Technical Car Experts Answers everything you need: How to replace timing belt for 2.4 engine on Mitsubishi?

Removal & Installation

2.4L Engine

If possible, position the engine so the No. 1 piston is at TDC.

Disconnect the negative battery cable.

Remove the splash shield under the engine.

Safely support the weight of the engine and remove the engine mount and bracket assembly.

Remove the drive belts and the timing belt covers.
NOTE
If timing belts are going to be reused, mark the direction of rotation on the belt. This will ensure the belt is reinstalled in same direction, extending belt life.

To loosen the timing (outer) belt tensioner, install special tool MD998738 or equivalent, to the slot and screw inward to move tensioner toward the water pump. Once the tension has been relieved, remove the outer timing belt.

If tensioner replacement is required, align the pin hole in the tensioner rod to the hole in the tensioner cylinder. Insert a 0.055 inch (1.4 mm) wire in the hole and remove the special tool from the slot. With the cylinder tension relieved, remove the auto tensioner cylinder assembly two mounting bolts.

Remove the outer crankshaft sprocket and flange.

Loosen the silent shaft (inner) belt tensioner and remove the belt. If pulley replacement is required, remove the center adjusting bolt.

Fig. Exploded view of the inner (B) timing belt and related components-1999 2.4L engine

Remove the crankshaft pulley retainer bolts and remove the pulley.

Fig. You will probably have to use a special tool to remove the crankshaft pulley bolt-1999 2.4L engine

Remove the crankshaft sprocket retainer bolt and washer from the sprocket, if used, and remove sprocket. If sprocket is difficult to remove, the appropriate puller may be used. If no bolts are used on the sprocket, use the appropriate puller to remove.

Fig. If you-re having trouble removing the sprocket, you may have to use a suitable puller

Hold the camshaft stationary using the hexagon cast between journals No. 2 and 3 and remove the retainer bolt. Remove the sprocket from the camshaft.

To install:

Install the sprockets to their appropriate shafts. Install the retainer bolts and Tighten the camshaft sprocket bolt to 65 ft. lbs. (90 Nm)

Inspect the timing belts in detail for any flaw or wear. Check the sprockets and tensioner for wear. The sprocket teeth should be well defined, not rounded and the valleys between the teeth should be clean. Turn both tensioner pulleys and check for any signs of bearing wear. If sprockets or pulleys show any sign of wear, they must be replaced.

WARNING

Do not spray or immerse the sprockets or tensioners in cleaning solvent. The sprocket may absorb the solvent and transfer it to the belt. The tensioners are internally lubricated and the solvent will dilute or dissolve the lubricant.

Align the timing marks of the silent shaft sprockets and the crankshaft sprocket with the timing marks on the front case. Wrap the timing belt around the sprockets so there is no slack in the upper span of the belt and the timing marks are still aligned.

Install the tensioner pulley and move the pulley by hand so the long side of the belt deflects about ¹ / ₄ inch.

Hold the pulley tightly so the pulley cannot rotate when the bolt is tightened. Tighten the bolt to 14 ft. lbs. (19 Nm) and recheck the deflection amount.

Align the timing marks of the camshaft, crankshaft and oil pump sprockets with their corresponding marks on the front case or rear cover.
NOTE
There is a possibility to align all timing marks and have the oil pump sprocket and silent shaft out of time, causing an engine vibration during operation. If the following step is not followed exactly, there is a 50 percent chance that the silent shaft alignment will be 180 degrees off.

Fig. Proper timing component alignment points-1999 2.4L engines

Before installing the timing belt, ensure that the left side (rear) silent shaft (oil pump sprocket) is in the correct position as follows:
1. Remove the plug from the rear side of the block and insert a tool with shaft diameter of 0.31 inches. (8mm) into the hole.
2. With the timing marks still aligned, the shaft of the tool must be able to go in at least 2 ¹ / ₂ inches. If the tool can only go in about 1 in., the shaft is not in the correct orientation and will cause a vibration during engine operation. Remove the tool from the hole and turn the oil pump sprocket 1 complete revolution. Realign the timing marks and insert the tool. The shaft of the tool must go in at least 2 ¹ / ₄ inches.
3. Recheck and realign the timing mark.
4. Leave the tool in place to hold the silent shaft while continuing.

If the camshaft belt tensioner was removed, use a vise to carefully push the auto tensioner rod in until the set hole in the rod aligned up with the hole in the cylinder. Place a wire into the hole to retain the rod. Mount the tensioner to the engine block and tighten the mounting bolt to 17 ft. lbs. (23 Nm).

Install the belt to the crankshaft sprocket, oil pump sprocket, then camshaft sprocket, in that order. While doing so, make sure there is no slack between the sprockets except where the tensioner is installed.

To adjust the timing (outer) belt perform the following steps:
1. Turn the crankshaft ¹ / ₄ turn counterclockwise, then turn it clockwise to move No. 1 cylinder to TDC.
2. Loosen the center bolt. Using tool MD998752 or equivalent and a torque wrench, apply a torque of 2.6 ft. lbs. (3.6 Nm). Tighten the center bolt.
3. Screw the special tool into the engine left support bracket until its end makes contact with the tensioner arm. At this point, screw the special tool in some more and remove the set wire attached to the auto tensioner, if the wire was not previously removed. Then remove the special tool.
4. Rotate the crankshaft two complete turns clockwise and let it sit for approximately 15 minutes. Then, measure the auto tensioner protrusion (the distance between the tensioner arm and auto tensioner body) to ensure that it is within 0.15-0.18 inch (3.8-4.5mm). If out of specification, repeat Step 1-4 until the specified value is obtained.
  NOTE
  Do not manually overtighten the belt or it will howl.

Install the upper and lower timing belt covers. Tighten the bolts to the specifications shown in the accompanying figure.

Fig. Timing belt cover retainer specifications-1999 2.4L engine

Install the drive belts and properly adjust.

Reinstall the engine mount and bracket assembly and safely lower the engine.

Install the splash shield.

Connect the negative battery cable. Start the engine and let it idle.

Run engine until thermostat opens. Check and adjust ignition timing.

Fig. Timing belt and related components-2000-2005 Eclipse and 1999-2003 Galant 2.4L engine

Fig. Timing belt -B- (balancer belt) and related components-2000-2005 Eclipse and 1999-2003 Galant 2.4L engine

Position the engine so that the No. 1 piston is at Top Dead Center (TDC).

Remove the timing belt covers.
NOTE
If the timing belts are going to be reused, mark the direction of rotation on the belt. This will ensure the belt is reinstalled in same direction, extending belt life.

To loosen the timing (outer) belt tensioner, install Mitsubishi Special tool MD998738 to the slot and screw inward to move the tensioner toward the water pump. Once the tension has been relieved, remove the outer timing belt.

If tensioner replacement is required, align the pin hole in the tensioner rod to the hole in the tensioner cylinder. Insert a 0.055 in. (1.4mm) wire in the hole and remove the special tool from the slot. With the cylinder tension relieved, remove the auto-tensioner cylinder assembly two mounting bolts.

Remove the outer crankshaft sprocket and flange.

Loosen the silent shaft (inner) belt tensioner and remove the belt.

Fig. Sprocket alignment timing belt -B- (balancer belt)-2000-2005 Eclipse and 1999-2003 Galant 2.4L engine

Fig. Timing belt sprocket alignment-2000-2005 Eclipse and 1999-2003 Galant 2.4L engine

To install:

WARNING

Align the timing marks of the silent shaft sprockets and the crankshaft sprocket with the timing marks on the front case. Route the timing belt around the sprockets so there is no slack in the upper span of the belt and the timing marks are still aligned.

Install the tensioner pulley and move the pulley by hand so the long side of the belt deflects approximately ¹ / ₄ in. (6mm).

Hold the pulley tightly so the pulley cannot rotate when the bolt is tightened. Tighten the bolt to 14 ft. lbs. (19 Nm) and recheck the deflection.

Align the timing marks of the camshaft, crankshaft and oil pump sprockets with their corresponding marks on the front case or rear cover.
NOTE
There is a possibility to align all timing marks and have the oil pump sprocket and silent shaft out of time, causing an engine vibration during operation. If the following step is not followed exactly, there is a 50 percent chance that the silent shaft alignment will be 180 degrees ( ¹ / ₂ turn) off.

Before installing the timing belt, ensure that the left side (rear) silent shaft (oil pump sprocket) is in the correct position as follows:
1. Remove the plug from the rear side of the block and insert a tool with shaft diameter of 0.31 in. (8mm) into the hole.
2. With the timing marks still aligned, the shaft of the tool must be able to go in at least 2 ¹ / ₂ in. (63.5mm). If the tool can only go in approximately 1 in. (25mm), the shaft is not in the correct orientation and will cause a vibration during engine operation. Remove the tool from the hole and turn the oil pump sprocket one complete revolution. Realign the timing marks and insert the tool. The shaft of the tool must go in at least 2 ¹ / ₄ in. (63.5mm).
3. Recheck and realign the timing marks.
4. Leave the tool in place to hold the silent shaft while continuing.

If the camshaft belt tensioner was removed, use a vise to carefully push the auto-tensioner rod in until the set hole in the rod is aligned with the hole in the cylinder. Place a wire into the hole to retain the rod. Mount the tensioner to the engine block and tighten the mounting bolt to 17 ft. lbs. (23 Nm).

Install the belt to the crankshaft sprocket, oil pump sprocket, then camshaft sprocket, in that order. While doing so, be sure there is no slack between the sprockets except where the tensioner is installed.

To adjust the timing (outer) belt perform the following steps:
1. Turn the crankshaft ¹ / ₄ turn counterclockwise, then turn it clockwise to move No. 1 cylinder to TDC.
2. Loosen the center bolt. Using tool MD998752 and a torque wrench, apply a torque of 2.6 ft. lbs. (3.6 Nm) to the tensioner. Tighten the center bolt.
3. Screw the special tool into the engine left support bracket until its end makes contact with the tensioner arm. At this point, screw the special tool in some more and remove the set wire attached to the auto-tensioner, if the wire was not previously removed. Then, remove the special tool.
4. Rotate the crankshaft two complete turns clockwise and let it sit for approximately 15 minutes. Then, measure the auto-tensioner protrusion (the distance between the tensioner arm and auto-tensioner body) to ensure that it is within 0.15-0.18 in. (3.8-4.5mm). If out of specification, repeat substeps a through d until the specified value is obtained.
  NOTE
  Do not manually overtighten the belt or it will howl.

Install the upper and lower timing belt covers.

Position the engine so that the No. 1 piston is at Top Dead Center (TDC).

Remove the timing belt covers.
NOTE
If the timing belts are going to be reused, mark the direction of rotation on the belt. This will ensure the belt is reinstalled in same direction, extending belt life.

To loosen the timing (outer) belt tensioner, install Mitsubishi Special tool MD998738 to the slot and screw inward to move the tensioner toward the water pump. Once the tension has been relieved, remove the outer timing belt.

If tensioner replacement is required, align the pin hole in the tensioner rod to the hole in the tensioner cylinder. Insert a 0.055 in. (1.4mm) wire in the hole and remove the special tool from the slot. With the cylinder tension relieved, remove the auto-tensioner cylinder assembly two mounting bolts.

Remove the outer crankshaft sprocket and flange.

Loosen the silent shaft (inner) belt tensioner and remove the belt.

To install:

WARNING

Align the timing marks of the silent shaft sprockets and the crankshaft sprocket with the timing marks on the front case. Route the timing belt around the sprockets so there is no slack in the upper span of the belt and the timing marks are still aligned.

Install the tensioner pulley and move the pulley by hand so the long side of the belt deflects approximately ¹ / ₄ in. (6mm).

Hold the pulley tightly so the pulley cannot rotate when the bolt is tightened. Tighten the bolt to 14 ft. lbs. (19 Nm) and recheck the deflection.

Align the timing marks of the camshaft, crankshaft and oil pump sprockets with their corresponding marks on the front case or rear cover.
NOTE
There is a possibility to align all timing marks and have the oil pump sprocket and silent shaft out of time, causing an engine vibration during operation. If the following step is not followed exactly, there is a 50 percent chance that the silent shaft alignment will be 180 degrees ( ¹ / ₂ turn) off.

Before installing the timing belt, ensure that the left side (rear) silent shaft (oil pump sprocket) is in the correct position as follows:
1. Remove the plug from the rear side of the block and insert a tool with shaft diameter of 0.31 in. (8mm) into the hole.
2. With the timing marks still aligned, the shaft of the tool must be able to go in at least 2 ¹ / ₂ in. (63.5mm). If the tool can only go in approximately 1 in. (25mm), the shaft is not in the correct orientation and will cause a vibration during engine operation. Remove the tool from the hole and turn the oil pump sprocket one complete revolution. Realign the timing marks and insert the tool. The shaft of the tool must go in at least 2 ¹ / ₄ in. (63.5mm).
3. Recheck and realign the timing marks.
4. Leave the tool in place to hold the silent shaft while continuing.

If the camshaft belt tensioner was removed, use a vise to carefully push the auto-tensioner rod in until the set hole in the rod is aligned with the hole in the cylinder. Place a wire into the hole to retain the rod. Mount the tensioner to the engine block and tighten the mounting bolt to 17 ft. lbs. (23 Nm).

Install the belt to the crankshaft sprocket, oil pump sprocket, then camshaft sprocket, in that order. While doing so, be sure there is no slack between the sprockets except where the tensioner is installed.

To adjust the timing (outer) belt perform the following steps:
1. Turn the crankshaft ¹ / ₄ turn counterclockwise, then turn it clockwise to move No. 1 cylinder to TDC.
2. Loosen the center bolt. Using tool MD998752 and a torque wrench, apply a torque of 2.6 ft. lbs. (3.6 Nm) to the tensioner. Tighten the center bolt.
3. Screw the special tool into the engine left support bracket until its end makes contact with the tensioner arm. At this point, screw the special tool in some more and remove the set wire attached to the auto-tensioner, if the wire was not previously removed. Then, remove the special tool.
4. Rotate the crankshaft two complete turns clockwise and let it sit for approximately 15 minutes. Then, measure the auto-tensioner protrusion (the distance between the tensioner arm and auto-tensioner body) to ensure that it is within 0.15-0.18 in. (3.8-4.5mm). If out of specification, repeat substeps a through d until the specified value is obtained.
  NOTE
  Do not manually overtighten the belt or it will howl.

Install the upper and lower timing belt covers.

Fig. Timing belt and related components-2004-2005 Galant and 2004-2005 Lancer 2.4L engine

Fig. Timing belt -B- (balancer belt) and related components-2004-2005 Galant and 2004-2005 Lancer 2.4L engine

Disconnect the negative battery cable. Remove the engine under cover.

Remove the crankshaft damper pulley.

Disconnect the control wiring harness connector, battery wiring harness connector and connector bracket to engine mounting insulator.

Remove the harness bracket. Remove the upper timing belt cover. Remove the water pump pulley. Remove the idler pulley.

Remove the auto tensioner. Remove the lower timing belt cover.

Turn the crankshaft clockwise and align each timing mark to set the number one piston to TDC of its compression stroke.

Remove the timing belt under cover rubber plug and then install special tool MD998738. Screw the special tool until it contacts the timing belt tensioner arm.
NOTE
The special tool must be screwed in gradually at the rate of a 30 degree turn per second. If it is screwed in all at once, the timing belt tensioner adjuster rod will not easily retract and the tool may bend.

Gradually screw in the special tool and then align the timing belt tensioner adjuster rod set hole -A- with the timing belt tensioner adjuster cylinder set hole -B-.

Insert a wire or pin in the set holes to lock the assembly in place. After removing the special tool, loosen the timing belt tensioner pulley mounting bolts and remove the timing belt. If the belt is being reused be sure to mark the direction of rotation (clockwise) on the belt.

Remove the timing belt tensioner pulley, tensioner arm and adjuster.

Remove the timing belt idler pulley. Remove the timing belt lower cover bracket. Remove the crankshaft position sensor.

Remove the crankshaft pulley center bolt and washer. Remove the drive sprocket. Remove the crankshaft angle sensing blade.

Remove the balancer timing belt tensioner. Remove the timing belt -B- (balancer belt) from its mounting.

Fig. Timing belt tensioner adjuster rod set hole -A- and cylinder set hole -B--2004-2005 Galant and 2004-2005 Lancer 2.4L engine

To install:

Fig. Belt tension checking-2004-2005 Galant and 2004-2005 Lancer 2.4L engine

Fig. Cylinder block plug location-2004-2005 Galant and 2004-2005 Lancer 2.4L engine

Fig. Timing belt sprocket alignment-2002-2004-2005 Galant and 2004-2005 Lancer 2.4L engine

Be sure that the crankshaft balancer shaft drive sprocket timing marks and balancer shaft sprocket timing marks are aligned.

Install the timing belt -B- (balancer belt) on the crankshaft balancer drive sprocket and balancer shaft sprocket. There should be no slack on the tension side.

Assemble an temporarily fix the center of the pulley of the balancer timing belt tensioner so that it is at the top left from the center of the assembling bolt, and the pulley flange is at the front side of the engine.
NOTE
When tightening the mounting bolts, ensure that the tensioner does not rotate with the bolts. Allowing it to rotate can cause excessive tension of the belt.

Lift your fingers and the balancer timing belt tensioner in the counterclockwise position. Apply minimal torque to the balancer timing belt so the belt is tense without looseness. Tighten the assembling bolt to 12-16 ft. lbs. (16-22 Nm).

Turn the crankshaft clockwise two turns to set the number one piston to TDC on the compression stroke. Check that the sprocket timing marks are aligned.

Apply slight pressure at the center of the belt between both sprockets. Inspect whether the belt deflection is within specification (0.20-0.27 inch.). Correct as required.

Install the crankshaft angle sensing blade, crankshaft drive sprocket, pulley washer and pulley center bolt. Apply clean engine oil to the retaining bolt prior to installation. Tighten the assembling bolt to 123 ft. lbs. (167 Nm).

Slowly compress the timing belt tensioner adjuster rod using a press or vise. Align the set hole -A- of the rod with set hole -B- of the timing belt tensioner adjuster cylinder.
NOTE
Do not compress the assembly too fast as damage to the rod may occur.

Insert a wire or pin in the aligned set holes to lock the assembly in place.

Install the timing belt tensioner adjuster to the engine and tighten the mounting bolt to 15-19 ft. lbs. (20-26 Nm).

Temporarily tighten the timing belt tensioner pulley. Align the timing marks on the camshaft sprocket, crankshaft drive sprocket and engine oil pump sprocket.

Adjust the timing mark of the engine oil pump sprocket, by removing the cylinder block plug. Insert a bolt (M6, section width 10MM, nominal length 45MM) from the plug hole.
NOTE
If the bolt comes in contact with the balancer shaft, turn the engine oil sprocket one rotation. Re-adjust the timing mark and check to see that the bolt fits. Do not remove the bolt until the valve timing belt is assembled.

Position the timing belt on the timing belt tensioner pulley and crankshaft driver sprocket, support it with your hand so that it does not slide.

Position the belt on the engine oil pump sprocket while pulling it with your other hand.

Position the timing belt on the timing belt idler pulley.
NOTE
Incorporate the timing belt. Then apply reverse rotation (counterclockwise) pressure to the camshaft sprocket. Recheck to see that each timing mark is aligned while the tension side of the belt is right.

Position the timing mark on the camshaft sprocket.

Turn the timing belt tensioner pulley upward using tool MD998767 to apply tension to the belt. Temporarily tighten and fix the belt tensioner pulley mounting bolt.

Check that the timing marks are aligned.

Remove the bolt that was inserted in the cylinder block plug hole. Replace the cylinder block plug hole bolt and torque to 21-25 ft. lbs. (27-33 Nm).
NOTE
Install tool MD998738 with your hands. Do not use any other tools to install the special tool as damage to the wire or pin inserted in the timing belt tensioner may occur.

Gradually screw the tool into position so that the wire or pin inserted in the timing belt tensioner adjuster moves slightly.

Turn the crankshaft in the clockwise direction; align each timing mark to set number one piston to TDC on the compression stroke.

Loosen the timing belt tensioner pulley mounting bolt. With tool MD998767 and a torque wrench, apply tension torque 31 inch lbs. to the timing belt. Tighten the timing belt tensioner pulley mounting bolt to 33-39 ft. lbs. (43-53 Nm).

Remove the wire or pin inserted in the timing belt tensioner adjuster. Remove tool MD998738. Install the rubber plug of the timing belt under cover.

Rotate the crankshaft clockwise two revolutions and leave it for about 15 minutes.

Insert the wire or pin, previously removed, and ensure that it can be pulled out with light load. When the wire or pin can be pulled out appropriate tension is applied on the timing belt.

If the wire or pin can not be pulled out easily repeat the above until it can.
NOTE
Always check the tightening torque of the crankshaft pulley center bolt when turning the crankshaft pulley center bolt counterclockwise. Retighten if it is loose.

Check again that the timing marks on the sprockets are aligned.

Continue the installation is the reverse order of the removal procedure.

Disconnect the negative battery cable. Remove the engine under cover.

Remove the crankshaft damper pulley.

Disconnect the control wiring harness connector, battery wiring harness connector and connector bracket to engine mounting insulator.

Remove the harness bracket. Remove the upper timing belt cover. Remove the water pump pulley. Remove the idler pulley.

Remove the auto tensioner. Remove the lower timing belt cover.

Turn the crankshaft clockwise and align each timing mark to set the number one piston to TDC of its compression stroke.

Remove the timing belt under cover rubber plug and then install special tool MD998738. Screw the special tool until it contacts the timing belt tensioner arm.
NOTE
The special tool must be screwed in gradually at the rate of a 30 degree turn per second. If it is screwed in all at once, the timing belt tensioner adjuster rod will not easily retract and the tool may bend.

Gradually screw in the special tool and then align the timing belt tensioner adjuster rod set hole -A- with the timing belt tensioner adjuster cylinder set hole -B-.

Insert a wire or pin in the set holes to lock the assembly in place. After removing the special tool, loosen the timing belt tensioner pulley mounting bolts and remove the timing belt. If the belt is being reused be sure to mark the direction of rotation (clockwise) on the belt.

Remove the timing belt tensioner pulley, tensioner arm and adjuster.

Remove the timing belt idler pulley. Remove the timing belt lower cover bracket. Remove the crankshaft position sensor.

Remove the crankshaft pulley center bolt and washer. Remove the drive sprocket. Remove the crankshaft angle sensing blade.

Remove the balancer timing belt tensioner. Remove the timing belt -B- (balancer belt) from its mounting.

To install:

Be sure that the crankshaft balancer shaft drive sprocket timing marks and balancer shaft sprocket timing marks are aligned.

Install the timing belt -B- (balancer belt) on the crankshaft balancer drive sprocket and balancer shaft sprocket. There should be no slack on the tension side.

Assemble an temporarily fix the center of the pulley of the balancer timing belt tensioner so that it is at the top left from the center of the assembling bolt, and the pulley flange is at the front side of the engine.
NOTE
When tightening the mounting bolts, ensure that the tensioner does not rotate with the bolts. Allowing it to rotate can cause excessive tension of the belt.

Lift your fingers and the balancer timing belt tensioner in the counterclockwise position. Apply minimal torque to the balancer timing belt so the belt is tense without looseness. Tighten the assembling bolt to 12-16 ft. lbs. (16-22 Nm).

Turn the crankshaft clockwise two turns to set the number one piston to TDC on the compression stroke. Check that the sprocket timing marks are aligned.

Apply slight pressure at the center of the belt between both sprockets. Inspect whether the belt deflection is within specification (0.20-0.27 inch.). Correct as required.

Install the crankshaft angle sensing blade, crankshaft drive sprocket, pulley washer and pulley center bolt. Apply clean engine oil to the retaining bolt prior to installation. Tighten the assembling bolt to 123 ft. lbs. (167 Nm).

Slowly compress the timing belt tensioner adjuster rod using a press or vise. Align the set hole -A- of the rod with set hole -B- of the timing belt tensioner adjuster cylinder.
NOTE
Do not compress the assembly too fast as damage to the rod may occur.

Insert a wire or pin in the aligned set holes to lock the assembly in place.

Install the timing belt tensioner adjuster to the engine and tighten the mounting bolt to 15-19 ft. lbs. (20-26 Nm).

Temporarily tighten the timing belt tensioner pulley. Align the timing marks on the camshaft sprocket, crankshaft drive sprocket and engine oil pump sprocket.

Adjust the timing mark of the engine oil pump sprocket, by removing the cylinder block plug. Insert a bolt (M6, section width 10MM, nominal length 45MM) from the plug hole.
NOTE
If the bolt comes in contact with the balancer shaft, turn the engine oil sprocket one rotation. Re-adjust the timing mark and check to see that the bolt fits. Do not remove the bolt until the valve timing belt is assembled.

Position the timing belt on the timing belt tensioner pulley and crankshaft driver sprocket, support it with your hand so that it does not slide.

Position the belt on the engine oil pump sprocket while pulling it with your other hand.

Position the timing belt on the timing belt idler pulley.
NOTE
Incorporate the timing belt. Then apply reverse rotation (counterclockwise) pressure to the camshaft sprocket. Recheck to see that each timing mark is aligned while the tension side of the belt is right.

Position the timing mark on the camshaft sprocket.

Turn the timing belt tensioner pulley upward using tool MD998767 to apply tension to the belt. Temporarily tighten and fix the belt tensioner pulley mounting bolt.

Check that the timing marks are aligned.

Remove the bolt that was inserted in the cylinder block plug hole. Replace the cylinder block plug hole bolt and torque to 21-25 ft. lbs. (27-33 Nm).
NOTE
Install tool MD998738 with your hands. Do not use any other tools to install the special tool as damage to the wire or pin inserted in the timing belt tensioner may occur.

Gradually screw the tool into position so that the wire or pin inserted in the timing belt tensioner adjuster moves slightly.

Turn the crankshaft in the clockwise direction; align each timing mark to set number one piston to TDC on the compression stroke.

Loosen the timing belt tensioner pulley mounting bolt. With tool MD998767 and a torque wrench, apply tension torque 31 inch lbs. to the timing belt. Tighten the timing belt tensioner pulley mounting bolt to 33-39 ft. lbs. (43-53 Nm).

Remove the wire or pin inserted in the timing belt tensioner adjuster. Remove tool MD998738. Install the rubber plug of the timing belt under cover.

Rotate the crankshaft clockwise two revolutions and leave it for about 15 minutes.

Insert the wire or pin, previously removed, and ensure that it can be pulled out with light load. When the wire or pin can be pulled out appropriate tension is applied on the timing belt.

If the wire or pin can not be pulled out easily repeat the above until it can.
NOTE
Always check the tightening torque of the crankshaft pulley center bolt when turning the crankshaft pulley center bolt counterclockwise. Retighten if it is loose.

Check again that the timing marks on the sprockets are aligned.

Continue the installation is the reverse order of the removal procedure.

3.0L (6g72) DOHC Engine

Position the engine so the No. 1 cylinder is at Top Dead Center (TDC) of its compression stroke.

Remove all necessary components for access to the timing belt covers, then remove the covers from the engine.
CAUTION
Be sure to disconnect the negative battery cable. Wait at least 90 seconds after the negative battery cable is disconnected to prevent possible deployment of the air bag.

If the same timing belt will be reused, mark the direction of the timing belt's rotation for installation in the same direction. Be sure the engine is positioned so the No. 1 cylinder is at the TDC of its compression stroke and the timing marks are aligned with the engine's timing mark indicators on the rear timing covers.

Remove the timing belt.
WARNING
Turning the camshaft sprocket when the timing belt is removed could cause the valves to contact with the pistons, resulting in severe engine damage.

Remove the bolts that secure the auto-tensioner to the engine block and remove the tensioner.

Fig. Sprocket alignment for timing belt installation

To install:

NOTE

The auto-tensioner assembly must be reset to correctly adjust belt tension.

Loosen the center bolt of tensioner pulley to provide timing belt slack. Remove the timing belt assembly.

Position the auto-tensioner into a vise with soft jaws. The plug at the rear of tensioner protrudes, be sure to use a washer as a spacer to protect the plug from contacting vise jaws.

Slowly push the rod into the tensioner until the set hole in rod is aligned with set hole in the auto-tensioner.

Insert a 0.055 in. (1.4mm) wire into the aligned set holes. Unclamp the tensioner from the vise and install it on the engine. Tighten tensioner mounting bolts to 17 ft. lbs. (24 Nm).
WARNING
DO NOT rotate or turn the camshafts when removing the sprockets or severe engine damage will result from internal component interference.

Align the mark on the crankshaft sprocket with the mark on the front case. Then, move the crankshaft sprocket 1 tooth counterclockwise.

Align the timing marks of the camshafts with the marks on the rear covers.

Using large paper clips to secure the timing belt to the sprockets, install the timing belt in the following order. Be sure camshafts-to-cylinder heads and crankshaft-to-front cover timing marks are aligned. Install the timing belt around the pulleys in the following order:
1. Exhaust camshaft sprocket (front bank).
2. Intake camshaft sprocket (front bank).
3. Water pump pulley.
4. Intake camshaft sprocket (rear bank).
5. Exhaust camshaft sprocket (rear bank).
6. Tensioner pulley.
7. Crankshaft pulley.
8. Idler pulley.
  NOTE
  Since the camshaft sprockets turn easily, secure them with box wrenches when installing the timing belt.

Align all timing mark on the crankshaft and raise tensioner pulley against belt to remove slack, snug tensioner bolt.

Check the alignment of all the timing marks and remove the clips that secure the timing belt to the camshaft sprockets.

Rotate the engine ¹ / ₄ turn counterclockwise, then rotate the engine clockwise to align the timing marks. Check that all the timing marks are in alignment.

Loosen the center bolt on the tensioner pulley. Using tool MD998752 or equivalent and a torque wrench, apply 84 inch lbs. (10 Nm) to the tool on the tensioner. Tighten the tensioner bolt to 35 ft. lbs. (49 Nm) and be sure the tensioner does not rotate with the bolt.

Rotate the crankshaft two complete turns clockwise and let it sit for approximately five minutes. Then, check that the set pin can easily be inserted and removed from the hole in the auto-tensioner.

Remove the set wire attached to the auto-tensioner.

Measure the auto-tensioner protrusion (the distance between the tensioner arm and auto-tensioner body) to ensure that it is within 0.15-0.18 in. (3.8-4.5mm). If out of specification, repeat adjustment procedure until the specified value is obtained.

Check again that the timing marks on all sprockets are in proper alignment.

Install the timing belt covers and all other applicable components.

3.0L (6g72) SOHC Engine

Position the engine so the No. 1 cylinder is at Top Dead Center (TDC) of its compression stroke.
CAUTION
Wait at least 90 seconds after the negative battery cable is disconnected to prevent possible deployment of the air bag.

Remove all necessary components for access to the timing belt covers, then remove the covers from the engine.

If the same timing belt will be reused, mark the direction of the timing belt's rotation for installation in the same direction. Be sure the engine is positioned so the No. 1 cylinder is at the TDC of its compression stroke and the timing marks are aligned with the engine's timing mark indicators.

Loosen the timing belt tensioner bolt and remove the belt. If the tensioner is not being removed, position it as far away from the center of the engine as possible and tighten the bolt.

If the tensioner is being removed, mark the outside of the spring to ensure that it is not installed backwards. Unbolt the tensioner and remove it along with the spring.
WARNING
Do not rotate the camshafts when the timing belt is removed from the engine. Turning the camshaft when the timing belt is removed could cause the valves to interfere with the pistons thus causing severe internal engine damage.

Fig. Align the sprockets properly before removing or installing the timing belt

To install:

Install the tensioner, if removed, and hook the upper end of the spring to the water pump pin and the lower end to the tensioner in exactly the same position as originally installed.

Ensure both camshafts are still positioned so the timing marks align with those on the rear timing covers. Rotate the crankshaft so the timing mark aligns with the mark on the front cover.

Install the timing belt on the crankshaft sprocket and while keeping the belt tight on the tension side, install the belt on the front (left) camshaft sprocket.

Install the belt on the water pump pulley, then the rear (right) camshaft sprocket and the tensioner.

Loosen the bolt that secures the adjustment of the tensioner and lightly press the tensioner against the timing belt.

Check that the timing marks are in alignment.

Rotate the crankshaft 2 full turns in the clockwise direction only, then realign the timing marks.

Tighten the bolt that secures the tensioner to 19 ft. lbs. (26 Nm).

Install the lower and the upper timing belt covers, along with all other applicable components.

3.0L Engine

Position the engine so the No. 1 cylinder is at TDC of its compression stroke.

Disconnect the negative battery cable.

CAUTION

Wait at least 90 seconds after the negative battery cable is disconnected to prevent possible deployment of the air bag.

Remove the engine undercover.

Remove the front undercover panel.

Remove the cruise control pump and the link assembly.

Remove the alternator.

Raise and suspend the engine so that force is not applied to the engine mount.

Remove the timing covers from the engine.

If the same timing belt will be reused, mark the direction of the timing belt's rotation for installation in the same direction. Make sure the engine is positioned so the No. 1 cylinder is at the TDC of its compression stroke and the timing marks are aligned with the engine's timing mark indicators on the valve covers or head.

Loosen the center bolt of tensioner pulley and unbolt auto-tensioner assembly. The auto-tensioner assembly must be reset to correctly adjust belt tension. Remove the timing belt.

Using a wrench, hold the camshaft at its hexagon and remove the camshaft sprocket bolt.

Remove and position the auto-tensioner into a vise with soft jaws. The plug at the rear of tensioner protrudes, be sure to use a washer as a spacer to protect the plug from contacting vise jaws.

Slowly push the rod into the tensioner until the set hole in rod is aligned with set hole in the auto-tensioner.

Insert a 0.055 in. (1.4mm) wire into the aligned set holes. Unclamp the tensioner from the vise and install it on the engine. Tighten tensioner to 17 ft. lbs. (24 Nm).

Clean and inspect both auto tensioner mounting bolts. Coat the threads of the old bolts with thread sealer. If new bolts are installed, inspect the heads of the new bolts. If there is white paint on the bolt head, no sealer is required. If there is no paint on the head of the bolt, apply a coat of thread sealer to the bolt. Install both bolts and tighten to 17 ft. lbs. (24 Nm).

Fig. Align the sprockets properly before removing or installing the timing belt-1995-96 Diamante with the 3.0L (6G72) SOHC engine

To install:

Install the tensioner, if removed, and hook the upper end of the spring to the water pump pin and the lower end to the tensioner in exactly the same position as originally installed.

Ensure both camshafts are still positioned so the timing marks align with those on the rear timing covers.

Rotate the crankshaft so the timing mark aligns with the mark on the front cover.

Install the timing belt on the crankshaft sprocket and while keeping the belt tight on the tension side, install the belt on the front (left) camshaft sprocket.

Install the belt on the water pump pulley, then the rear (right) camshaft sprocket and the tensioner.

Loosen the bolt that secures the adjustment of the tensioner and lightly press the tensioner against the timing belt.

Check that the timing marks are in alignment.

Rotate the crankshaft 2 full turns in the clockwise direction only, then realign the timing marks.

Tighten the bolt that secures the tensioner to 19 ft. lbs. (26 Nm).

Install the lower and the upper timing belt covers, along with all other applicable components.

Fig. Timing belt and related components-2000-2005 Eclipse and 1999-2003 Galant 3.0L engine

Disconnect the negative battery cable.

Remove the alternator. Remove the engine mount bracket. Remove the power steering fluid pump drive belt.

Remove the crankshaft pulley. Remove the tensioner pulley assembly.

Remove the front right upper timing belt cover. Remove the front left upper timing belt cover.

Remove the front lower timing belt cover. Remove the right engine support bracket.

Turn the crankshaft clockwise to align each timing mark and set the number one cylinder to TDC on the compression stroke. If the belt is going to be reused, mark the direction of rotation. Remove the timing belt. Remove the auto tensioner, tensioner pulley and tensioner arm

To install:

Align the timing marks on the camshaft sprockets with those on the rocker cover and the timing mark on the crankshaft sprocket with that on the engine block.
NOTE
The right side camshaft sprocket can turn easily due to the spring force applied, so be careful not to get your fingers caught.

Fig. Timing belt sprocket alignment-2000 3.0L and 3.8L engines

Install the timing belt first on the crankshaft sprocket, than on the idler pulley, then on the left camshaft sprocket, then on the water pump pulley, then on the right camshaft sprocket and finally on the tensioner pulley.

Turn the right camshaft sprocket counterclockwise until the tension side of the timing belt is firmly stretched. Check all timing marks, again.

Use special tool MD998767 to push the tensioner pulley into the timing belt, and then temporarily tighten the center bolt.

Use special tool MD998769 to turn the crankshaft ¼ turn counterclockwise, then turn it again clockwise until the timing marks are aligned.

Holding the auto tensioner with your hand press the end of the pushrod against a metal surface with a force of about 32 lbs. Measure how far the push rod is pushed in. Specification should be 0.04 inch. If not within specification replace the auto tensioner assembly.

Fig. Auto tensioner pushrod test and specification-3.0L and 3.8L engines

Position the auto tensioner perpendicular in a vise. If the tensioner has a plug at the base, be sure to use a washer to protect the plug.

Slowly compress the pushrod of the auto tensioner until the pin hole -A- is aligned the pin hole -B- in the cylinder. Insert a pin into both holes once they are aligned. Install the auto tensioner to the engine.
NOTE
When tightening the center bolt, be careful that the tensioner pulley does not turn with the bolt.

Loosen the center bolt of the tensioner pulley. Use tool MD998767 and a torque wrench and apply tension torque to the timing belt in a downward motion. Tighten the center bolt to 32-40 ft. lbs. (42-54 Nm).

Remove the tensioner set pin. Turn the crankshaft clockwise twice to align the timing marks. Wait at least 5 minutes, then check that the auto tensioner pushrod extends within the standard value range -A- of 0.15-0.20 inch. If not repeat the operation again.

Fig. Auto tensioner center bolt and pushrod check-3.0L and 3.8L engines

Check again that the timing marks of the sprockets are aligned.

Continue the installation in the reverse order of the removal procedure.

Disconnect the negative battery cable.

Remove the alternator. Remove the engine mount bracket. Remove the power steering fluid pump drive belt.

Remove the crankshaft pulley. Remove the tensioner pulley assembly.

Remove the front right upper timing belt cover. Remove the front left upper timing belt cover.

Remove the front lower timing belt cover. Remove the right engine support bracket.

Turn the crankshaft clockwise to align each timing mark and set the number one cylinder to TDC on the compression stroke. If the belt is going to be reused, mark the direction of rotation. Remove the timing belt. Remove the auto tensioner, tensioner pulley and tensioner arm

To install:

Align the timing marks on the camshaft sprockets with those on the rocker cover and the timing mark on the crankshaft sprocket with that on the engine block.
NOTE
The right side camshaft sprocket can turn easily due to the spring force applied, so be careful not to get your fingers caught.

Install the timing belt first on the crankshaft sprocket, than on the idler pulley, then on the left camshaft sprocket, then on the water pump pulley, then on the right camshaft sprocket and finally on the tensioner pulley.

Turn the right camshaft sprocket counterclockwise until the tension side of the timing belt is firmly stretched. Check all timing marks, again.

Use special tool MD998767 to push the tensioner pulley into the timing belt, and then temporarily tighten the center bolt.

Use special tool MD998769 to turn the crankshaft ¼ turn counterclockwise, then turn it again clockwise until the timing marks are aligned.

Holding the auto tensioner with your hand press the end of the pushrod against a metal surface with a force of about 32 lbs. Measure how far the push rod is pushed in. Specification should be 0.04 inch. If not within specification replace the auto tensioner assembly.

Position the auto tensioner perpendicular in a vise. If the tensioner has a plug at the base, be sure to use a washer to protect the plug.

Slowly compress the pushrod of the auto tensioner until the pin hole -A- is aligned the pin hole -B- in the cylinder. Insert a pin into both holes once they are aligned. Install the auto tensioner to the engine.
NOTE
When tightening the center bolt, be careful that the tensioner pulley does not turn with the bolt.

Loosen the center bolt of the tensioner pulley. Use tool MD998767 and a torque wrench and apply tension torque to the timing belt in a downward motion. Tighten the center bolt to 32-40 ft. lbs. (42-54 Nm).

Remove the tensioner set pin. Turn the crankshaft clockwise twice to align the timing marks. Wait at least 5 minutes, then check that the auto tensioner pushrod extends within the standard value range -A- of 0.15-0.20 inch. If not repeat the operation again.

Check again that the timing marks of the sprockets are aligned.

Continue the installation in the reverse order of the removal procedure.

3.5L Engine

Disconnect the negative battery cable.

Drain the cooling system.

CAUTION

Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

Remove the drive belts.

Remove the upper radiator shroud.

Remove the fan and fan pulley.

Without disconnecting the lines, remove the power steering pump from its bracket and position it to the side. Remove the pump brackets.

Remove the belt tensioner pulley bracket.

Without releasing the refrigerant, remove the air conditioning compressor from its bracket and position it to the side.

Remove the bracket.

Remove the cooling fan bracket.

On some vehicles it may be necessary to remove the pulley from the crankshaft to access the lower cover bolts.

Remove the timing belt cover bolts and the upper and lower covers from the engine.

Detach the crankshaft position sensor connector.

Using SST MB990767-01 and MD998754, or their equivalents, remove the crankshaft pulley from the crankshaft.

Use a shop rag to clean the timing marks to assist in properly aligning the timing marks.

Loosen the center bolt on the tension pulley and remove the timing belt.

NOTE

If the same timing belt will be reused, mark the direction of timing belt's rotation, for installation in the same direction. Be sure engine is positioned so No. 1 cylinder is at the TDC of it's compression stroke and the sprockets timing marks are aligned with the engine's timing mark indicators.

Remove the auto-tensioner, the tension pulley and the tension arm assembly.

Remove the sprockets by holding the hexagonal portion of the camshaft with a wrench while removing the sprocket bolt.

Fig. Clean the timing marks to verify their position when aligning-3.5L engine

To install:

Install the crankshaft pulley and turn the crankshaft sprocket timing mark forward (clockwise) three teeth to move the piston slightly past No. 1 cylinder top dead center.

If removed, install the camshaft sprockets and tighten the bolts to 64 ft. lbs. (88 Nm).

Align the timing mark of the left bank side camshaft sprocket.

Align the timing mark of the right bank side camshaft sprocket, and hold the sprocket with a wrench so that it doesn't turn.

Set the timing belt onto the water pump pulley.

Check that the camshaft sprocket timing mark of the left bank side is aligned and clamp the timing belt with double clips.

Set the timing belt onto the idler pulley.

WARNING

If any binding is felt when adjusting the timing belt tension by turning the crankshaft, STOP turning the engine, because the pistons may be hitting the valves.

Turn the crankshaft one turn counterclockwise and set the timing belt onto the crankshaft sprocket.

Set the timing belt on the tension pulley.

Place the tension pulley pin hole so that it is towards the top. Press the tension pulley onto the timing belt, and then provisionally tighten the fixing bolt. Tighten the bolt to 35 ft. lbs. (48 Nm).

Slowly turn the crankshaft two full turns in the clockwise direction until the timing marks align. Remove the four double clips.

Install the crankshaft position sensor connector.

Install the upper and lower covers on the engine and secure them with the retaining screws. Be sure the packing is properly positioned in the inner grooves of the covers when installing.

Install the crankshaft pulley if it was removed. Tighten the bolt to 110 ft. lbs. (150 Nm).

Install the air conditioning bracket and compressor on the engine. Install the belt tensioner.

Install the power steering pump into position. Install the fan pulley and fan.

Install the fan shroud on the radiator.

Refill the cooling system.

Connect the negative battery cable.

Start the engine and check for fluid leaks.

3.8L Engine

Fig. Timing belt and related components-2004-2005 Galant 3.8L engine

Disconnect the negative battery cable. Remove the engine under cover. Remove the engine cover. Remove the engine side cover.

Remove the alternator. Remove the power steering fluid pump drive belt.

Remove the crankshaft pulley. Disconnect the control wiring harness and injector wiring connector.

Disconnect the knock sensor connector and crankshaft position sensor connector.

Remove the connector bracket. Disconnect the oil pressure switch connector and engine oil control valve connector.

Remove the engine mounting stay and the connector bracket.

Remove the front right upper timing belt cover. Remove the front left upper timing belt cover.

Remove the tensioner pulley and tensioner bracket.

Remove the crankshaft position sensor harness clamp.

Remove the front lower timing belt cover. Remove the engine support bracket.

Turn the crankshaft clockwise to align each timing mark and set the number one cylinder to TDC on the compression stroke. If the belt is going to be reused, mark the direction of rotation. Remove the timing belt. Remove the auto tensioner, tensioner pulley and tensioner arm

To install:

Align the timing marks on the camshaft sprockets with those on the rocker cover and the timing mark on the crankshaft sprocket with that on the engine block.
NOTE
The right side camshaft sprocket can turn easily due to the spring force applied, so be careful not to get your fingers caught.

Install the timing belt first on the crankshaft sprocket, than on the idler pulley, then on the left camshaft sprocket, then on the water pump pulley, then on the right camshaft sprocket and finally on the tensioner pulley.

Turn the right camshaft sprocket counterclockwise until the tension side of the timing belt is firmly stretched. Check all timing marks, again.

Use special tool MD998767 to push the tensioner pulley into the timing belt, and then temporarily tighten the center bolt.

Use special tool MD998769 to turn the crankshaft ¼ turn counterclockwise, then turn it again clockwise until the timing marks are aligned.

Holding the auto tensioner with your hand press the end of the pushrod against a metal surface with a force of about 32 lbs. Measure how far the push rod is pushed in. Specification should be 0.04 inch. If not within specification replace the auto tensioner assembly.

Position the auto tensioner perpendicular in a vise. If the tensioner has a plug at the base, be sure to use a washer to protect the plug.

Slowly compress the pushrod of the auto tensioner until the pin hole -A- is aligned the pin hole -B- in the cylinder. Insert a pin into both holes once they are aligned. Install the auto tensioner to the engine.
NOTE
When tightening the center bolt, be careful that the tensioner pulley does not turn with the bolt.

Loosen the center bolt of the tensioner pulley. Use tool MD998767 and a torque wrench and apply tension torque to the timing belt in a downward motion. Tighten the center bolt to 32-40 ft. lbs. (42-54 Nm).

Remove the tensioner set pin. Turn the crankshaft clockwise twice to align the timing marks. Wait at least 5 minutes, then check that the auto tensioner pushrod extends within the standard value range -A- of 0.19-0.24 inch. If not repeat the operation again.

Check again that the timing marks of the sprockets are aligned.

Continue the installation in the reverse order of the removal procedure.

Evolution

Fig. Timing belt and related components-Evolution

Fig. Timing belt -B- (balancer belt) and related components-Evolution

Disconnect the negative battery cable. Remove the engine under cover.

Remove the side cover. Remove the crankshaft damper pulley.

Remove the front axle crossmember bar. Remove the front exhaust pipe.

Disconnect the power steering pressure hose connection. Remove the timing belt upper cover. Remove the water pump pulley.

Remove the idler pulley and auto tensioner.

Remove the timing belt lower cover. Remove the engine mounting insulator.

Turn the crankshaft clockwise and align each timing mark to set the number one piston to TDC of its compression stroke.

Remove the timing belt under cover rubber plug and then install special tool MD998738. Screw the special tool until it contacts the timing belt tensioner arm.
NOTE
The special tool must be screwed in gradually at the rate of a 30 degree turn per second. If it is screwed in all at once, the timing belt tensioner adjuster rod will not easily retract and the tool may bend.

Gradually screw in the special tool and then align the timing belt tensioner adjuster rod set hole -A- with the timing belt tensioner adjuster cylinder set hole -B-.

Insert a wire or pin in the set holes to lock the assembly in place. After removing the special tool, loosen the timing belt tensioner pulley mounting bolts and remove the timing belt. If the belt is being reused be sure to mark the direction of rotation (clockwise) on the belt.

Remove the timing belt tensioner pulley, tensioner arm and adjuster.

Remove the power steering pressure switch connector, fluid pump heat protector, fluid pump, bracket and reservoir assembly. Remove the power steering fluid pump bracket.

Remove the timing belt idler pulley. Remove the crankshaft position sensor.

Remove the crankshaft pulley center bolt and washer. Remove the drive sprocket. Remove the crankshaft angle sensing blade.

Remove the balancer timing belt tensioner. Remove the timing belt -B- (balancer belt) from its mounting.

To install:

Be sure that the crankshaft balancer shaft drive sprocket timing marks and balancer shaft sprocket timing marks are aligned.

Install the timing belt -B- (balancer belt) on the crankshaft balancer drive sprocket and balancer shaft sprocket. There should be no slack on the tension side.

Assemble an temporarily fix the center of the pulley of the balancer timing belt tensioner so that it is at the top left from the center of the assembling bolt, and the pulley flange is at the front side of the engine.
NOTE
When tightening the mounting bolts, ensure that the tensioner does not rotate with the bolts. Allowing it to rotate can cause excessive tension of the belt.

Lift your fingers and the balancer timing belt tensioner in the counterclockwise position. Apply minimal torque to the balancer timing belt so the belt is tense without looseness. Tighten the assembling bolt to 12-16 ft. lbs. (16-22 Nm).

Turn the crankshaft clockwise two turns to set the number one piston to TDC on the compression stroke. Check that the sprocket timing marks are aligned.

Apply slight pressure at the center of the belt between both sprockets. Inspect whether the belt deflection is within specification (0.20-0.27 inch.). Correct as required.

Install the crankshaft angle sensing blade, crankshaft drive sprocket, pulley washer and pulley center bolt. Apply clean engine oil to the retaining bolt prior to installation. Tighten the assembling bolt to 123 ft. lbs. (167 Nm).

Slowly compress the timing belt tensioner adjuster rod using a press or vise. Align the set hole -A- of the rod with set hole -B- of the timing belt tensioner adjuster cylinder.
NOTE
Do not compress the assembly too fast as damage to the rod may occur.

Insert a wire or pin in the aligned set holes to lock the assembly in place.

Install the timing belt tensioner adjuster to the engine and tighten the mounting bolt to 15-19 ft. lbs. (20-26 Nm).

Temporarily tighten the timing belt tensioner pulley. Align the timing marks on the camshaft sprocket, crankshaft drive sprocket and engine oil pump sprocket.

Adjust the timing mark of the engine oil pump sprocket, by removing the cylinder block plug. Insert a bolt or the shaft of a screwdriver 2.36 inches or more.
NOTE
If the bolt or screwdriver shaft comes in contact with the balancer shaft and can only be inserted 0.79-0.98 inches, turn the engine oil sprocket one rotation. Re-adjust the timing mark and check to see that the bolt or screwdriver shaft fits. Do not remove the bolt or screwdriver until the valve timing belt is assembled.

Fig. Tool contact against balancer shaft-Evolution

To install the timing belt, pass the belt around the crankshaft camshaft drive sprocket, the engine oil pump sprocket and the timing belt idler pulley, in that order.

Fig. Timing belt sprocket alignment-Evolution

Pass the timing belt around the camshaft sprocket (exhaust side) and hold it with paper clamps in the location shown in the illustration

Fig. Paper clamp installation and locating point-Evolution

Use a wrench to align the timing mark on the rocker cover with that on the camshaft sprocket. Pass the timing belt around the tensioner pulley.
NOTE
Install the timing belt. Then apply reverse rotation (counterclockwise) pressure to the camshaft sprocket. Recheck to see that each timing mark is aligned while the tension side of the belt is right.

Remove the two paper clamps.

Turn the timing belt tensioner pulley upward using tool MD998767 to apply tension to the belt. Temporarily tighten and fix the belt tensioner pulley mounting bolt.

Check that the timing marks are aligned.

Remove the bolt or screwdriver shaft that was inserted in the cylinder block plug hole. Replace the cylinder block plug hole bolt and torque to 21-25 ft. lbs. (27-33 Nm).
NOTE
Install tool MD998738 with your hands. Do not use any other tools to install the special tool as damage to the wire or pin inserted in the timing belt tensioner may occur.

Gradually screw the tool into position so that the wire or pin inserted in the timing belt tensioner adjuster moves slightly.

Turn the crankshaft in the clockwise direction; align each timing mark to set number one piston to TDC on the compression stroke.

Loosen the timing belt tensioner pulley mounting bolt. With tool MD998767 and a torque wrench, apply tension torque 31 inch lbs. to the timing belt. Tighten the timing belt tensioner pulley mounting bolt to 33-39 ft. lbs. (43-53 Nm).

Remove the wire or pin inserted in the timing belt tensioner adjuster. Remove tool MD998738. Install the rubber plug of the timing belt under cover.

Rotate the crankshaft clockwise two revolutions and leave it for about 15 minutes.

Insert the wire or pin, previously removed, and ensure that it can be pulled out with light load. When the wire or pin can be pulled out appropriate tension is applied on the timing belt.

If the wire or pin can not be pulled out easily repeat the above until it can.
NOTE
Always check the tightening torque of the crankshaft pulley center bolt when turning the crankshaft pulley center bolt counterclockwise. Retighten if it is loose.

Check again that the timing marks on the sprockets are aligned.

Continue the installation is the reverse order of the removal procedure.

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Monday, June 13, 2011

How to replace timing belt for 2.4 engine on Mitsubishi?

Removal & Installation

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