1990–1999 Mitsubishi Eclipse / Eclipse Spyder Service Manual – Volume 1: Chassis & Body

Mitsubishi’s Eclipse / Eclipse Spyder Service Manual, Volume 1: Chassis & Body, includes engine and transaxle overhaul for Eclipse FWD/AWD and Spyder FWD applications. It distinguishes the 420A, turbocharged 4G63, and SOHC 4G64 engines, along with Federal and California configurations. The separate Volume 2 Electrical is not included; this volume contains electrical diagnosis within its covered systems.

PDF Search, Chapter Access, and Diagram Detail

Text search and diagram detail: An embedded OCR text layer supports searches across most sections, but recognition errors affect some terms and numbers. MFI diagnostic pages PDF pp. 610–616 do not support text search. Chapter bookmarks provide access to the main sections. Small wiring labels and connector pin numbers require zooming in the reviewed diagrams.

Supplied as one printable English PDF with 2,103 pages, including the cover, SRS warning page, and 27 blank or notes pages.

Engine Overhaul, Drivetrain Diagnosis, and Spyder Top Service

The following are selected areas of coverage. Additional topics include auto-cruise control diagnosis and keyless-entry code registration.

• Engine repair: Step-by-step procedures for engine removal, cylinder-head service, timing-belt replacement, hydraulic lash-adjuster testing, and internal engine overhaul.

• Fuel and emissions: MFI trouble-code diagnosis, scan-tool data lists, ECM terminal checks, fuel-pressure testing, and EVAP and EGR system inspection.

• Manual and automatic transaxles: Internal disassembly and reassembly, synchronizer inspection, clutch service, hydraulic-pressure tests, and differential adjustment.

• Brakes and steering: Separate FWD/AWD ABS diagnosis, hydraulic-unit checks, brake bleeding, power-steering pressure tests, and steering-gear service.

• Chassis and driveline: Front and rear suspension repair, wheel-alignment checks, propeller-shaft service, axle inspection, and power plant mounts.

• Spyder body systems: Electric convertible-top troubleshooting, top assembly removal, topstack drive components, quarter-window adjustment, and weatherstrip replacement.

• Interior and climate control: SRS inspection and diagnosis, interior trim and restraint components, heater service, and air-conditioning testing and component repair.

This manual is suited to technicians familiar with automotive diagnosis and overhaul, including the use of scan tools, pressure gauges, and the specified special tools.

Engine and Chassis Overview

Separate engine sections distinguish on-vehicle checks from internal overhaul. Cylinder-head and valve work extends to valve-seat reconditioning and guide replacement, while bottom-end coverage includes piston and connecting-rod inspection, bearing-clearance measurement, and crankshaft end-play checks.

Timing-belt installation and auto-tensioner adjustment are documented alongside component-positioning illustrations. The timing-belt section warns that compressing the auto-tensioner too quickly can damage its rod.

Cooling, intake, exhaust, and lubrication sections cover water-pump and thermostat service, turbocharger and charge-air-cooler inspection, and oil-cooler work. Maintenance schedules distinguish required, general, and severe-use service.

MFI Diagnosis and Electrical Test References

Diagnostic flow charts connect trouble codes and driveability symptoms to sensor, actuator, connector, and harness checks. Together with scan-tool data and ECM terminal specifications, these references support fault isolation before a component is selected for replacement.

Illustrations include the MFI System Diagram and Vacuum Circuit Diagram. Federal and California distinctions remain attached to the applicable procedures and configurations.

Transaxle Overhaul and Driveline Adjustment

Manual-transaxle chapters cover shafts, synchronizers, differentials, and bearing-preload adjustment. Automatic-transaxle sections extend to clutch assemblies, valve bodies, hydraulic controls, and transfer components where applicable.

Hydraulic Circuit diagrams, Shift Pattern charts, sectional views, and standard tooth-contact pattern drawings support the associated diagnosis and assembly checks. Component-specific torque tables, lubricant data, inspection limits, and special-tool references accompany the repair procedures.

Convertible Top, Body, and Safety Systems

Spyder-specific coverage includes top-control fault charts, drive-motor and driven-gear service, top fit adjustment, and quarter-window alignment. Convertible-top assembly removal can tear the drain trough if it is mishandled.

Body and exterior sections address glass, doors, panels, and weatherstrips. The SRS section includes a Circuit Diagram with connector views, diagnostic charts, and post-collision checks.

Because automotive repair carries inherent physical risks and requires proper tooling, always review the included safety precautions and handling procedures before starting any diagnostic work or teardown. The manual specifies authorized Mitsubishi dealer service for SRS components and related systems.

A Preview of 4G63 Fastener and Bearing Limits

For the 4G63 cylinder-head bolts, the manual specifies a maximum length below the head of 99.4 mm (3.91 in.) when assessing reuse. This inspection limit accompanies the cylinder-head installation procedures.

The 4G63 crankshaft inspection data distinguish standard end play of 0.05–0.18 mm from a service limit of 0.25 mm. These values appear with the bearing and crankshaft checks used during bottom-end overhaul.