REMOVAL AND INSTALLATION

Removal steps 1. Connector bracket 2. Timing belt front upper cover 3. Timing belt front lower cover <<A>> >>K<< 4. Timing belt >>J<< 5. Tensioner pulley 6. Tensioner arm >>I<< 7. Auto-tensioner 8. Idler pulley 9. Bracket 10. Crankshaft angle sensor <<B>> >>H<< 11. Oil pump sprocket <<C>> >>G<< 12. Crankshaft bolt >>G<< 13. Crankshaft pulley washer <<D>> >>G<< 14. Crankshaft sprocket >>G<< 15. Crankshaft sensing blade 16. Tensioner "B" <<E>> >>F<< 17. Timing belt "B" <<F>> >>E<< 18. Counterbalance shaft sprocket >>D<< 19. Spacer <<G>> >>C<< 20. Crankshaft sprocket "B" 21. Crankshaft key 22. Alternator bracket >>B<< 23. Engine support bracket 24. Timing belt rear cover <<H>> >>A<< 25. Camshaft sprocket bolt 26. Camshaft sprocket

caution Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and tensioner must be washed or immersed in solvent. Replace parts if contaminated. If there is oil or water on any part, check the front case oil seals, camshaft oil seal, and water pump for leaks. 1.Mark the belt running direction for reinstallation. 2.Loosen the tensioner pulley bolt, and then remove the timing belt.

2.Insert a Phillips screwdriver (shank diameter 8 mm) through the plug hole to block the left counterbalance shaft. 3.Loosen the nut, and then remove the oil pump sprocket.

1.Using special tool Flywheel stopper (MD998781), hold the drive plate. 2.Removal the crankshaft bolt and washer.

1.Set special tool Crankshaft sprocket puller (MD998778) as shown in the illustration. 2.Screw in the center bolt of the special tool to remove the crankshaft sprocket.

caution Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and tensioner must be free from oil and water. These parts should not be washed or immersed in solvent. Replace parts if contaminated. If there is oil or water on each part, check the front case oil seals, camshaft oil seal and water pump for leaks. 1.Mark the belt running direction for reinstallation. 2.Loosen the tensioner "B" bolt, and then remove the timing belt "B."

1.Set special tool Sprocket stopper (MD998785) as shown to prevent the counterbalance shaft sprocket from turning together. 2.Loosen the bolt and remove the sprocket.

1.Set special tool Crankshaft sprocket puller (MD998778) as shown in the illustration. 2.Screw in the center bolt of the special tool to remove crankshaft sprocket "B."

1.Using special tools to prevent the camshaft sprocket from rotating. End yoke holder (MB990767) Pulley holder pin (MD998719) 2.Remove the camshaft sprocket.

1.Using special tools to prevent the camshaft sprocket from rotating. End yoke holder (MB990767) Pulley holder pin (MD998719) 2.Tighten the camshaft sprocket bolt to the specified torque. Tightening torque: 89 ± 9 N·m

1.Remove thoroughly the old sealant remaining on the indicated bolt and in its hole. 2.Coat the bolt with sealant, then install and tighten it. Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent Tightening torque: 49 ± 5 N·m

Clean and then degrease the front case of the front case, crankshaft sprocket "B" and crankshaft surface on which sprocket "B" is attached. note Degreasing is necessary to prevent decrease in the friction between contacting surfaces.

1.Apply a thin coat of clean engine oil to the lip area of the oil seal. 2.Install the spacer with the chamfered end facing toward the oil seal.

1.Install the counterbalance shaft sprocket and screw on the bolt. 2.Install special tool Sprocket stopper (MD998785) as shown in the illustration to lock the counterbalance shaft. 3.Tighten the bolt, and then remove the special tool. Tightening torque: 45 ± 3 N·m

1.Align timing marks on the crankshaft sprocket "B" and counterbalance shaft sprocket with the marks on the front case. 2.Install the timing belt "B" on the crankshaft sprocket "B" and counterbalance shaft sprocket. There should be no slack on the tension side.

3.Make sure that the tensioner pulley center and the bolt center are positioned as shown in the illustration.

4.Move tensioner "B" in the direction of the arrow while lifting with your finger to give sufficient tension to the tension side of timing belt. In this condition, tighten the bolt to secure tensioner "B." When the bolt is tightened, use care to prevent the tensioner pulley shaft from turning with the bolt. If the shaft is turned with the bolt, the belt will be over tensioned. Tightening torque: 19 ± 3 N·m

5.Check that timing marks on the sprockets are aligned with the timing marks on the front case. 6.With your index finger, press the midway of span on the tension side of timing belt "B." The bolt must deflect 5 to 7 mm.

1.Clean and then degrease the contacting surfaces of the crankshaft sprocket, sensing blade and crankshaft. note Degreasing is necessary to prevent decrease in the friction between contacting surfaces. 2.Clean the bolt hole in the crankshaft, the crankshaft contacting surface of the crankshaft sprocket, and the washer. 3.Install the sensing blade and the crankshaft sprocket to the crankshaft. 4.Apply a small amount of engine oil to the threads and seating surface of the crankshaft bolt. 5.Install the washer to the crankshaft bolt with the larger chamfered side toward the bolt head.

6.Using special tool Flywheel stopper (MD998781), hold the drive plate. 7.Tighten the crankshaft bolt to the specified torque. Tightening torque: 167 N·m

1.Insert a Phillips head screwdriver (shank diameter 8 mm) through the plug hole on the left side of the cylinder block to block the left counterbalance shaft. 2.Install the oil pump sprocket. 3.Apply a thin coat of engine oil to the seating surface of the nut. 4.Tighten the nut to the specified torque. Tightening torque: 54 ± 5 N·m

1.Clamp the auto-tensioner in a vise with soft jaws.

2.Push in the rod little by little with the vise until the set hole A in the rod is aligned with hole B in the cylinder. 3.Insert a wire (1.4 mm in diameter) into the set holes. This auto-tensioner setting wire will be used during timing belt alignment. 4.Unclamp the auto-tensioner from the vise.

5. caution Leave the wire installed in the auto-tensioner. Install the auto-tensioner onto the front case and tighten to the specified torque. Tightening torque: 23 ± 3 N·m

Set the tensioner pulley so that the holes for attaching a wrench may be positioned as shown in the illustration.

1.Align the timing mark on the camshaft sprocket with the timing mark on the rocker cover.

2.Align the timing mark on the crankshaft sprocket with the timing mark on the front case.

3.Align the timing mark on oil pump sprocket with its mating mark.

4.Remove the plug on the cylinder block and insert a Phillips head screwdriver (shank diameter 8 mm) through the hole. If it can be inserted as deep as 60 mm or more, the timing marks are correctly aligned. If the inserted depth is only 20 to 25 mm, turn the oil pump sprocket one turn and realign the timing marks. Then check to ensure that the screwdriver can be inserted 60 mm or more. Keep the screwdriver inserted until the timing belt is completely installed.

5.Set the special tool Set screw (MD998738) as shown and screw it in up to the position where the wire inserted in the auto-tensioner when installing it can be moved lightly. 6.Install the timing belt on the crankshaft sprocket, oil pump sprocket, idler pulley, camshaft sprocket, and tensioner pulley in that order.

7.Lift up the tensioner pulley in the direction of the arrow and tighten the center bolt. 8.Check that all timing marks are aligned. 9.Remove the screwdriver inserted in step 5 and install the plug. 10.Turn the crankshaft a quarter turn counterclockwise. Then, turn it clockwise until the timing marks are aligned again.

11.Install special tool Tension pulley socket wrench (MD998767), socket wrench and torque wrench, onto the tensioner pulley, and loosen the tensioner pulley center bolt. note Use a torque wrench that can measure 0 to 5.0 N·m. 12.Torque to 3.5 N·m with the torque wrench. 13.Holding the tensioner pulley with special tool Tension pulley socket wrench (MD998767) and torque wrench, tighten the center bolt to specification. Tightening torque: 48 ± 5 N·m

14. The wire inserted at the auto-tensioner installation is pulled out and then the special tool Set screw (MD998738) is removed by hand. 15.Give two clockwise turns to the crankshaft. Wait for 15 minutes, then proceed with the following inspection steps.

16.Check to see whether the metal wire (inserted when the auto-tensioner was installed) can be removed without any resistance. If the metal wire can be removed without any resistance, it means that the belt has a proper tension. Therefore, remove the metal wire. In this condition, check that the rod protrusion of the auto-tensioner is within the standard value. Standard value: 3.8 - 4.5 mm 17.If the metal wire offers resistance when removed, repeat the previous steps 10 through 15 until the standard value is obtained as measured by the rod projection of the auto-tensioner rod.