Mitsubishi Eclipse 1996 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Eclipse Year: 1996 Codes Chassis Code: D31A, D32A, D38A, D39A Engine Codes: 4G63 (2.0L DOHC Turbo), 4G64 (2.4L SOHC) 👋 Introduction Market Position...

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标签: 1996 Car Cars Eclipse Misc Mitsubishi

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Eclipse

Year:

Codes

Chassis Code:

D31A, D32A, D38A, D39A

Engine Codes:

4G63 (2.0L DOHC Turbo), 4G64 (2.4L SOHC)

👋 Introduction

Market Position

Segment:

Compact Sports Coupe / Convertible

Target Audience:

Enthusiasts, DIY mechanics, owners seeking in-depth technical knowledge.

Competitive Analysis

Key Competitors 1996:

Nissan 240SX, Toyota Celica, Mazda MX-6, Ford Probe, Honda Prelude.

Key Features

Engine Options:

Available with naturally aspirated and turbocharged engines, offering different performance levels.

Drivetrain Options:

Offered in Front-Wheel Drive (FWD) and sophisticated All-Wheel Drive (AWD) configurations, particularly with the turbocharged engines.

Design:

Distinctive styling, often associated with the DSM (Diamond-Star Motors) collaboration.

📋 Manual Details

Coverage Areas

Coverage:

All aspects of repair, maintenance, troubleshooting, and diagnostics for the 1996 Mitsubishi Eclipse.

Page Count

Estimated Pages:

1500-2000 (typical for comprehensive factory service manuals)

Manual Type

Type:

Full Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, cylinder head, block, crankshaft, pistons, connecting rods, timing belt/chain, lubrication system, cooling system.

Engine Performance:

Fuel injection system, ignition system, emission control systems (EVAP, EGR), turbocharger system (for turbo models).

Transmission Manual:

Clutch, gearbox, gears, shift linkages, flywheel, clutch fluid.

Transmission Automatic:

Automatic transmission assembly, torque converter, valve body, transmission control unit (TCU), transmission fluid, cooler lines.

Drivetrain:

Front-wheel drive (FWD) and All-wheel drive (AWD) systems, differentials, drive axles, CV joints, propeller shaft (AWD).

Brakes:

Hydraulic system, ABS (Anti-lock Braking System), brake calipers, rotors, pads, master cylinder, brake lines, parking brake.

Suspension:

Front suspension (MacPherson struts, control arms), rear suspension (multi-link independent on some AWD models), springs, shock absorbers, bushings, sway bars.

Steering:

Power steering system, steering rack, tie rods, steering column, steering wheel.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting system (headlights, taillights, interior lights), fuses, relays, wiring diagrams.

Body And Chassis:

Body panels, doors, hood, trunk lid, bumpers, interior trim, chassis structure, rust prevention.

HVAC:

Heating, ventilation, and air conditioning (HVAC) system, refrigerant, compressor, condenser, evaporator, cabin filter.

Safety Systems:

Airbags, seatbelts, crash safety structures.

Procedures Included

Maintenance:

Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement, brake pad replacement, tire rotation.

Troubleshooting:

Diagnostic procedures for common symptoms (e.g., engine misfires, starting issues, braking problems), fault code interpretation (OBD-II).

Repair:

Step-by-step instructions for component removal, installation, and overhaul of all major systems.

Diagnostics:

Testing procedures for sensors, actuators, and electrical circuits using multimeters and diagnostic tools.

Rebuilding:

Detailed instructions for complete engine and transmission rebuilds.

Refurbishment:

Guidance on restoring worn components and systems.

Restoration:

Information applicable to bringing a classic vehicle back to original specifications.

Technical Depth

Depth:

Comprehensive: Covers basic maintenance to full engine/transmission rebuilds and advanced diagnostics.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Likely text-searchable if produced from original digital files.

Print Quality

Print Readability:

Designed for clear viewing and printing of diagrams, illustrations, and text.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine 1 Variant:

2.0L DOHC 16-valve 4G63 Inline-4 (Naturally Aspirated)

Engine 1 Displacement:

1997 cc (2.0 Liters)

Engine 1 Horsepower:

Approx. 140 hp @ 6000 rpm

Engine 1 Torque:

Approx. 135 lb-ft @ 4000 rpm

Engine 2 Variant:

2.0L DOHC 16-valve 4G63 Turbocharged Inline-4

Engine 2 Displacement:

1997 cc (2.0 Liters)

Engine 2 Horsepower:

Approx. 210 hp @ 6000 rpm (GST/GSX models)

Engine 2 Torque:

Approx. 214 lb-ft @ 3000 rpm (GST/GSX models)

Engine 3 Variant:

2.4L SOHC 16-valve 4G64 Inline-4

Engine 3 Displacement:

2351 cc (2.4 Liters)

Engine 3 Horsepower:

Approx. 141 hp @ 5500 rpm

Engine 3 Torque:

Approx. 155 lb-ft @ 2500 rpm

Performance

Engine Control:

ECI-Multi (Electronic Controlled Injection) Multi-Point Fuel Injection.

Turbocharger System:

Garrett T25/T28 variant with intercooler (on turbo models).

Fuel System

Fuel Delivery:

Sequential multi-port fuel injection.

Fuel Type:

Unleaded gasoline (91 octane recommended for turbo models).

🔧 Transmission

Standard

Transmission Std:

5-speed Manual Transmission (F5M33 for FWD, W5M33 for AWD)

Optional

Transmission Opt:

4-speed Automatic Transmission (KM175 for FWD, V4A51 for AWD)

Features

AWD System:

Viscous coupling center differential with optional electronically controlled limited-slip rear differential (on AWD models).

Fluid Specifications

Manual Transmission Fluid:

API GL-4, SAE 75W-90 or 80W-90 gear oil.

Automatic Transmission Fluid:

Diamond SP-II or equivalent ATF.

📐 Dimensions

Exterior

Length:

Approx. 173.0 inches (4394 mm)

Width:

Approx. 69.1 inches (1755 mm)

Height:

Approx. 50.0 inches (1270 mm) (Coupe)

Wheelbase:

Approx. 100.4 inches (2550 mm)

Track Width Front:

Approx. 59.3 inches (1506 mm)

Track Width Rear:

Approx. 59.1 inches (1501 mm)

Weights

Curb Weight Est:

2850 - 3300 lbs (1293 - 1497 kg) depending on trim and drivetrain.

Gross Vehicle Weight Rating Gvw:

Approx. 4000 lbs (1814 kg)

Towing Capacity:

Not Recommended

🛡️ Safety Features

Ratings

NHTSA Frontal Impact Driver:

Not rated (vehicle design predates some current rating methodologies)

NHTSA Frontal Impact Passenger:

Not rated (vehicle design predates some current rating methodologies)

IIHS Offset Crash Test:

Acceptable to Marginal (depending on specific test protocols and year of analysis)

Active Features

Available on GSX, GST, and optional on other trims. 4-wheel disc brakes standard on performance models.

Traction Control:

Available on some AWD turbo models.

Passive Features

Airbags:

Driver and front passenger airbags standard.

Seat Belts:

Three-point inertia-reel seat belts front, two-point lap belts rear (some models).

Rollover Protection:

Reinforced A-pillars and roof structure for coupe models. Convertible models had a pop-up roll bar system integrated behind the seats.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/Cassette or optional CD player with 4-6 speaker systems.

Climate Control:

Manual climate control; optional automatic climate control on higher trims.

Driver Assistance

Cruise Control:

Standard on most models.

Connectivity

OBD Ii Port:

Equipped with OBD-II diagnostic port, facilitating engine and emissions diagnostics.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 3,000 - 5,000 miles (4,800 - 8,000 km) or 3-6 months, depending on driving conditions.

Engine Oil Filter Change:

With every oil change.

Timing Belt Replacement:

Every 60,000 miles (96,000 km) or 5 years for the 4G63 and 4G64 engines.

Spark Plug Replacement:

Every 30,000 - 60,000 miles (48,000 - 96,000 km) depending on plug type (copper vs. platinum).

Transmission Fluid Change Manual:

Every 60,000 miles (96,000 km) or as needed.

Transmission Fluid Change Automatic:

Every 30,000 - 50,000 miles (48,000 - 80,000 km) or as needed.

Fluid Specifications

Engine Oil Capacity:

Approx. 4.5 quarts (4.3 liters) with filter for 2.0L/2.4L engines.

Engine Oil Type:

API SG or SH, SAE 5W-30 or 10W-30 recommended (check owner's manual for exact viscosity based on climate).

Coolant Type:

Mitsubishi Long Life Coolant (or equivalent ethylene glycol-based coolant with corrosion inhibitors).

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid.

Power Steering Fluid:

Mitsubishi Power Steering Fluid or Dexron-III/Mercon ATF.

Known Issues

Turbo Models Oil Sludge:

Risk of oil sludge buildup in the 4G63 turbo engine if oil changes are neglected, leading to turbocharger damage or engine failure.

Timing Belt Tensioner:

Potential failure of the timing belt tensioner can cause belt slippage and severe engine damage.

Cv Joint Boots:

Ruptured CV joint boots can lead to premature failure of the Constant Velocity Joints, especially on AWD models.

Suspension Bushings:

Wear and tear on suspension bushings can lead to noise, poor handling, and alignment issues.

ABS Sensor Failure:

ABS wheel speed sensors can fail, leading to ABS warning lights and loss of ABS function.

Radiator Corrosion:

Older radiators may develop leaks or corrosion, leading to coolant loss.

📚 Vehicle History

Brand Heritage

Mitsubishi Motors:

Mitsubishi Motors Corporation, a Japanese multinational automotive manufacturer with a history dating back to the early 20th century.

Model Evolution

Eclipse Generation 2:

The 1996 model year marks the beginning of the second generation of the Mitsubishi Eclipse, built on the new D30 platform.

Dsm Collaboration:

Developed in partnership with Chrysler Corporation under the Diamond-Star Motors (DSM) joint venture. Shared platform and powertrains with the Eagle Talon and Plymouth Laser.

Production

Assembly Plant:

Normal, Illinois, USA (DSM Plant)

Production Years:

Second generation: 1995-1999

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The turbocharged Eclipse GSX was frequently recognized on Car and Driver's 10Best lists in the early to mid-1990s for its performance and value.