Technical Service Bulletin

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Technical Service Bulletin Page 1 of 8 SUBJECT: CONVERTIBLE TOP WEAR AND ADJUSTMENTS No: DATE: June, 2011 MODEL: 2007 11 Eclipse Spyder CIRCULATE TO: [ ] GENERAL MANAGER [ X ] PARTS MANAGER [ X ]

1 Technical Service Bulletin Page 1 of 8 SUBJECT: CONVERTIBLE TOP WEAR AND ADJUSTMENTS No: DATE: June, 2011 MODEL: Eclipse Spyder CIRCULATE TO: [ ] GENERAL MANAGER [ X ] PARTS MANAGER [ X ] TECHNICIAN [ X ] SERVICE ADVISOR [ X ] SERVICE MANAGER [ X ] WARRANTY PROCESSOR [ ] SALES MANAGER This bulletin supercedes TSB 09 42A 013, issued September, 2009, to expand the affected model years, provide a complete rewrite of Condition 2, Procedure 1B due to a new shim type, and change corresponding parts information. Changes are italicized and indicated by. PURPOSE Convertible top covers on some affected vehicles may exhibit wear at points of contact with the top frame. This occurs when sections of the stowed top rub against each other as the vehicle is driven, or when the top is in operation. Wear usually occurs in the following areas: At the C pillar near the rear glass. On the top cover between the 2nd and 3rd bows. On the top cover at the 1st bow (header) and side piping. This Technical Service Bulletin provides adjustments and modifications to help prevent recurrence of wear after top replacement. These steps should be performed whenever a top cover is replaced and be completed before it is installed. AFFECTED VEHICLES Eclipse Spyder. PROCEDURE Procedures described in this TSB should only be performed during top cover replacement. Technicians should conduct ALL modifications shown, regardless of top wear location. NOTE: This TSB only describes modifications and adjustments made to the top frame. Refer to Group 42 Body in the service manual for top cover replacement steps. Always have the engine running when operating the top. Operating the top without the engine running can cause slow operation and a discharged battery. Stop the engine to work on the vehicle. CONDITION 1 Wear at the quarter area (C pillar, near rear window glass). Rear Window Description This condition occurs from the inside out. The top cover rubs an adjustment plate on the left or right side of the top frame as it is being lowered or raised (a hole may not be visible on the outer surface in all cases). Modify the adjustment plate to eliminate sharp corners. continued Copyright 2011, Mitsubishi Motors North America, Inc. (3757) The information contained in this bulletin is subject to change. For the latest version of this document, go to the Mitsubishi Dealer Link, MEDIC, or the Mitsubishi Service Information website (

Page 2 of 8 ADJUSTMENT 1. Use the top switch to raise the #5 bow to a vertical position. 2. Locate the serrated adjustment plate at the control link and #5 bow connection indicated in the photos below.

NOTE: It is not necessary to remove the roll pin from the serrated plate. Adjustment Plate Repair area (see photo at right for details).

b. Scribe lines to create an intersection point. c. Scribe an arc as shown, centered on the intersection point. d.

2 Page 2 of 8 ADJUSTMENT 1. Use the top switch to raise the #5 bow to a vertical position. 2. Locate the serrated adjustment plate at the control link and #5 bow connection indicated in the photos below. 3. Note and mark the roll pin s position in the slot (normally all the way up). Working on one side at a time, disassemble the control link to #5 bow connection and remove the adjustment plate. NOTE: It is not necessary to remove the roll pin from the serrated plate. Adjustment Plate Repair area (see photo at right for details). Roll pin Remove this area from both corners Roll pin 8mm 8mm Intersection point 4. Grind the serrated plate at the end opposite the roll pin to remove 2 sharp corners. Refer to the drawing. a. Measure 8mm in each direction from the corners of the plate. b. Scribe lines to create an intersection point. c. Scribe an arc as shown, centered on the intersection point. d. Grind the corners of the serrated plate along the scribed line until they are rounded. Original shape of plate 5. Clean, prime and repaint the plate with gloss or semi gloss black paint to cover any exposed metal. 6. When the paint is dry, reinstall and adjust the plate to the roll pin s original location. Tighten the bolt to Nm (19 23 ft. lbs). 7. Repeat for the opposite side of the vehicle. After grinding.

Adjust the control link to reduce contact between the top cover and rear rail garnish. NOTE: Pay attention to vehicle production dates when performing Procedure 1.

3 Page 3 of 8 CONDITION 2 Wear between the 2nd and 3rd bows (typical appearance shown) Description This condition occurs when the top is open. Normal movement of the stowed top causes rubbing between the top cover and the rear rail garnish. Add washers or shims as instructed to increase clearance between folded top sections. Adjust the control link to reduce contact between the top cover and rear rail garnish. NOTE: Pay attention to vehicle production dates when performing Procedure 1. PROCEDURE 1 Add washers (dimensions: I.D.: 6 mm, O.D.: <13mm, T.: 1 mm) or shims as instructed to increase clearance between folded top sections. There are two different adjustments depending on vehicle production date. Procedure 1A involves adding a washer behind stop bolts on the front rails Vehicles built through September, Procedure 1B involves adding a shim to the front rails Vehicles built from October, Procedure 1A. Vehicles with stop bolt on the front rails built through September, 2006: Stop bolt location model vehicles built through September, 2006 have a stop bolt on the front section of the side rails. If there are no stop bolts as shown, use procedure B later in this TSB. 1. Open the top so the front rails are nearly vertical. 2. Locate and remove the indicated stop bolt and washers. NOTE: Some vehicles will not have washers installed.

Page 4 of 8 3. Vehicles built up to June, 2006: Add one washer and reinstall the bolt and assembled washers, and tighten to 26 32 Nm (19 23 ft. lbs).

Reinstall the bolt and assembled washers, and tighten to 26 32 Nm (19 23 ft. lbs). Stop bolt with 2 washers. Washer dimensions: I.D. 6 mm, O.D. >11 mm, Thickness 1 2 mm.

, grind one side to insure clearance between the washer and Control Link A (see photo, left below).

4 Page 4 of 8 3. Vehicles built up to June, 2006: Add one washer and reinstall the bolt and assembled washers, and tighten to Nm (19 23 ft. lbs). Vehicles built from June through September, 2006 were built with TWO washers on the RH stop bolt and ONE on the LH stop bolt: Add ONE washer to the RH side, and TWO to the LH side. Reinstall the bolt and assembled washers, and tighten to Nm (19 23 ft. lbs). Stop bolt with 2 washers. Washer dimensions: I.D. 6 mm, O.D. >11 mm, Thickness 1 2 mm. IMPORTANT: See bolt and washer installation note that follows. NOTE: If using a washer larger than 11 mm O.D., grind one side to insure clearance between the washer and Control Link A (see photo, left below). Place the top in the closed position and check to make sure there is clearance between the washer and the link, and between the bolt head and the link (see photo, right below). Grind one side of washer to match width of bolt head. Bolt head and washer to Control Link A clearance. Control Link A 4. Repeat for the other side of the vehicle. 5. Proceed to Top Cover Installation and Operation Check on page 6.

6559A163 contains instructions for installing the shims.

Open the top enough to access the center rail linkage. 2.

! CAUTION IF THE PLASTIC SHIM IS NOT REMOVED IT CAN CAUSE TONNEAU CLOSING PROBLEMS.

Remove the inner e clip (photo left below) from the pin attaching control link A to the center rail linkage.

Remove only the inner e clip to attach the shim. 4.

5 Page 5 of 8 PROCEDURE 1B. Vehicles without stop bolt on the front rails built from October 2006 through model year 2011: NOTE: Shim Kit 6559A163 contains instructions for installing the shims. Use the instructions in the TSB and discard the supplied instructions 1. Open the top enough to access the center rail linkage. 2. If a plastic shim is installed on the front rail remove it. Remove plastic shims if installed.! CAUTION IF THE PLASTIC SHIM IS NOT REMOVED IT CAN CAUSE TONNEAU CLOSING PROBLEMS. Plastic shim shown green for photographic purposes. Center Rail Control Link A 3. Remove the inner e clip (photo left below) from the pin attaching control link A to the center rail linkage. Do not remove the pin (photo right below). NOTE: The pin is secured with e clips on both ends. Remove only the inner e clip to attach the shim. 4. Install a stainless steel shim to the top frame on each side of the vehicle as follows: a. Clean the area where the shim will be applied with isopropyl alcohol. b. Peel the red adhesive protective tape from the shim and install it as shown (photo left below). 5. Install a new e clip from the shim kit (photo center below). It may be necessary to apply inboard pressure on the pin to properly seat the clip (photo right below). New shim NOTE: Shim overlaps the top of the link. Press the pin inward to seat clip.

Page 6 of 8 6. Repeat all steps for the opposite side. 7. Proceed to Top Cover Installation and Operation Check on page 8.

Open the top far enough to access the control link attachment to the #2 bow (photo left below). 2.

Tighten the screws to 26 32 Nm (19 23 ft. lbs) while holding the control link outboard. screws Move Adjustment location (see photo right for details).

6 Page 6 of 8 6. Repeat all steps for the opposite side. 7. Proceed to Top Cover Installation and Operation Check on page 8. PROCEDURE 2 All Affected Vehicles Adjust the control link to reduce contact between the top cover and rear rail garnish. 1. Open the top far enough to access the control link attachment to the #2 bow (photo left below). 2. Loosen two attaching screws and move the control link outboard as far as it will travel (photo right below). 3. Tighten the screws to Nm (19 23 ft. lbs) while holding the control link outboard. screws Move Adjustment location (see photo right for details). #2 bow Control link 4. Repeat for the opposite side. CONDITION 3 Wear on 1st bow and edge piping (typical appearance shown) All Affected Vehicles Description This condition occurs when the top is down. There are no adjustments or modifications to the frame for this condition. Replace the top cover.

Page 7 of 8 TOP COVER INSTALLATION AND OPERATION CHECK 1. Install the top cover and headliner. 2.

If resistance is too high, raise the front section of the frame for access and add an additional washer or shim (shims/washers can be added with the top cover installed) as outlined in Condition 2,

If the tonneau struggles to close, the stowed top may be sitting too high. Adjust the downstop to lower the stowed top position.

7 Page 7 of 8 TOP COVER INSTALLATION AND OPERATION CHECK 1. Install the top cover and headliner. 2. Check clearance by inserting a piece of paper between the folded layers of the topcover as indicated in the photos below. Minimal resistance should be felt when pulling it out. If resistance is too high, raise the front section of the frame for access and add an additional washer or shim (shims/washers can be added with the top cover installed) as outlined in Condition 2, Procedure 1. Perform drag test at this location on both sides. 3. Check for proper tonneau cover operation and closure by inspecting flushness of the panels to surrounding parts. If the tonneau struggles to close, the stowed top may be sitting too high. Adjust the downstop to lower the stowed top position. PARTS INFORMATION Use the Genuine Mitsubishi Parts listed below: Description Part Number Qty. Shim Kit (vehicles built from October, 2006 through 2011 models) 6559A163 1 Convertible Top Cover (Black or Gray) See CAPS 1 Rivet, Folding Top (for top cover installation) 6559A Rivet, Folding Top (for top cover installation) 6559A033 4 Each Shim kit includes: 2 shims 2 e clips NOTE: Some kits include an instruction sheet. It can be discarded. Additional items required: Washers (qty 2) I.D.: 6mm, O.D.: > 11mm, T.: 1 2mm Pressure roller or plastic trim squeegee. Isopropyl alcohol. Black semi gloss paint.

8 Page 8 of 8 WARRANTY INFORMATION This bulletin is supplied as technical information only and is not an authorization to repair. Repairs should only be made in conjunction with a convertible top cover replacement. If an affected vehicle is observed with the described condition, diagnose the condition, repair as described in this bulletin and submit a normal warranty claim using the following information. The information given below is for adjustments only. Use normal LOTS operation number and time for top cover replacement. Convertible Top Frame Modifications Nature Code: 562 Cause Code: 150 Labor Operation No Time Allowance: 0.8 hr. Warranty Coverage: Basic coverage.

SAFETY RECALL BULLETIN

SAFETY RECALL BULLETIN Page 1 of 14 SUBJECT: FUEL TANK BRACKET SAFETY RECALL Following the instructions in this recall bulletin, inspect the left rear fuel tank bracket for signs of weakening of the material.