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Mitsubishi Eclipse 1990-1998 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Eclipse Generation: 1st Generation (D20/D30) Codes Chassis Codes: D20, D30 Platform: Mitsubishi Galant FWD/AWD Platform 👋 Introduction Market Position Positioning: The Mitsubishi Eclipse...
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Mitsubishi Eclipse 1990-1998 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Eclipse
Generation:
1st Generation (D20/D30)
Codes
Chassis Codes:
D20, D30
Platform:
Mitsubishi Galant FWD/AWD Platform
👋 Introduction
Market Position
Positioning:
The Mitsubishi Eclipse (1990-1998) was a groundbreaking compact sports coupe that bridged the gap between mainstream economy cars and dedicated sports cars, offering accessible performance and stylish design.
Competitive Analysis
Competitors:
Competed directly with vehicles such as the Honda Prelude, Toyota Celica, Nissan 240SX, and Ford Probe. Its AWD turbo models were particularly competitive against vehicles like the Subaru SVX and early DSM (Diamond-Star Motors) counterparts like the Plymouth Laser and Eagle Talon.
Key Features
Distinguishing Attributes:
Sleek, aerodynamic styling, available all-wheel drive, potent turbocharged 4G63 engine (especially in GST/GSX trims), independent suspension, and a focus on driver engagement. The V6 engine offered a smoother, more refined power delivery.
📋 Manual Details
Coverage Areas
Years Covered:
1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998
Model Variants Covered:
GS, GST, GSX, RS, SP, Base
Engine Variants Covered:
4G63 2.0L SOHC NA, 4G63 2.0L DOHC Turbocharged (non-intercooled and intercooled), 6G72 3.0L SOHC V6
Transmission Variants Covered:
5-speed Manual, 4-speed Automatic
Page Count
Estimated Pages:
Approximately 1500+
Manual Type
Type:
Comprehensive Service & Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF, ePub, etc.) / Printable
📖 Manual Coverage
Systems Covered
Engine:
Diagnosis, inspection, repair, overhaul for all covered engine variants (4G63 SOHC/DOHC, 6G72 V6)
Fuel System:
Fuel injection, fuel pumps, injectors, pressure regulators, fuel tanks, lines
Cooling System:
Radiator, water pump, thermostat, hoses, fan clutch/electric fan
Lubrication System:
Oil pump, oil filter, oil pan, oil passages
Ignition System:
Spark plugs, coils, distributor (if applicable), ignition control module, timing
Turbocharger System:
Turbocharger unit, wastegate, blow-off valve, intercooler (for GST/GSX models)
Exhaust System:
Exhaust manifolds, catalytic converter, mufflers, pipes
Drivetrain:
Clutches, flywheels, manual transmission (F5M21/F5M33), automatic transmission (KM2A1/KM2B1)
Axles And Differentials:
Front and rear axles, CV joints, center differential (AWD), viscous coupling unit (AWD)
Suspension System:
Front struts, rear shocks, control arms, ball joints, bushings, coil springs
Steering System:
Steering rack, power steering pump, hoses, steering column
Braking System:
Front and rear discs, calipers, master cylinder, ABS (if equipped), brake lines, parking brake
Electrical System:
Battery, alternator, starter, lighting, relays, fuses, wiring diagrams
Instrumentation And Controls:
Dashboard gauges, switches, HVAC controls, power windows/locks
Body And Frame:
Body panels, doors, glass, seals, structural components, chassis repair
HVAC System:
Air conditioning, heating, ventilation, blower motor, refrigerant system
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, spark plug replacement, belt inspections/replacement
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs) interpretation, electrical troubleshooting
Repair:
Step-by-step repair procedures for all major components and systems, including engine rebuilds, transmission overhauls, brake caliper replacement, suspension component replacement
Disassembly And Assembly:
Detailed instructions for removing, inspecting, and reinstalling components
Adjustments:
Valve adjustments, idle speed adjustments, timing adjustments, clutch adjustments
Rebuilding:
Instructions for rebuilding engines, transmissions, carburetors (if applicable), and other major components
Electrical Troubleshooting:
Detailed wiring diagrams, component testing procedures, fault isolation strategies
Body Repair:
Procedures for dent repair, panel replacement, glass installation
Technical Depth
Depth:
Expert-level, covering everything from basic maintenance to complete engine and transmission overhauls, including detailed torque specifications and diagnostic procedures.
📊 Manual Specifications
File Format
Digital Features:
Searchable text, bookmarked chapters, high-resolution diagrams, zoomable images.
Print Quality
Image Clarity:
High-resolution images and clear, legible diagrams.
Binding Type
Print Binding:
Professional perfect binding or spiral binding for lay-flat use.
Paper Type
Print Paper:
Durable, high-quality paper stock suitable for workshop environments.
⚙️ Engine Specifications
Primary Engine
4G63 Sohc Na:
2.0L Inline-4, 16-valve, naturally aspirated. Power output varied by year and specific model, typically around 135-145 hp and 130-140 lb-ft of torque.
4G63 DOHc Turbo:
2.0L Inline-4, 16-valve, turbocharged with intercooler (from 1992 onwards for GST/GSX). Power output ranged from 195 hp to 210 hp and 203 lb-ft to 214 lb-ft of torque.
6G72 V6 Na:
3.0L V6, 12-valve, naturally aspirated. Power output typically around 140-150 hp and 170-180 lb-ft of torque.
Performance
0 60 Mph Turbo AWD:
Approximately 6.0 - 7.0 seconds (depending on specific model and year).
0 60 Mph V6 FWD:
Approximately 8.5 - 9.5 seconds.
Fuel System
Injection Type:
Electronic Multi-Port Fuel Injection (MPI).
Fuel Type:
Unleaded gasoline. Premium unleaded required for turbocharged models.
🔧 Transmission
Standard
Trans Type Rs Sp:
5-speed Manual Transmission (F5M21 or F5M33 for AWD).
Optional
Trans Type Gs V6:
4-speed Automatic Transmission (KM2A1 or KM2B1 for AWD).
Features
AWD System:
Full-time viscous coupling all-wheel drive system with a 45% front / 55% rear torque split, featuring a limited-slip center differential.
Manual Trans Fluid:
API GL-4 SAE 75W-90 Gear Oil.
Automatic Trans Fluid:
Mopar ATF+3 or equivalent (check manual for exact spec).
📐 Dimensions
Exterior
Length:
Approx. 170-173 inches (4318-4394 mm).
Width:
Approx. 68.7 inches (1745 mm).
Height:
Approx. 50.0-51.0 inches (1270-1295 mm).
Wheelbase:
Approx. 98.7 inches (2507 mm).
Interior
Seating Capacity:
4 (2+2 configuration).
Cargo
Trunk Volume:
Approx. 7.7 cu ft (0.22 m³).
Weights
Curb Weight:
Approx. 2800-3200 lbs (1270-1450 kg), depending on trim and drivetrain.
Wheel Bolt Pattern:
4x114.3 mm (4x4.5 inches).
Tire Sizes:
Commonly 195/60R15, 205/55R15, 215/50R16, 215/55R16 (varies by trim).
🛡️ Safety Features
Ratings
NHTSA Ratings:
Frontal crash test ratings were available but varied by model year. Generally considered adequate for its time.
Active Features
ABS:
Anti-lock Braking System (ABS) available on higher trims (e.g., GSX, GST) and optional on some GS models. Typically a 4-wheel ABS system.
Traction Control:
Traction Control System (TCS) was often paired with AWD and turbocharged models, particularly in later years of this generation.
Passive Features
Airbags:
Driver and passenger airbags standard on most models, especially from the mid-1990s onwards. Some early models may not have had passenger airbags.
Seatbelts:
Front 3-point retractable seatbelts with pretensioners, rear lap and shoulder belts.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM cassette player with optional CD player. Speaker configurations varied by trim, typically 4-8 speakers.
Climate Control:
Manual climate control with A/C and heater. Some higher trims may have featured automatic climate control.
Driver Assistance
Cruise Control:
Standard on most models, particularly GS and above trims.
Connectivity
Original Connectivity:
Limited to basic features like power windows, power locks, and optional power mirrors. No integrated modern connectivity features.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000-5,000 miles (5,000-8,000 km) or 3-6 months, depending on driving conditions and oil type.
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection.
Spark Plug Replacement:
Every 30,000-60,000 miles (48,000-96,000 km), depending on plug type.
Timing Belt Replacement:
Crucial for 4G63 engines (non-interference in early models, interference in later ones). Typically every 60,000-90,000 miles (96,000-144,000 km). The manual will specify exact intervals and if it's an interference engine.
Fluid Specifications
Engine Oil:
API SG/SH, SAE 5W-30 or 10W-30 recommended. Check manual for specific viscosity based on climate.
Coolant:
Ethylene glycol-based coolant. Typically a 50/50 mix of antifreeze and distilled water.
Brake Fluid:
DOT 3 or DOT 4.
Power Steering Fluid:
Dexron II or equivalent (consult manual).
Known Issues
Turbo Failure:
Turbocharger failure on 4G63T engines can occur due to poor maintenance, oil starvation, or abuse. Overheating is also a concern.
Timing Belt Failure:
Critical maintenance item. Failure can lead to catastrophic engine damage on interference engines.
Cv Joint Wear:
Front CV joints can wear out, especially on AWD models with spirited driving.
Clutch Wear:
Clutch wear is common on manual transmission models with high mileage or aggressive driving.
Electrical Gremlins:
Older vehicles can develop electrical issues related to aging wiring, grounds, and components.
Rust:
Body rust can be an issue, particularly around wheel wells, rocker panels, and the rear hatch area, depending on climate and care.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors:
Mitsubishi Motors has a history of producing robust and performance-oriented vehicles, with a strong presence in motorsport (e.g., Dakar Rally, World Rally Championship).
Model Evolution
Eclipse Launch:
The first-generation Eclipse was launched in 1989 for the 1990 model year, as part of a joint venture with Chrysler (Diamond-Star Motors - DSM) in Normal, Illinois. It was a significant departure from previous Mitsubishi models in North America, aiming for a younger, performance-oriented demographic.
Facelift:
A significant facelift occurred for the 1992 model year, introducing revised front and rear styling, improved aerodynamics, and the introduction of the turbocharged DOHC 4G63 engine with intercooler, along with AWD, for the GST and GSX models. The 1995 model year saw a minor update with revised interior and exterior trim. The second generation replaced this model in 1999.
Production
Manufacturing Location:
Normal, Illinois, USA (Diamond-Star Motors plant).
🏆 Awards & Recognition
Recognitions
Car And Driver Awards:
Car and Driver magazine consistently included the turbocharged AWD models in its '10Best' list for several years during the early to mid-1990s, recognizing its performance and value.
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