITSUBISHI FOR REPLACEMENT PARTS RAD MITSUBISHI ap MM or IHSISNSLIW MITSUBISHI ACO000057AB 00 19 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 THEFT PROTECTION In order to protect against theft a Vehicle Identification Number VIN is atta
3. ITEMS GTS GTS MNPVL4M MRPVL4M Vehicle Overall length 4 490 176 8 4 490 176 8 dimension mm in Overall width width Overall width 2 1 750 689 1 1 750 68 9 1 750 6 Overall height 3 1 310 t 5 1 310 t 5 unladen Wheelbase 2 560 100 68 2 560 100 i Overhang front 7 i010 38 7 1010 39 8 Dietas 5 520067 2552 Minimum running 150 5 9 150 5 9 ground clearance Vehicle weight Curb weight 1 3 241 1 500 3 307 kg Ib Gross vehicle weight ib NN 820 4 013 1 820 4 013 rating Gross axle weight 1 050 2 315 1 050 2 315 rating front Gross axle weight 770 1 698 770 1 698 rating rear Seating capacity 4 Engine Model No 6G72 Displacement 3 0L Transaxle Model No F5M51 F4A52 Type 5 speed 4 speed manual automatic Fuel system Fuel supply system Electronic controlled multiport fuel injection TSB Revision GENERAL BODY AND CHASSIS 00 31 GENERAL DATA AND SPECIFICATIONS ECLIPSE SPYDER gt 002712 A GENERAL SPECIFICATIONS Model without 3 0L Engine with Variable Induction System ITEMS GS GS GT GT BNHEL4M BRHEL4M BNXEL4M BRXEL4M Vehicle Overall length 4 490 176 8 14 490 176 8 4 490 176 8 4 490 176 8 dimension mm in Overall width width 2 1 750 68 1 750 68 9 1 750 68 1 750 68 9 1 750 68 1 750 68 9 1 750 68 9 EL height 34
4. 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 6 Check the clock spring connectors and protective tube for damage and terminals for deformities 7 Visually check the case for damage A 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 front 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 Mating marks alignment After turning the clock spring fully clockwise turn it approxi mately 3 4 5 turns counterclockwise until the mating marks are aligned TSB Revision GENERAL BODY AND CHASSIS 00 63 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 A DANGER The SRS may not activate if any of the above compo nents are not installed properly which could result in serious injury or death to the vehicle s
5. AKX01272 AB INCORRECT CORRECT AKX00434 AC 00 43 5 SPARK PLUGS REPLACE A CAUTION Platinum plugs are used on the 3 0L engine model without VIC Iridium plugs are used on the 3 0L engine model with VIC Use care not to damage the platinum tips and iridium tips of the platinum plugs and iridium 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 M1001002000120 MAKER 2 4L 3 0L ENGINE 3 0L ENGINE ENGINE without VIC with VIC NGK 5 11 56 11 IFR6B DENSO K16PR U11 PK16PR11 SK20PR B8 CHAMPION RC10YC4 RC10PYP4 2 The new plugs should be checked for the proper gap Spark plug gap lt 2 4L Engine 3 0L Engine without VIC 1 0 1 1 mm 0 039 0 043 inch lt 3 0L Engine with VIC 0 7 0 8 mm 0 039 0 043 inch 3 Install the spark plugs and tighten to 25 4 N m 18 3 ft Ib 6 IGNITION CABLES REPLACE N 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 s
6. AC000070 AC TSB Revision GENERAL BODY AND CHASSIS 00 25 AC000071 AC TOWING AND HOISTING REAR TOWING PICKUP A CAUTION e This vehicle cannot be towed by a wrecker using sling type equipment otherwise the lower arm may become deformed If this vehicle is towed use a wheel lift or flat bed equipment Do not use the steering column lock to secure the front wheels for towing e Make sure the transaxle is in Neutral if vehicle will have drive wheels on the ground f these requirements 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 TOWING WHEN KEYS ARE NOT AVAILABLE When a locked vehicle must be towed and keys are not avail able the vehicle may be lifted and towed from the front pro vided 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 protruding or damaged parts 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 when it is lifted by the towing equipment unless the vehicle is
7. e Intake air temperature sensor failed Open or shorted intake air temperature sensor circuit or loose connector PCM failed 7 Start of the diagnosis procedure for that DTC 8 Identifies the special tool s necessary for diagnosing that DTC STEP 1 Using scan tool MB991502 check data list item 13 Intake Air Temperature Sensor amp CAUTION To prevent damage to scan tool MB991502 always turn the ignition switch to LOCK OFF position before connecting or disconnecting scan tool MB991502 1 Connect scan tool MB991502 to the data link connector 2 Turn the ignition switch to ON position 3 Set scan tool MB991502 to the data reading mode for item 13 Intake Air Temperature Sensor e The intake air temperature and temperature shown with the scan tool should approximately match 4 Turn the ignition switch to LOCK OFF position Q Is the sensor operating properly YES It can be assumed that this malfunction is intermittent Refer to GROUP 00 How to Use Troubleshooting 9 Provides 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 inspec tion while referring to GROUP OOE Harness Con nector Inspection 00 2 Here Check harness between power supply and terminal xx also includes checking for blown fuse For inspection
8. 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 fluid level by referring to the diagram at left The A T fluid level must be at the HOT mark NOTE The 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 check the A T fluid level by referring to the left dia gram 13 Firmly insert the dipstick into the oil filler tube TSB Revision 00 56 GENERAL BODY AND CHASSIS MAINTENANCE SERVICE 14 ENGINE COOLANT CHANGE Check the cooling system parts such as the radiator heater and oil cooler hoses thermostat and the connections for leak age and damage CHANGING COOLANT 1 Turn the ignition switch to the ON position and then rotate the heater control to the MAX HOT position 2 Turn the ignition switch to the OFF position 3 Raise the vehicle at the front with a garage jack x 24 yt JACK AC106167AB A 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 pres sure escape through the vinyl t
9. 10 2 N m 4449 in Ib 79418 in Ib 89 17 in Ib M8 1 25 12 32 Num 22 4 Nm 25 4 107 17 in Ib 1623 ft lb 1853 ft lb M10 24434 44410 N m 53 7 N m 183 ft lb 33 7 ft lb 39 5 ft lb M12 41 8 83112 98 12 N m 30 6 ft lb 6119 ft lb 72 9 ft lb M14 73412 N m 140 20 155 25 N m 54 9 ft Ib 104 14 ft Ib 115 18 ft Ib M16 110220 N m 210130 235495 N m 811515 ft lb 155122 ft lb 174425 ft lb M18 165425 N m 300440 N m 340150 N m 122 18 ft lb 222429 ft lb 251537 ft lb M20 225435 Nm 410360 N m 480 70 N m 166126 ft lb 303444 ft lb 354 52 ft lb M22 300 40 N m 555485 N m 645495 N m 222 29 ft lb 410162 ft lb 476470 ft lb M24 15 395455 Nm 7354105 N m 8554125 Nm 292 40 ft lb 543 77 ft lb 631592 ft lb TSB Revision 00 34 GENERAL BODY AND CHASSIS LUBRICATION AND MAINTENANCE Flange bolt and nut tightening torque THREAD SIZE NOMINAL BOLT DIAMETER mm STANDARD TIGHTENING TORQUE PITCH HEAD MARK 4 HEAD MARK 7 HEAD MARK 8 mm M6 1 0 5 0 1 0 N m 1012 1242 4459 in Ib 89 17 in Ib 107217 in Ib M8 1342 24 4 N m 27 5 111 22 in Ib 18 3 ft lb 20 4 ft lb M10 2614 N m 19 3 ft lb M10 1 5 24 4 1843 ft lb M12 1 25 4648 3446 ft lb M12 1 75 4348 3246 ft lb 49 9 5847 Nm 36 7 ft lb 43 5 ft lb 4518 55410 3356 ft lb 4147 ft lb
10. GENERATOR TENSIONER PULLEY IDLER PULLEY TAP LIGHTLY WITHA FINGER 10 20mm SE 0 4 0 8in MB991668 TREE MICROPHONE 15 1150 00 45 A CAUTION To prevent damage to scan tool MB991502 always turn the ignition switch to the LOCK OFF position before con ne 1 2 3 cting or disconnecting scan tool MB991502 Connect special tool MB991668 to the scan tool MB991502 Connect scan tool MB991502 to the data link connector Turn the ignition switch to the ON and select scan tool MB991502 Belt Tension Measurement from the menu screen 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 belt within an angle of 15 degree angle A 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 val ues measured by the microphone may not correspond to actual values If the microphone is touching the belt while the mea surement is being made the values measured by the microphone may not correspond to actual values
11. Tightening torque 32 2 N m 24 1 ft lb 5 Pour new A T fluid Diamond ATF SP Ill or equivalent in through the oil filler tube Adding volume Approximately 5 5 dm 5 8 quarts TSB Revision GENERAL BODY AND CHASSIS 00 55 MAINTENANCE SERVICE A 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 AC000101 lt 2 4L ENGINE gt 3 0L ENGINE HOT ACO000098 AB FLUID LEVEL mm in 10 0 4 20 0 8 DIPSTICK 30 1 2 40 60 80 104 140 176 FLUID TEMPERATURE F AC002477AB 8 9 contaminated A T fluid Pour the new fluid in through the oil filler tube NOTE Check for contamination or burnt smell If A T fluid is still contaminated or burnt repeat Steps 6 and 7 before pro ceeding to Step 8 Reconnect the hose which was disconnected in step 1 above and firmly replace the dipstick 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 11 Check that the A T fluid level is at the COLD mark on 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 80 158 176 F and then check the
12. A T fluid reaches its normal operating temperature 70 80 C 158 176 check the A T fluid level by referring to the left dia gram Park the vehicle on a level surface 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 After wiping off any dirt around the dipstick remove the dipstick and check the condition of the A T fluid 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 cooler line flushing may be necessary TSB Revision 00 54 GENERAL BODY AND CHASSIS 2 4L ENGINE 3 0L ENGINE g IHOT AC000098 AB AC000100 MAINTENANCE SERVICE 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 If the A T fluid level is too high rotating components inside the transaxle will churn the fluid and air into a foamy liquid Both conditions level too low or too high will cause the hydraulic pressure to drop whi
13. 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 77 ft Ib N CAUTION Check after turning the crankshaft one or more rotation clockwise 4 Check the belt deflection amount and tension and readjust if necessary 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 A CAUTION Check after turning the crankshaft one or more rotation clockwise 4 Check the belt deflection amount and tension and readjust if necessary 10 ENGINE OIL CHANGE Use the specified oil Refer to P 00 36 1 After warming up the engine remove the oil filler cap A WARNING Use care as oil could be hot 2 Remove the drain plug to allow the engine oil to drain M1001002600207 TSB Revision GENERAL BODY AND CHASSIS 00 51 lt 2 4L ENGINE DRAIN PLUG GASKET 3 0L ENGINE DRAIN PLUG GASKET OIL PAN lt DRAIN 39 5 N m PLUG 29 x 4 ft Ib A TAC000092AB GOOD MAXIMUM e ACX00892 AB MB991396 OR GENERAL SERVICE TOOL ACO000093 AE MAINTENANCE SERVICE 3 Replace the drain plug gasket with
14. SENSOR IF IT FALS THE VISUAL CHECK Refer to GROUP 52B Side Impact Sensor P 52B 153 NOTE The illustration at left shows the left side impact sensor LH The position of the side impact sensor RH is symmetri cal to this SRS AIR BAG CONTROL UNIT SRS ECU A WARNING The SRS may not activate if the SRS ECU with built in 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 Replace the SRS ECU if it fails the visual checks above ACODOTHAB Refer to GROUP 52B SRS Air bag Control Unit P 52B 142 C y 22 CENTER REINFORCEMENT RH AIR BAG MODULE STEERING WHEEL AND CLOCK SPRING A 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 144 2 Check the pad cover for dents cracks or deformation TSB Revision 00 62 GENERAL BODY AND CHASSIS ao MAINTENANCE SERVICE lt DRIVER S SIDE gt CONNECTOR x INFLATOR CASE COVER INFLATOR CASE AC000116 AB PROTECTIVE TUBES ACX01302 AB MATING MARK ACX00602 AB
15. The part designation number corresponds to the number in the illustration to indicate disas sembly steps GENERAL BODY AND CHASSIS HOW TO USE THIS MANUAL Indicates procedures to be performed be fore the work in that section is started and procedures to be performed after the work in that section is finished Component diagram A diagram of the component parts is pro vided near the front of each section in order to give the reader a better understanding of the installed condition of component parts e Installation steps Specified in case installation is impossible in reverse order of removal steps Omitted if installation is possible in reverse order of re moval steps e Assembly steps Classifications of major maintenance service points When there are major points relative to maintenance and servicing procedures such as essential maintenance and service points maintenance and service standard values information regarding the use of special tools etc These are arranged together as major maintenance and service points and explained in detail Specified in case assembly is impossible in reverse order of disassembly steps Omitted if assembly is possible in reverse order of disas sembly steps lt lt A gt gt Indicates that there are essential points for removal or disassembly gt gt A lt lt Indicates that there are essential points for installation or assembly Symbol
16. a new one and then tighten the drain plug to the specified torque Tightening torque 39 5 N m 29 4 ft Ib NOTE Install the drain plug gasket so it faces in the direc tion shown in the illustration 4 Pour new engine oil in through the oil filler Engine oil capacity 4 3 dm 4 5 quarts add 0 3 dm 0 32 quarts if replacing the oil filter 5 Start the engine and run it at idle for a few minutes 6 Stop the engine and check to ensure that the engine oil level is within the level range indicated on the dip stick 11 ENGINE OIL FILTER REPLACE M1001002700196 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 withstand ing 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 TSB Revision 00 52 GENERAL BODY AND CHASSIS MAINTENANCE SERVICE 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 filte
17. ade quately 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 TSB Revision 00 26 GENERAL BODY AND CHASSIS TOWING AND HOISTING LIFTING AND JACKING SUPPORT LOCATION FLOOR JACK A CAUTION e Never support any point other than the specified one or that point will be deformed e For lifting put rubber or similar material between the side sill and rigid rack or the side sill area will be dam aged RIGID RACK UE 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 AC000072 AB TSB Revision GENERAL BODY AND CHASSIS 00 27 TOWING AND HOISTING A CAUTION When service procedures require removing rear suspen sion fuel tank and spare tire place additional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping when the location of the center of gravity changes AC000073AB TSB Revision 00 28 GENERAL BODY AND CHASSIS GENERAL DATA AND SPECIFICATIONS GENERAL DATA AND SPECIFICATIONS M1001000900213 ECLIPSE gt AC002714 GE
18. driver and front passenger 11 Check the steering wheel for excessive free play REPLACE ANY PART IF IT FAILS VISUAL INSPECTION Refer to GROUP 52B Air bag Module and Clock Spring P 52B 144 FRONT SEATBACK ASSEMBLY WITH SIDE AIRBAG MODULE WARNING If any improper part is found during the following inspection replace the front seatback assembly with a new one e Dispose of the old one according to the specified procedure Refer to GROUP 52B Air bag Module Disposal Procedures P 52B 157 Never attempt to measure the circuit resistance of the air bag module squib even if you are using the specified tester If the circuit resistance is mea sured with a tester accidental air bag deployment will result in serious personal injury 1 Check the air bag module deployment section for dents or s deformation 2 Check the connector for damage the terminals for deformation and harness for binds AIR BAG MODULE AC000118 AB AIR BAG MODULE DEPLOYMENT SECTION 002988 Revision 00 64 GENERAL BODY AND CHASSIS MAINTENANCE SERVICE WIRING HARNESS INSTRUMENT PANEL WIRING HARNESS SIDE AIRBAG WIRING HARNESS ECLIPSE ONLY AC000119 AC HARNESS LH 1 Check the connector for poor connection A DANGER The SRS system may not operate if SRS harnesses or connectors are damaged or improperly connected w
19. each component for evidence of leakage Check the oil level by removing the filler plug CEHCK OIL LEVEL 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 FILLER PLUG TRANSAXLE OIL AC102278AB TSB Revision GENERAL BODY AND CHASSIS 00 53 MAINTENANCE SERVICE CHANGE OIL RJ A PA 9 22120 _ AC000095AB FLUID LEVEL mm in DIPSTICK 40 60 80 104 140 176 FLUID TEMPERATURE C F AC002477AB Remove the filler plug Remove the drain plug and drain the oil Tighten the drain plug to the specified torque Tightening torque 32 2 N m 24 1 ft lb 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 2 3 quarts 3 0L Engine 2 8 dm 3 0 quarts 5 Tighten the filler plug to the specified torque Tightening torque 32 2 Nm 24 1 ft Ib 13 AUTOMATIC TRANSAXLE FLUID CHECKING A T FLUID LEVEL 1 M1001002900190 Drive the vehicle until the A T fluid temperature rises to the normal temperature 70 80 158 176 F NOTE The A T fluid temperature is measured with MUT II NOTE If it takes some amount of time until the
20. labels can be found in the following locations e Hood e Sun visor e Glove box e SRS ECU e Steering wheel e Air bag module Driver s side or front passenger s side e Side air bag module e Clock spring e Steering gear box M1001000500215 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 157 Air bag Module Disposal Procedures 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 occur to the SRS components 2 SRS components should not be subjected to temperatures of over 93 C 200 F Remove the SRS components before drying or baking the vehicle after painting After re installing them check the SRS warning ligh
21. order description are under stood before starting work e 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 proce dure If the confirmed symptoms can not be found on any symptom index determine other possible causes e Analyze the system diagrams and list all possible causes for the problem symptoms e Rank all these possible causes in order of proba bility 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 M1001008800221 FIND THE PROBLEM After the symptoms have been confirmed and prob able 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 care fully to a
22. 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 the problems occurring in electric circuitry are generally the connectors com ponents the ECU and the harnesses between con nectors in that order These inspection procedures follow this order They first try to discover a problem with a connector or a defective component TSB Revision 00 8 GENERAL BODY AND CHASSIS HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS DTC P0110 Intake Air Temperature Circuit Malfunction INTAKE AIR TEMPERATURE SENSOR INCORPORATED IN VOLUME AIR FLOW SENSOR 1 Relevant circuit s of the component which the DTC indicates are described RED BLUE D 108 MU803781 POWERTRAIN CONTROL MODULE PCM 2 Shows the location of the connector s from the circuit s above CONNECTOR B 48 ie INTAKE AIR 3 Explains about the operation principle of the component or its relevant parts in that circuit ACX00224 AK CIRCUIT OPERATION The intake air temperature sensor is a negative e Approximately 5 volts are applied to the intake air temperature coefficient type o
23. 0 52 8 340 52 8 340 52 8 1 340 52 8 unladen Wheelbase 2 560 100 8 2 560 100 8 2 560 100 8 2 560 100 8 510 59 4 1 510 59 4 1 510 59 4 1 510 59 4 L 6 1 510 59 4 1 510 59 4 1 510 59 4 1 510 59 4 Overhang front 1010 39 8 1010 39 8 1010 39 8 1010 39 8 Overhang rear 8 920 36 2 920 36 2 920 36 2 920 36 2 Minimum running 163 6 4 163 6 4 165 6 5 165 6 5 ground clearance Vehicle weight Curb weight 1 405 8 097 1 435 3 164 1 490 3 285 1 520 3 351 kg Ib Gross vehicle weight 1 770 3 903 1 770 3 903 1 865 4 112 11 865 4 112 rating Gross axle weight 985 2 172 985 2 172 1 070 2 359 1 070 2 359 rating front Gross axle weight 785 1 731 785 1 731 795 1 753 795 1 753 rating rear 4 Seating capacity Engine 5072 Transaxle Model No No F4A51 anual automat manual automate Fuel system Fuel supply system Electronic controlled multiport fuel injection TSB Revision 00 32 GENERAL BODY AND CHASSIS GENERAL DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS Model with 3 0L Engine with Variable Induction System ITEMS GT GT MNXEL4M RXEL4M Vehicle Overall length 1 4 490 176 8 4 490 176 8 dimension mm in Overall width 1 750 68 9 1 750 68 9 Overall height 3 1 340 52 8 1 340 52 8 unladen Wheelbase 2 560 100 8 2 560 100 8 1 510 59 4 1 510
24. 00 1 GROUP 00 GENERAL BODY AND CHASSIS CONTENTS HOW TO USE THIS MANUAL 00 3 MAINTENANCE SERVICE 00 42 1 FUEL SYSTEM TANK PIPE LINE AND TROUBLESHOOTING GUIDELINES 00 6 CONNECTION AND FUEL TANK FILLER TUBE CAP CHECK FOR LEAKS 00 42 HOW TO USE TROUBLESHOOTING 2 FUEL HOSES CHECK CONDITION 00 42 INSPECTION SERVICE POINTS 00 6 3 AIR CLEANER ELEMENT REPLACE 00 42 4 EVAPORATIVE EMISSION CONTROL VEHICLE IDENTIFICATION 00 16 ORA TIVE EMISSION CANISTER CHECK FOR LEAKS AND VEHICLE IDENTIFICATION 00 16 1 00 42 VEHICLE IDENTIFICATION 5 SPARK PLUGS REPLACE 00 43 CODE PLATE 00 18 iri une PRECAUTIONS BEFORE 7 DISTRIBUTOR CAP AND ROTOR CHECK 3 0L ENGINE gt 00 44 8 TIMING BELT REPLACE 00 44 TOWING AND HOISTING E CHECK CONDITION 00 44 GENERAL DATA AND 10 ENGINE OIL CHANGE 00 50 00 28 11 ENGINE OIL FILTER REPLACE 00 51 12 MANUALTRANSAXLE OIL 00 52 TIGHTENING TORQUE 00 33 13 AUTOMATIC TRANSAXLE FLUID 00 53 AND 14 ENGINE COOLANT CHANGE 00 56 0034 INSPECTFOR WEAR 00 57 16 REAR DRUM BRAKE LININGS AND REAR RECOMMENDED LUBRICANTS AND WHEEL CYLINDER
25. 1223 Harness Set 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 TSB Revision GENERAL BODY AND CHASSIS 00 11 HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS MB991219 ACX00865 AB SRS ECU HARNESS CONNECTOR AC001607AB ACX00867 AB e From back side of the connector SRS ECU harness side connector Since the SRS ECU harness connector is plated to improve conductivity observe the warning below when checking this connector A WARNING Insert the backprobing tool into the connector from the harness side and connect the tester to the back probing 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 backprob ing 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 When Inspecting a Male Pin A 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 Touch the pin directly with the test probe TSB Revision 00 12 GENERAL BODY AN
26. 59 4 fTread rear f6 1 510 59 4 1 510 59 4 Overhang front 1010 39 8 1010 39 8 Ovemangres 8 920 352 920 56 2 Minimum running 165 6 5 165 6 5 ground clearance Vehicle weight Curb weight 1 510 3 329 1 540 3 395 kg Ib Gross vehicle weight 1 865 4 112 1 865 4 112 rating Gross axle weight 1 070 2 359 1 070 2 359 rating front Gross axle weight 795 1 753 795 1 753 rating rear 4 Seating capacity Engine 5072 Displacement 3 0L manual automatic Fuel system Fuel supply system Electronic controlled multiport fuel injection TSB Revision GENERAL BODY AND CHASSIS 00 33 TIGHTENING TORQUE TIGHTENING TORQUE Each torque value in the table is a standard value for 1 If toothed washers are inserted tightening under the following conditions 2 If plastic parts are fastened 1 Bolts nuts and washers are all made of steel and 3 If bolts are tightened to plastic or die cast plated with zinc inserted nuts 2 The threads and bearing surface of bolts and 4 If self tapping screws or self locking nuts are nuts are all in dry condition used The values in the table are not applicable M1001001100221 Standard bolt and nut tightening torque THREAD SIZE STANDARD TIGHTENING TORQUE NOMINAL BOLT PITCH HEAD MARK 4 HEAD MARK 7 HEAD MARK 8 DIAMETER mm mm M5 2 5 0 5 N m 5 01 0 6 0 1 0 N m 2354 in Ib 4449 in Ib 53 9 in Ib M6 1 0 5 0 1 0 9 0 2 0
27. 95 15 N m 105415 N m 70411 ft lb 78311 ft lb 83 12 N m 98412 N m 61 9 ft lb 7249 ft lb LUBRICATION AND MAINTENANCE Maintenance and lubrication service recommenda tions have been compiled to provide maximum pro tection 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 oper ated 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 Ameri can Petroleum Institute API and the National Lubri cating Grease Institute NLGI MAINTENANCE SCHEDULES Information for service maintenance is provided in the SCHEDULED MAINTENANCE TABLE Three schedules are provided one for Required Mainte nance one for General Maintenance and one for Severe Usage Service 1001001200217 The item numbers in SCHEDULED MAINTENANCE TABLE correspond to the section numbers in MAINTENANCE SERVICE SEVERE SERVICE Vehicles operating under severe service conditions will require more frequent service Component service information is included for vehi cles operating under one or more of the following conditions 1 Trailer towing
28. AKE HOSE CONNECTION LUBRICATION AND SEALING POINTS REMOVAL STEPS Cont gt gt lt lt 3 DISC BRAKE ASSEMBLY 4 BRAKE DISC INSTALLATION SERVICE POINT gt gt A lt lt DISC BRAKE ASSEMBLY INSTALLATION 1 To check the brake drag force after mounting the pad measure the hub torque in the advancing direction using a spring balance with the pad is removed 44 CAUTION Do not allow any oil grease or other contamination to contact the friction surfaces of the pads and brake discs 2 After re installing the caliper support to the knuckle install the pad clips and the pads to the caliper support TSB Revision reusable part Denotes tightening torque If there is no indication of tightening torque refer to tightening torque Repair kit or parts sets are shown Only very frequently used parts are shown Operating procedures cautions etc Removal installation disassembly and assembly are described The title of the page following the page on which the diagram of component parts is presented indicating the locations of lubrication and sealing procedures Indicates by symbols where lubrication is necessary AC102241AB 00 6 GENERAL BODY AND CHASSIS TROUBLESHOOTING GUIDELINES TROUBLESHOOTING GUIDELINES VERIFY THE COMPLAINT e Make sure the customer s complaint and the ser vice writer s work
29. 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 cus tomer s responses it should be reasoned which con dition is most likely Use special tool MB991219 to inspect the engagement of the male pins and female pins Pin drawing force 1 N 0 2 pound or more 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 cir cuit s and perform the simulation tests on the con nectors 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 condition related intermittent malfunctions try to change the condi tions 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 mal function has been eliminated TSB Revision 00 14 GENERAL BODY AND CHASSIS HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS SIMULATION TESTS NOTE In case of di
30. 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 Terminal Resistance and Continuity Checks 1 Turn the ignition switch to LOCK OFF position 2 Disconnect the ECU connector A CAUTION If resistance and continuity checks are per formed 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
31. D CHASSIS HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS CONNECTOR INSPECTION SERVICE POINTS VISUAL INSPECTION e Connector is disconnected or improperly connected Connector pins are pulled out Stretched an broken wires at terminal section Low contact pressure between male and female terminals Low connection pressure due to rusted terminals or foreign matter lodged in terminals CONNECTOR DISCONNECTED OR IMPROPERLY CONNECTED HARNESS WIRE BREAKAGE AT TERMINAL SECTION LOW CONTACT 6 PRESSURE 25 ACX00868AC CONNECTOR PIN INSPECTION If the connector pin stopper is damaged the terminal connec tions male and female pins will not be perfect even when the wy connector body is connected because the pins may pull out of the back side of the connector Therefore gently pull the wires gt one by one to make sure that no pins pull out of the connector ACX00869AB TSB Revision GENERAL BODY AND CHASSIS 00 13 HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS CONNECTOR ENGAGEMENT INSPECTION Required Special Tool MB991219 Inspection Harness contained in MB991223 Test Harness MB991219 A ACX00870 AB 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
32. Do not take the measurement while the vehicle s engine is running 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 189 232 134 159 Hz TSB Revision 00 46 GENERAL BODY AND CHASSIS 2 4L ENGINE gt TENSION GAUGE WATER PUMP GENERATOR PULLEY PULLEY CRANK SHAFT PULLEY AKX01151AB lt 3 0L ENGINE gt GENERATOR TENSIONER PULLEY PULLEY IDLER PULLEY lt A C COM CRANK PRESSOR SHAFT PULLEY PULLEY TENSION GAUGE AKX01152 AB MAINTENANCE SERVICE lt When using the tension gauge gt 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 Tension N Ib 392 588 490 686 88 132 110 154 TSB Revision GENERAL BODY AND CHASSIS 00 47 MAINTENANCE SERVICE 2 4L ENGINE gt 98 A Ib WATER PUMP PULLEY CRANK SHAFT PULLEY GENERATOR PULLEY AKX01153 AB 3 0L ENGINE gt GENERATOR PULLEY PRESSOR AEN 98 N 22 Ib PULLEY PULLEY 1154 AB 2 4L ENGINE gt AKX01155 AB Belt
33. NERAL SPECIFICATIONS Model with 2 4L Engine ITEMS RS RS GS GS MNJEL4M 9M MRJELAM 9M MNHELA4M 9M MRHELAM 9M Vehicle Overall length 1 4 490 176 8 4 490 176 8 4 490 176 8 4 490 176 8 dimension mm in 1 750 68 9 1 750 68 9 1 750 68 9 1 750 68 9 Overall width Overall height unladen oo po 1 340 51 6 1 310 51 6 1 310 51 6 Wheelbase 2 560 100 8 2 560 100 8 2 560 100 8 2 560 100 8 1 510 59 4 1 510 59 4 1 510 59 4 1 510 59 4 Tread rear 6 1 510 69 4 1 510 59 4 1 510 594 1 510 69 4 Overhang front 1010 39 8 1010 39 8 1010 39 8 1010 39 8 Overhang rear 8 920 36 2 920 36 2 920 36 2 920 36 2 Minimum running 148 5 8 148 5 8 148 5 8 148 5 8 ground clearance Vehicle weight Curb weight 1 320 2 910 1 350 2 976 1 345 2 965 1 375 3 031 kg Ib Gross vehicle weight 1 750 3 859 1 750 3 859 1 750 3 859 1 750 3 859 rating Gross axle weight 980 2 161 980 2 161 980 2 161 980 2 161 rating front Gross axle weight 770 1 698 770 1 698 770 1 698 770 1 698 rating rear Seating capacity 4 Enge ModeiNo jace 5 speed 4 speed 5 speed 4 speed manual automatic manual automatic Fuel system Fuel supply system Electronic controlled multiport fuel injection TSB Revision GENERAL BODY AND CHASSIS 00 29 GENERAL DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS Model with 3 0L Engine without Variab
34. PSE VEHICLES FOR FEDERAL EMISSION REGULATION VIN EXCEPT SEQUENCE BRAND ENGINE MODEL CODE NUMBER DISPLACEMENT MITSUBISHI ECLIPSE 2 4L D52AMNJEL4M D52AMRJEL4M 46 D52AMNHEL4M D52AMRHEL4M 4A3AC84H_3E 3 0L D53AMNXEL4M D53AMRXEL4M 4A3AC54H_3E D53AMNGEL4M D53AMRGEL4M D53AMNPVLAM D53AMRPVLAM VEHICLES FOR CALIFORNIA EMISSION REGULATION VIN EXCEPT SEQUENCE BRAND ENGINE MODEL CODE NUMBER DISPLACEMENT MITSUBISHI ECLIPSE 2 4L D52AMNJEL9M D52AMRJEL9M 4A3ACAAG D52AMNHELOM D52AMRHELOM ECLIPSE SPYDER VEHICLES FOR FEDERAL EMISSION REGULATION VIN EXCEPT SEQUENCE BRAND ENGINE MODEL CODE NUMBER DISPLACEMENT 4A3AE45G_3E MITSUBISHI ECLIPSE 2 4L D52ABNHEL4M SPYDER 4 D52ABRHEL4M 4A3AE85H_3E 3 0L D53ABNXEL4M D53ABRXEL4M 4A3AE75G_3E D53ABNGVL4M D53ABRGVL4M VEHICLES FOR CALIFORNIA EMISSION REGULATION VIN EXCEPT SEQUENCE BRAND ENGINE MODEL CODE NUMBER DISPLACEMENT 4A3AE45G_3E MITSUBISHI ECLIPSE 2 4L D52ABNHEL9M SPYDER D52ABRHEL9M TSB Revision 00 18 GENERAL BODY AND CHASSIS VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION CODE PLATE MODEL ENGINE TRANS COLOR TRIM a MISS IT M1001005400213 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 3 ET D BSS
35. S INSPECT FOR WEAR LUBRICANT CAPACITIES TABLE 00 36 ANDLEAKS 00 57 17 BRAKE HOSES CHECK FOR SCHEDULED MAINTENANCE DETERIORATION OR LEAKS 00 58 TABLE 5 00 39 Continued on next page 00 2 DLA g L L IDUDDD E E p pwI V ellIDO eDD SDp SLEL L AL AU JAUJA A A AAA A I 18 BALL JOINT AND STEERING LINKAGE 21 EXHAUST SYSTEM CONNECTIONS SEALS INSPECT FOR GREASE LEAKS AND PIPES AND CONVERTER HEAT SHIELDS 00 58 CHECK AND SERVICE AS REQUIRED 00 64 19 DRIVE SHAFT BOOTS INSPECT FOR 22 00 65 GREASE LEAKS AND DAMAGE 00 58 20 SRS AIR BAG INSPECT FOR MAIN SEALANT AND ADHESIVE 0059 00 65 GENERAL BODY AND CHASSIS 00 3 HOW TO USE THIS MANUAL 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 des ignations is covered in this manual under VEHICLE IDENTIFICATION ON VEHICLE SERVICE ON VEHICLE SERVICE section has procedures
36. TESTS If verification of the symptom s is difficult proce dures for checking operation and verifying symptoms are shown 3 DIAGNOSTIC FUNCTION The following trouble code diagnosis are shown e How to read diagnostic trouble codes e How to erase diagnostic trouble codes e Input inspection service points TSB Revision GENERAL BODY AND CHASSIS 00 7 HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS 4 DIAGNOSTIC TROUBLE CODE CHART If the scan tool displays a diagnostic trouble code retrieve an applicable inspection procedure accord ing to this chart 5 SYMPTOM CHART If there are symptoms even though the results of inspection using the scan tool show that all diagnos tic 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 7 SYMPTOM PROCEDURES Indicates the inspection procedures corresponding to each symptoms classified in the Symptom Chart 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 Terminal numbers for the ECU connectors inspec tion items and standard values have been provided in this chart as reference information Terminal Voltage Checks 1 Connect a needle nosed wire probe to a voltmeter probe A
37. Y AND CHASSIS VEHICLE IDENTIFICATION LABEL AREA A FOR ORIGINAL EQUIPMENT PARTS B FOR REPLACEMENT PARTS QUARTER PANEL OUTER ACO000064AB THE ILLUSTRATION INDICATES LEFT OUER SIDE RIGHT SIDE IS SYMMETRICALLY OPPOSITE DOOR THE ILLUSTRATION INDICATOR LEFT OUER SIDE RIGHT SIDE IS SYMMETRICALLY OPPOSITE B ACO000065 AB LIFTGATE ECLIPSE ACO000068AB TRUNK LID ECLIPSE SPYDER gt AC004278AB Cc J t B 22222 TSB Revision 00 21 00 22 GENERAL BODY AND CHASSIS PRECAUTIONS BEFORE SERVICE TARGET AREA A FOR ORIGINAL EQUIPMENT PARTS B FOR REPLACEMENT PARTS REAR BUMPER PRECAUTIONS BEFORE SERVICE SUPPLEMENTAL RESTRAINT SYSTEM SRS 1 Items to review 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
38. ace 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 M1001001800219 The air cleaner element will become dirty during use reducing its effectiveness 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 4 EVAPORATIVE EMISSION CONTROL SYSTEM EXCEPT EVAPORATIVE EMISSION CANISTER CHECK FOR LEAKS AND CLOGGING If the fuel vapor vent line is clogged or damaged fuel vapor will escape into the atmosphere causing excessive emissions Dis connect the line at both ends and blow it clean with com pressed air Remove the fuel tank filler tube cap from the filler tube and check to see if there is evidence that the seal makes improper contact to the filler tube TSB Revision GENERAL BODY AND CHASSIS MAINTENANCE SERVICE 3 0L ENGINE WITHOUT gt 9 PLATINUM TIPS AKX00383 AG 3 0L ENGINE WITH VIC gt IRIDIUM TIP 9 PLATINUM TIP AKX00383 AH PLUG GAP GAUGE EM REMENT ES DIRECTION
39. ades O 1 2 3 etc Whenever Chassis Lubricant is specified Multipur pose Grease NLGI grade Number 2 should be used FUEL USAGE STATEMENT N CAUTION Using leaded gasoline in your car will damage the catalytic converters and heated oxygen sen sors 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 gas oline 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 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 per formance level may be reduced MON Motor Octane Number RON Research Octane Number GASOLINE CONTAINING ALCOHOL Some gasoline sold at service stations contain alco hol 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 9096 unleaded gasoline may be used in your vehicle If driveability problems are experienced as a result of using gasohol it is recommended that the ve
40. and fuel tank filler tube cap F CENE Rn L S Evaporative emission Check for leaks and clogging control system every 5 years or except evaporative emission canister Spark plugs Replace standard type sns mu Platinum tipped type Ignition cables Replace every 5 years or miss Distributor cap and Check every 5 years rotor GENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE PERFORMANCE NO GENERAL SERVICE KILOMETERS 24 48 72 96 120 144 168 MAINTENANCE INTERVALS THOUSANDS MILEAGE IN 15 30 45 60 75 90 105 THOUSANDS 8 Timing belt Replace at x1 At 160 000 km 2 100 000 miles 9 Drive belt for the Check condition at X X X generator water pump and power steering pump 10 Engine oil Change oil every 12 months or Every 12 000 km 7 500 miles 12 Manual transaxle oil Check oil level every at X TSB Revision 00 40 GENERAL BODY AND CHASSIS SCHEDULED MAINTENANCE TABLE NO GENERAL SERVICE KILOMETERS 24 48 72 96 120 144 168 MAINTENANCE INTERVALS IN THOUSANDS MILEAGE IN 15 30 45 60 75 90 105 THOUSANDS 13 Automatic transaxle Check fluid level every 12 X X X X X X X fluid 4 months or 14 Engine coolant Change at first 4 years or X after that every Every X 2 years or 48 000km h 30 000 miles 15 Disc bra
41. ard value using the adjusting bolt Standard value ITEMS DURING DURING ADJUSTMENT REPLACEMENT Vibration 141 153 170 190 ADJUSTING BOLT AKX01156AB frequency Hz Tension N Ib 539 637 785 981 121 143 176 221 Deflection 9 0 10 1 6 2 7 6 Reference value 0 35 0 40 0 24 0 30 mm in 3 Tighten the tension pulley fixing nut Tightening torque 49 10 N m 36 7 ft Ib TSB Revision GENERAL BODY AND CHASSIS 00 49 MAINTENANCE SERVICE POWER STEERING OIL PUMP DRIVE BELT TENSION CHECK AND ADJUSTMENT lt 2 4L ENGINE gt Check the drive belt tension by the following procedure OIL RUME PULLEY ON When using scan tool MB991502 Required Special Tools e MB991502 Scan Tool MUT II e MB991668 Belt Tension Meter Set Gently tap the middle of the belt between the pulleys the loca tion indicated by the arrow with your finger as shown in the 4 PULLEY illustration and check that the vibration frequency of the belt is AC102990AB within the standard value NOTE Refer to for details on the method of measuring the vibration frequency using the scan tool POWER STEERING OIL PUMP PULLEY When using a tension gauge Use a belt tension gauge to check that the belt tension is within the standard value ADJUSTING BOLT Belt deflection check Apply 98 N 22 pound of force to the middle of the driv
42. by a unit of N m in Ib or N m ft lb For fas teners with no assigned torque value refer to P 00 33 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 located 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 ABBREVIATIONS The following abbreviations are used in this manual for classification of model types M T Indicates manual transaxle or models equipped with manual transaxle Indicates automatic transaxle or models equipped with automatic transaxle MFI Indicates multiport fuel injection or engines equipped with multiport fuel injection 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 lt 6G72 gt engine or a model equipped with such an engine PCM Powertrain control module ECM Engine control module SWS Simplified Wiring System TSB Revision 00 4 EXPLANATION OF MANUAL CONTENTS Maintenance and servicing procedures The numbers provided within the diagram indicate the sequence for maintenance and servicing procedures e Removal steps The part designation number corresponds to the number in the illustration to indicate remov al steps e Disassembly steps
43. ch will result in late shift ing and slipping of the clutches and brakes In either case air bubbles can interfere with normal valve clutch and brake operation Also foaming can cause A T fluid to escape from the transaxle vent where it may be mis taken for a leak 6 Securely insert the dipstick NOTE The fluid should always be replaced when e When troubleshooting the transaxle e When overhauling the transaxle e When the oil is noticeably dirty or burnt vehicle was driven under severe conditions CHANGE A T FLUID If you have an A T fluid changer use this changer to replace the A T fluid If you do not have an 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 A 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 3 7 quarts 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 fluid Discharge volume Approximately 2 0 dm 2 1 quarts 4 Install the drain plug with a new gasket and tighten it to the specified torque
44. ched 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 is stamped into replacement parts for the engine and the transmission A 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 cov ered 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 TSB Revision 00 20 GENERAL BODY AND CHASSIS VEHICLE IDENTIFICATION LOCATIONS LABEL AREA A FOR ORIGINAL EQUIPMENT PARTS B FOR REPLACEMENT PARTS ENGINE 4064 AC000058AB ENGINE lt 6G72 gt AC000061AB MANUAL TRANSAXLE lt F5M42 gt AC000059 AB MANUAL TRANSAXLE lt F5M51 gt AC000062AB AUTOMATIC TRANSAXLE ACO000060AB FENDER THE ILLUSTRATION INDICATES LEFT OUER SIDE RIGHT SIDE IS SYMMETRICALLY OPPOSITE AC000063AB TSB Revision GENERAL BOD
45. dE element 5 Smkpus Renee X X X X fan 10 Change every 3 months or Every 4 800 km 3 000 miles A B C D and G 11 Engine oil filter Replace every 6 months or Every 9 600 km 6 000 miles A B C D and G 12 Manual Change oil at X X X B G and H transaxle oil 13 Automatic Change fluid at B Gand H transaxle fluid 15 Disc brake pads Inspect for wear every 6 Every 9 600 km 6 000 miles A and F months or 16 Rear drum brake Inspect for wear every 12 Every 2 400 km 15 000 miles A and F linings and rear months or wheel cylinders 22 Rotate every 6 months or Every 9 600 km 6 000 miles B C E 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 TSB Revision 00 42 GENERAL BODY AND CHASSIS MAINTENANCE SERVICE MAINTENANCE SERVICE 1 FUEL SYSTEM TANK PIPE LINE AND CONNECTION AND FUEL TANK FILLER TUBE CAP CHECK FOR LEAKS M1001001600226 Check for damage or leakage in the fuel lines and connections 2 FUEL HOSES CHECK CONDITION M1001001700212 1 Inspect the surf
46. deflection check 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 ITEM 2 4L ENGINE 3 0L ENGINE Deflection Reference 6 7 9 0 8 5 10 9 value mm in 0 26 0 35 0 33 0 43 GENERATOR DRIVE BELT TENSION ADJUSTMENT lt 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 TSB Revision 00 48 GENERAL BODY AND CHASSIS MAINTENANCE SERVICE Standard value ITEMS DURING DURING ADJUSTMENT REPLACEMENT Vibration 201 222 267 299 frequency Hz Tension N Ib 441 539 785 981 99 121 176 220 Deflection 7 2 8 4 4 4 5 3 Reference value 0 28 0 33 0 17 0 21 mm in 4 Tighten the lock bolt Tightening torque 23 2 N m 16 2 ft Ib 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 Ib lt 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 stand
47. e belt CRANKSHAFT PULLEY co00088AB between the pulleys at the place indicated by the arrow and check that the amount of deflection is within the standard value Standard value lt 2 4L ENGINE gt ITEMS WHEN DURING DURING CHECKED ADJUSTMENT REPLACEMENT Vibration 108 132 114 126 137 157 frequency Hz Tension 392 588 441 539 637 834 Ib 88 132 99 121 143 187 Deflection 11 7 15 3 12 5 143 8 8 11 0 Reference 0 46 0 60 0 49 0 56 0 35 0 43 value mm in TSB Revision 00 50 2 4L ENGINE gt TENSIONER PULLEY AC 4 COMPRESSOR PULLEY AC102991AB 3 0L ENGINE POWER STEERING FIXING BOLT OIL PUMP PULLEY 44 x 10 N m gt lt 33 7 ft Ib 5 ad ADJUSTING BOLT FIXING NUT CRANKSHAFT PULLEY GENERAL BODY AND CHASSIS MAINTENANCE SERVICE lt 3 0L ENGINE ITEMS WHEN DURING DURING CHECKED ADJUSTMENT REPLACEMENT Vibration 125 154 133 148 160 183 frequency Hz Tension 373 569 422 520 608 804 16 84 128 95 117 137 181 Deflection 11 0 14 2 11 7 13 4 8 4 9 3 Reference 0 43 0 56 0 46 0 53 0 33 0 37 value mm in If the tension or deflection is outside the standard value adjust by the following procedure lt 2 4L
48. eated M1001002100064 TSB Revision 00 44 GENERAL BODY AND CHASSIS AKX01147 MAINTENANCE SERVICE 7 DISTRIBUTOR CAP AND ROTOR CHECK lt 3 0L ENGINE gt M1001002200050 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 e Check the cap for cracks e Check the cap and rotor electrodes for damage e Wipe clean the cap and rotor e Clean the corrosion off the terminals inside the distributor cap 8 TIMING BELT REPLACE M1001002300154 Replace the belt with a new one according to the maintenance schedule on P 00 39 to assure proper engine performance For removal and installation procedures refer to GROUP 11A Timing Belt P 11A 32 and Timing Belt B P 11A 36 lt 2 4L engine gt or GROUP 11C Timing Belt P 11C 37 lt 3 0L engine gt 9 DRIVE BELT FOR THE GENERATOR WATER PUMP POWER STEERING PUMP CHECK CONDITION M1001002500222 GENERATOR DRIVE BELT TENSION CHECK lt When using scan tool MB991502 gt Required Special Tools e MB991502 Scan Tool MUT II e MB991668 Belt Tension Meter Set TSB Revision GENERAL BODY AND CHASSIS MAINTENANCE SERVICE 2 41 ENGINE MB991668 15 MICROP HONE TAP LIGHTLY WITH A FINGER GENERATOR PULLEY AKX01149AB lt 3 0L ENGINE gt
49. eering wheel straight forward position 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 lug gage compartment etc APPLYING ANTI CORROSION AGENT OR OTHER UNDERCOAT AGENTS Be careful not to apply oil or grease to the heated oxygen sen sor If applied the sensor may malfunction Protect the heated oxygen sensor with a cover before applying anti corrosion agent etc TSB Revision 00 24 GENERAL BODY AND CHASSIS TOWING AND HOISTING SCAN TOOL MUT II N CAUTION Turn the ignition switch to LOCK OFF position before disconnecting or connecting the scan tool To operate the scan tool refer to MUT II Operating Instruc tions SCAN TOOL MUT II Z ACX00882 AB TOWING AND HOISTING WRECKER TOWING RECOMMENDATION FRONT TOWING PICKUP A CAUTION This vehicle cannot be towed by a wrecker using sling type equipment otherwise the bumper may become deformed If this vehicle is towed use wheel lift or flat bed equipment The vehicle may be towed on its rear wheels for extended dis tances provided the parking brake is released It is recom mended that vehicles be towed using the front pickup whenever possible SLIDING TYPE
50. es on the vehicle MAIN SEALANT AND ADHESIVE TABLE M1001003800215 APPLICATION 3M NO LOCTITE PERMATEXGNO ENGINE AND Between rocker cover and 3M AAD Part No 8660 Permatex Ultra Black DRIVETRAIN camshaft bearing cap Ultrapro High Temp Silicone 598 No 82180 Between rocker cover Gasket or semicircular packing and 3M AAD Part No 8679 cylinder head Between oil Black 8678 Black Press In pressure switch and engine Place Silicone gasket strips Between engine coolant 3M AAD Part 8731 Loctite 242 Blue Service temperature switch engine Medium Strength Blue Tool Removable 24200 coolant temperature sensor Threadlocker thermo valve thermo switch joint engine coolant temperature gauge unit large size and engine Between oil pan and engine 3M AAD Part No Permatex Ultra Gray 599 block 3M AAD Part No No 82194 3M AAD Part No 3M AAD Part No WEATHER Between tempered glass 3M AAD Part 8509 STRIPPING body flanges and Auto Bedding and Glazing FOR GLASS weatherstrip Compound or 3M AAD Part No 8633 Windo weld Resealant WEATHER Between laminated glass and 3M AAD Part No 8633 STRIPPING weatherstrip FOR GLASS TSB Revision 00 66 GENERAL BODY AND CHASSIS MAIN SEALANT AND ADHESIVE TABLE APPLICATION 3M NO LOCTITEG PERMATEXGNO INTERIORS Adhesive of vinyl chloride 3M AAD Part No 8088 Permatex Vinyl Repair Kit cloth General Trim Adh
51. esive or No 81786 3M AAD Part No 8064 Vinyl Trim Adhesive Adhesion of door 3M AAD Part No 8001 Permatex Super Black weatherstrip yellow or Weatherstrip Adhesive 3M AAD Part No 8008 No 82 81850 black Super Weatherstrip Adhesive or 3M AAD Part No 8011 Black Weatherstrip Adhesive Sealing of various grommets 3M AAD Part 8509 and packing 3M AAD Part No 8678 Adhesion of headliners and AAD Part No 8088 Permatex Spray various interior decorative General Trim Adhesive or Adhesive No 82019 materials 3M AAD Part No 8090 Super Trim Adhesive BODY Sealing of sheet metal joints 3M AAD Part No 8531 SEALANTS drip rail floor side panels Heavy Drip Check Sealer trunk front panel tail gate gray or hinge 3M AAD Part No 8302 Ultrapro Autobody Sealant clear or 3M AAD Part No 8361 Urethane A B Sealant gray or white Miscellaneous body sealants 3M AAD Part No 8633 2 originally mounted w Windo weld Resealant adhesive tape e Waterproof door film e Fender panel e Splash shield e Mud guard e Rear combination lamp Fuel Tank and Pad 3M AAD Part No 8088 Permatex Spray General Trim Adhesive or Adhesive No 82019 3M AAD Part No 8090 Super Trim Adhesive TSB Revision GENERAL BODY AND CHASSIS MAIN SEALANT AND ADHESIVE TABLE 00 67 APPLICATION CHASSIS SEALANT Sealing of various threaded parts dust c
52. etc TSB Revision 00 16 GENERAL BODY AND CHASSIS VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION Z AC000051 M1001000400274 VEHICLES IDENTIFICATION NUMBER LOCATION The vehicle identification number VIN is located on a plate attached to the left top side of the instrument panel 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 X NO ITEMS stad 1 Country 4 USA 2 Make A Mitsubishi 3 Vehicle type 3 Passenger car 12345678910 11 4 Others A Driver and passenger air bags ems 5 Line C ECLIPSE E ECLIPSE SPYDER 6 Price class 3 Medium 4 High 5 Premium 7 ULTIMATE 8 Sports 7 Body 4 3 door hatch back 5 2 door convertible 8 Engine G 2 4L S 4 4G64 H 3 0L S 4 6G72 9 Check digits 0 1 2 3 9 X 10 Model year 3 2003 year 11 Plant E Mitsubishi Motor Manufacturing of America Inc 12 Serial number 000001 to 999999 NOTE Check digit means a single number or letter X used to verify the accuracy of transcription of vehicle identification number TSB Revision GENERAL BODY AND CHASSIS 00 1 7 VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER LIST ECLI
53. f resistor When the temperature sensor output terminal terminal 6 intake air temperature rises the resistance from the PCM terminal 64 via the resistor in the decreases PCM The ground terminal terminal 5 is The intake air temperature sensor output voltage grounded with or PCM terminal 57 increases when the resistance increases and decreases when the resistance decreases ACX00861AD TSB Revision GENERAL BODY AND CHASSIS 00 9 HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS 4 Explains about technical details TECHNICAL DESCRIPTION The intake air temperature sensor con intake air temperature to a voltag The PCM checks whether thig Voltage is within a specified range DTC SET CONDITIONS Check Conditions Two seconds or more have passed since the engine was started Judgement Criteria ntake air temperature sensor output voltage has continued to be 4 6 volts or higher corresponding to an air intake temperature of 45 C 49 F or lower for 2 seconds DIAGNOSIS Required Special Tool MB991502 Scan Tool MUT II e ntake air temperature sensor output voltage has continued to be 0 2 volt or lower correspopai to an air intake temperature of 125 2 higher for 2 seconds b Describes the conditions for that DTC being set stored 6 Describes possible cause s for that DTC TROUBLESHOOTING HINTS The most likely causes for this code to be set are
54. fficulty in finding the cause of the intermit tent malfunction the data recorder function in the scan tool is effective For these simulation tests shake then gently bend pull and twist the wiring of each of these examples to duplicate the inter mittent malfunction e Shake the connector up and down and right and left e Shake the wiring harness up and down and right and left Especially check the splice points of wiring harnesses care fully Refer to GROUP 80B SPLICE LOCATION 00 2 e Vibrate the part or sensor ACX00871 AB TSB Revision GENERAL BODY AND CHASSIS 00 1 5 HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS BATTERY CIRCUIT 1 OCCURRENCE ACX00872 AB INSPECTION SERVICE POINTS FOR A BLOWN FUSE Remove the blown fuse and measure the resistance between the load side of the blown fuse and the ground Close the switches of all circuits which are connected to this fuse If the resistance is almost 0 Q at this time there is a short some where between these switches and the load If the resistance is not 0 Q 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 e Harness being clamped by the vehicle body e Damage to the outer casing of the harness due to wear or heat e Water getting into the connector or circuitry e Human error mistakenly shorting a circuit
55. for performing inspections and adjustments of partic ularly important components These procedures are done with regard to maintenance and servicing but other inspections looseness play cracking dam age etc must also be performed SERVICE PROCEDURES The service steps are arranged in numerical order Attention 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 whether or not a part or setting up on inspection is correct LIMIT Shows the maximum or minimum value for judging whether or not a part or setting up on inspection is acceptable REFERENCE VALUE Indicates the adjustment value prior to starting the work presented in order to facilitate assembly and adjustment procedures and so they can be com pleted in a shorter time M1001000100295 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 Ifa DANGER is not followed the result is severe bodily harm or even death e If a WARNING is not followed the result could be bodily injury e f 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 tol erance
56. hich could result in serious injury or death to the vehicle s driver and front passenger 2 Check the harness for binds the connectors for damage and the terminals for deformation REPLACE ANY CONNECTOR OR HARNESS THAT FAILS THE VISUAL INSPECTION Refer to GROUP 52B SRS Service Precaution P 52B 144 21 EXHAUST SYSTEM CONNECTIONS PIPES AND CONVERTER HEAT SHIELDS CHECK AND SERVICE AS REQUIRED M1001005800170 1 Check for holes and exhaust gas leaks due to damage corrosion etc 2 Check the joints and connections for looseness and exhaust gas leaks 3 Check the rubber hangers and brackets for damage TSB Revision GENERAL BODY AND CHASSIS 00 65 MAIN SEALANT AND ADHESIVE TABLE BCs ec e AC000120 22 TIRES ROTATE M1001008900187 Rotate tires regularly to equalize tire wear and help extend tire life Recommended tire rotation is every 12 000 km 7 500 miles under normal driving conditions and every 9 600km 6 000 miles 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 tir
57. hicle be operated on gasoline Methanol Do not use gasoline containing metha nol wood alcohol Using this type of alcohol can result in vehicle performance deterioration and dam age 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 METHYL TERTIARY BUTYL ETHER MTBE Unleaded gasoline containing 1596 or less MTBE may be used in your vehicle Fuel containing MTBE over 1596 in volume may cause reduced engine per formance 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 TSB Revision 00 36 GENERAL BODY AND CHASSIS RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE RECOMMENDED LUBRICANTS PARTS SPECIFICATIONS REMARKS Engine oil Engine oil displaying ILSAC For further details refer to certification mark Starburst LUBRICANTS SELECTION symbol conforming to API section classification SJ EC or SJ CD EC Manual transaxle API classification GL 4 SAE grade number SAE75W 90 or 75W 85W M1001001300214
58. icated 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 AC000109 AB TSB Revision GENERAL BODY AND CHASSIS 00 59 MAINTENANCE SERVICE 20 SRS AIR BAG INSPECT FOR SRS SYSTEM M1001003700199 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 DATE OF MANUFACTURE CERTIFICATION LABEL MADE IN U S A DATE MFD BY MTSUBISHI NOTOR MFG OF AMERICA INC GVWR LBS GAWR LBS GAWA LBS FR KG RR THIS VEHICLE CONFORMS TO ALL APPLIVABLE FEDERAL MOTOR VEHICLE SAFETY BUMPER AND THEFY PREVENTION STANDARDS IN EFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE MDH VEHICLE TYPE PASSENGER CAR MUG00265 AC000111AB 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 23 SRS WARNING LIGHT AC000112 AB TSB Revision 00 60 GENERAL BODY AND CHASSIS MAINTENANCE SERVICE SRS COMPONENT VISUAL CHECK DANGER Wait at least 60 seco
59. ke pads Inspect for wear every 12 X X X X X X X months or 16 Rear drum brake linings Inspect for wear and leaks every X X X and rear wheel cylinders 2 years or 17 Brake hoses Check for deterioration or leaks X X X X X X X every 12 months or 18 joint and steering Inspect for grease leaks and X X X linkage seals damage every 2 years or 19 Drive shaft boots Inspect for grease leaks and X X X X X X X damage every 12 months or 20 SRS air bag Inspect the SRS system at 10 years 21 Exhaust system Check and service as required X X X connection portion of every 2 years or muffler muffler pipes and converter heat shields 22 Tires Rotate every 12 months or Every 12 000 km 7 500 miles NOTE 1 For California Massachusetts Vermont and maine this maintenance is recommended but not required 2 Not required if belt was previously changed 3 If the mileage is less than 12 000 km 7 500 miles each year the oil filter should be replaced at every oil change is Change fluid under severe usage conditions only TSB Revision GENERAL BODY AND CHASSIS 00 41 SCHEDULED MAINTENANCE TABLE SCHEDULED MAINTENANCE UNDER SEVERE USAGE CONDITIONS Maintenance should be carried out according to the following table MAINTENANCE SERVICE KILOMETERS 24 48 72 96 120 144 168 SEVERE ITEM INTERVALS IN USAGE THOUSANDS CONDITIONS MILEAGE IN 75 THOUSANDS 3 Air cleaner Replace at X X Aan
60. le Induction System ITEMS GT GT GT GT MNXEL4M MRXEL4M MNGEL4M MRGEL4M Vehicle Overall length 4 490 176 8 4 490 176 8 4 490 176 8 4 490 176 8 dimension mm in Overall width 2 1 750 6 1 750 68 9 1 1 750 68 9 1 750 6 Overall height 1 310 5 1 310 51 6 310 m 5 1 310 t 5 unladen Wheelbase 4 2560 100 8 2 560 100 8 2 560 100 8 2 560 100 8 Tread font 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 44 1 510 59 4 1 510 59 4 Overhang front 7 1010 39 8 1010 39 8 1010 39 8 1010 39 8 oveangres 9 920 36 2 920 36 2 920 36 2 920 36 2 Minimum running 150 5 9 150 5 9 150 5 9 150 5 9 ground clearance Vehicle weight Curb weight 1 425 3 142 1 455 3 208 1 465 3 230 1 495 3 296 kg Ib Gross vehicle weight 1 820 4 013 1 820 4 013 1 820 4 013 1 820 4 013 rating Gross axle weight 1 050 2 315 11 050 2 315 1 050 2 315 1 050 2 315 rating front Gross axle weight 770 1 698 770 1 698 770 1 698 770 1 698 rating rear 4 Seating capacity Engine 5072 qu Transaxle Model No No F4A51 manual automatic manual Fuel system Fuel supply system Electronic controlled multiport fuel injection TSB Revision 00 30 GENERAL BODY AND CHASSIS GENERAL DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS Model with 3 0L Engine with Variable Induction System
61. nds after disconnecting the bat TAPE tery cable before doing any further work The SRS e SATIRE system is designed to retain enough voltage to deploy the air bag for a short time even after the bat tery 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 A WARNING Battery posts terminals and related accessories con tain 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 8 3 Disconnect a connector from the SRS ECU BATTERY CABLE ACX00902 AB SIDE IMPACT SENSORS A WARNING e If the side impact sensor is not installed securely and correctly the side airbag may not operate nor mally 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 SIDE IMPACT SENSOR TSB Revision GENERAL BODY AND CHASSIS 00 61 MAINTENANCE SERVICE REPLACE THE SIDE IMPACT
62. o 3 000 r min several times then stop the engine 12 Remove the radiator cap after the engine has become cold and pour in coolant up to the brim Reinstall the cap A CAUTION Do not overfill the reserve tank 13 Add coolant to the reserve tank between the FULL and LOW mark if necessary 15 DISC BRAKE PADS INSPECT FOR WEAR M1001003200194 Check for fluid contamination and wear Replace the complete set of pads if any one pad is 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 ACX00898 AB 16 REAR DRUM BRAKE LININGS AND REAR WHEEL CYLINDERS INSPECT FOR WEAR AND LEAKS M1001003300179 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 A CAUTION The shoes for the right and left wheels should be replaced at the same time Never split or intermix brake shoe sets 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 boo
63. or police taxi or commercial type operation 2 Operation of Vehicle 1 Short trip operation at freezing temperature engine not thoroughly warmed up 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 TSB Revision GENERAL BODY AND CHASSIS 00 35 LUBRICATION AND MAINTENANCE ENGINE OIL A CAUTION Test results submitted to EPA have shown that laboratory animals develop skin cancer after pro longed 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 SELEC TION LUBRICANTS AND GREASES Semi solid lubricants bear the NLGI designation and are further classified as gr
64. overs Differential Ultrapro High Temp Silicone carrier packing dust covers and ball joint and linkage Packing and shims of Sealant of various flange faces and threaded parts Packing of fuel gauge unit 3M NO LOCTITEG PERMATEXGNO Loctite 272 High Strength and High Temperature 3M AAD Part No 8730 High Strength Red Thread lock or 3M AAD Part No 8731 Medium Strength Blue Threadlocker 3M AAD Part No 8672 27200 No 25223 Gasket or 3M AAD Part No 8679 black or steering box sealing of rack 3M AAD Part No 8678 support cover and top cover black Press In Place of steering box housing seal Silicone gasket strips of junction face of knuckle arm flange 3M AAD Part No 8661 or 3M AAD Part No 8663 Super Silicone sealant Seal of brake shoe hold down 3M AAD Part No 8633 ES pin and wheel cylinder of drum brakes QUICK FIX ADHESIVE ANAEROBIC STRONG SEALING AGENT Fixing of various threads bolts screws Fixing of differential drive gear bolt or Connecting of tilt steering Windo weld Resealant Permatex The Right Stuff 3M AAD Part No 8155 Loctite amp Quicktite Super Quick Fix Adhesive Glue 21309 3M AAD Part No 8730 High Strength Threadlocker 27200 3M AAD Part No 8731 bolt Fan pulley gear Sealing Medium Strength of small gaps and flange faces UNDERCOATIN G AGENT Threadlocker 3M AAD Part No 8883 Rubbe
65. r used on this vehicle is a high quality filter The filter must withstand a pressure of 1 765 kPa 256 psi manufacturer s specifications to avoid filter and ultimately 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 an oil filter wrench etc ENGINE NUMBER SPECIAL TOOL TIGHTENING TORQUE 2 4L MD360935 MB991396 or equivalent Approximately one turn 14 2 N m 124 18 in Ib MD325714 MB991396 or equivalent Approximately 3 4 turn 16 4 N m 12 3 ft Ib MD332687 MD365876 MD136466 General service tool Approximately 3 4 turn 17 3 N m 34 2 ft Ib MD322508 3 0L MD352626 General service tool Approximately one turn 14 2 N m 124 18 in Ib 6 Add new engine oil through the oil filler 12 MANUALTRANSAXLE OIL M1001002800126 Inspect
66. rized Undercoating Aerosol or 3M AAD Part No 8864 Body Schutz Undercoating qt Loctite 271 High Strength Threadlocker 27100 or Permatex Heavy Duty Undercoating 81833 TSB Revision NOTES
67. s for lubrication sealants and adhesives Symbols are used to show the locations for lubrication and for application of sealants and adhesives These symbols are included in the diagram of compo nent parts or on the page following the component parts page The symbols do not always have accomp anying text to support that symbol h bg Grease Sealant or adhesive Brake fluid or automatic transmission fluid Engine oil gear oil or air conditioning com Adhesive tape or butyl rubber tape Multi purpose grease unless there is a brand or type specified pressor oil AC102240AB TSB Revision GENERAL BODY AND CHASSIS Indicates the group title BASIC BRAKE SYSTEM HOW TO USE THIS MANUAL Indicates Indicates the the group section title number FRONT DISC BRAKE ASSEMBLY FRONT DISC BRAKE ASSEMBLY REMOVAL AND INSTALLATION Pre removal Operation Brake Fluid Draining 9014 Nm m 22 34 _ N 3 Post installation Operation e Brake Fluid Supplying anc Air Bleeding Refer to 00 5 Indicates the page number Mark denotes non 1 4 3 BRAKE CALIPER KIT PAD SET SHIM KIT SEAL AND BOOT KIT ae de 2 GASKET Required Special Tool MB990520 Disc Brake Piston Expander REMOVAL STEPS BR
68. service points when there is a blown fuse refer to Inspec tion Service Points for a Blown Fuse Inspection Service Points NO Go to Step 2 ACX00862AD MEASURES TO TAKE AFTER REPLACING THE ECU If the trouble symptoms have not disappeared even after replacing the ECU repeat the inspection proce dure from the beginning TSB Revision 00 10 GENERAL BODY AND CHASSIS HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS 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 Required Special Tool MD998459 Test Harness Waterproof Connectors Be sure to use special tool MB998459 Never insert a test probe from the harness side as this will reduce the water proof performance and result in corrosion Ordinary non waterproof Connectors Check by inserting the multi meter test probe from the har ness 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 CONNECTOR IF INSPECTING WITH THE CONNECTOR DISCONNECTED When Inspecting a Female Pin e From front side of the connector Required Special Tool MB991219 Inspection Harness Included in MB99
69. t 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 AC002717 AB TSB Revision 00 58 GENERAL BODY AND CHASSIS MAINTENANCE SERVICE 17 BRAKE HOSES CHECK FOR DETERIORATION OR LEAKS M1001003400198 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 _ AC000107AB wheel tire or chassis 18 BALL JOINT AND STEERING LINKAGE SEALS INSPECT FOR GREASE LEAKS AND DAMAGE M1001003500195 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 19 DRIVE SHAFT BOOTS INSPECT FOR GREASE LEAKS AND DAMAGE M1001003600192 1 These components which are permanently lubr
70. t operation to make sure that the system functions properly TSB Revision GENERAL BODY AND CHASSIS 00 23 PRECAUTIONS BEFORE SERVICE ACX00880AB APPROXIMATELY ca ACX00881AB SERVICING ELECTRICAL SYSTEM A WARNING Battery posts terminals and related accessories con tain 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 A CAUTION Before connecting or disconnecting the negative bat tery cable be sure to turn the ignition switch to the LOCK OFF position and turn off the lights If this is not done there is the possibility of semiconductor parts being damaged e After completion of the work and the negative battery terminals is connected warm up the engine and allow it to idle for approximately 10 minutes under the condi tions described below in order to stabilize engine con trol conditions and then check to be sure that the idle is satisfactory 2 When servicing the electrical system disconnect the negative cable terminal from the battery Engine coolant temperature 85 95 185 203 F Lights and all accessories OFF Transmission N or P position St
71. 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 e Do not use a mixture of different brands of anti freeze COOLANT TEMPERATURE C F _ FREEZING SAFE OPERATING COOLANT AND SPECIFIC GRAVITY TEMPERATURE TEMPERATURE CONCENTRATION SPECIFIC VOLUME 10 50 20 68 30 86 40 50 C F C F 1 4 3 5 04 122 1 095 1 090 1 084 1077 11 070 42 4 37 35 55 1 103 1 098 1 092 11 084 1 076 50 58 45 49 60 Example The safe operating temperature is 15 5 F when the specific gravity is 1 058 at the coolant temperature of 20 685 TSB Revision GENERAL BODY AND CHASSIS 00 39 SCHEDULED MAINTENANCE TABLE SCHEDULED MAINTENANCE TABLE M1001001400222 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 SERVICE KILOMETERS 24 48 72 96 120 144 CONTROL SYSTEM INTERVALS MAINTENANCE THOUSANDS 168 MILEAGE IN 75 105 THOUSANDS Fuel system tank Check for leaks every 5 years or X pipe line and connection
72. ube After relieving the steam pressure remove the cap by slowly turning it coun terclockwise 4 Remove the radiator cap radiator drain plug and if equipped engine coolant drain plug to drain the coolant 5 Remove the reserve tank and drain the coolant 6 After completely draining the coolant reinstall the drain plugs and flush the engine and radiator using a radiator cleaning fluid 7 After the flushing is completed completely drain the cleaning fluid and install the radiator and engine drain plugs PLUG AC000106 AB A 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 corrosion of the aluminum components 8 By referring to the section on coolant select an appropriate concentration for safe operating temperature within the range of 30 to 60 Use special tool MB991871 to refill the coolant A convenient mixture is a 50 water and 50 96 antifreeze solution freezing point 31 C 32 8 F Recommended antifreeze MITSUBISHI GENUINE Part NO MD970389 or equiva lent Quantity 2 4L Engine 7 0 dm 7 4 quarts lt 3 0L Engine 8 0 dm 8 5 quarts TSB Revision GENERAL BODY AND CHASSIS 00 57 MAINTENANCE SERVICE 9 Reinstall the radiator cap 10 Start the engine and let it warm up until the thermostat opens 11 After repeatedly revving the engine up t
73. void missing an important step in the diagno sis 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 pro cedures to help diagnose the problem come up with a series of checks based on the ranked list of proba ble causes Troubleshooting checks should be made in the order that the list of causes was ranked e general to specific e most likely to least likely e easy to check to hard to check REPAIR THE PROBLEM When the step by step troubleshooting checks find a fault perform the proper repairs Be 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 Be sure to check the system thoroughly Sometimes new problems are revealed after repairs have been made HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS 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 TROU BLESHOOTING Troubleshooting strategy is shown in each group M1001000200258 2 SYSTEM OPERATION AND SYMPTOM VERIFICATION

P.00-6 - Tearstone

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