Timing Belt
TIMING BELTREMOVAL AND INSTALLATION
CAUTION: Never overhaul the V.V.T. sprocket.
Removal Steps 1-12:
Removal Steps 13-37 & Required Special Tools:
REMOVAL SERVICE POINTS
[[A]] PLUG CAP REMOVAL
Loosen the plug cap, holding the hexagonal portion of the camshaft with a wrench.
[[B]] TIMING BELT REMOVAL
1. If the timing belt is to be reused, make an arrow mark with something like chalk on the back of the belt indicating the direction of rotation so it may be reinstalled in the same direction.
CAUTION: Never remove the timing belt with any piston at the top dead center (TDC). If a piston is at TDC, the exhaust valves of the cylinder are pushed by the exhaust cams, compressing the valve springs. If the belt is removed under this condition, the sprocket will be turned in the reverse direction by the force of the springs, incurring risk of injury to person.
2. Set the timing mark of the exhaust camshaft sprocket to a point about one tooth before the TDC of the No. 1 cylinder piston on compression stroke.
3. Loosen the lock nut of the tensioner pulley, then remove the timing belt.
[[C]] OIL PUMP SPROCKET REMOVAL
1. Remove the plug on the left side of the cylinder block.
2. Insert a Phillips crosspoint screwdriver [shank diameter 8 mm (0.3 inch)] through the plug hole to block the left counterbalance shaft.
3. Loosen the nut, and then remove the oil pump sprocket.
[[D]] CRANKSHAFT BOLT LOOSENING
1. Install special tool MD998781 to hold the flywheel or drive plate.
2. Loosen and remove the crankshaft bolt and washer.
[[E]] CRANKSHAFT SPROCKET REMOVAL
1. Set special tool MD998778 as shown in the illustration.
2. Screw in the center bolt of the special tool to remove the crankshaft sprocket.
[[F]] TIMING BELT "B" REMOVAL
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."
[[G]] COUNTERBALANCE SHAFT SPROCKET REMOVAL
1. Set special tool MD998785 as shown to prevent the counterbalance shaft sprocket from turning together.
2. Loosen the bolt and remove the sprocket.
[[H]] CRANKSHAFT SPROCKET "B" REMOVAL
1. Set special tool MD998778 as shown in the illustration.
2. Screw in the center bolt of the special tool to remove crankshaft sprocket "B."
[[I]] V.V.T. SPROCKET BOLT REMOVAL
Loosen the V.V.T. sprocket bolt, holding the hexagonal portion of the camshaft with a wrench.
[[J]] CAMSHAFT SPROCKET REMOVAL
Remove the camshaft sprocket bolt while preventing the camshaft from rotation using a wrench fitted on the hexagonal portion of the camshaft.
INSTALLATION SERVICE POINTS
]]A[[ CAMSHAFT SPROCKET INSTALLATION
Tighten the camshaft sprocket bolt while preventing the camshaft from rotation using a wrench fitted on the hexagonal portion of the camshaft.
Tightening torque: 88 ± 10 Nm (65 ± 7 ft. lbs.)
]]B[[ V.V.T. SPROCKET / V.V.T. SPROCKET BOLT INSTALLATION
1. Apply minimum amount of engine oils adequately to the following portions.
^ All directions of camshaft top
^ Inner and outer surfaces of place in which V.V.T. sprocket is inserted
^ Threads and top seat of V.V.T. sprocket bolt
^ V.V.T. sprocket bolt seat
2. Install the V.V.T. sprocket.
3. Firmly and deeply insert the V.V.T. sprocket, and then confirm the V.V.T. sprocket is not rotated, holding the hexagonal portion of the camshaft with a wrench.
4. Holding the hexagonal portion of the camshaft with a wrench, tighten the V.V.T. sprocket bolt to the specified torque of 65 ± 5 Nm.
5. Holding the hexagonal portion of the camshaft with a wrench, confirm the V.V.T. sprocket is not rotated.
NOTE: This shows the V.V.T. sprocket being locked at the most retarded angle with the inside pin.
]]C[[ ENGINE SUPPORT BRACKET INSTALLATION
Coat the threads of the seal bolt A in the illustration with 3M(TM) AAD Part number 8672 or equivalent before tightening.
Tightening torque: 49 ± 5 Nm (36 ± 3 ft. lbs.)
]]D[[ CRANKSHAFT SPROCKET "B" INSTALLATION
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.
]]E[[ SPACER INSTALLATION
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.
]]F[[ COUNTERBALANCE SHAFT SPROCKET INSTALLATION
1. Install the counterbalance shaft sprocket and screw in the bolt.
2. Install special tool 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 Nm (33 ± 2 ft. lbs.)
]]G[[ TIMING BELT "B" INSTALLATION
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 relationship between the tensioner pulley center and the bolt center is 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 Nm (14 ± 2 ft. lbs.)
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 the span on the tension side of timing belt "B." The bolt must deflect 5 to 7 mm (0.20 to 0.28 inch).
]]H[[ CRANKSHAFT SENSING BLADE/CRANKSHAFT SPROCKET/CRANKSHAFT BOLT INSTALLATION
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 small amount of oil to the threads and seating surface of the crankshaft bolt.
5. Install the washer to the crankshaft bolt with its largely chamfered side toward the bolt head.
6. Lock the flywheel using the special tool MD998781.
7. Tighten the crankshaft bolt to the specified torque.
Tightening torque: 167 Nm (123 ft. lbs.)
]]I[[ OIL PUMP SPROCKET INSTALLATION
1. Insert a Phillips head screwdriver [shank diameter 8 mm (0.3 inch)] 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 Nm (40 ± 3 ft. lbs.)
]]J[[ AUTO-TENSIONER INSTALLATION
1. If the auto-tensioner rod remains in its fully extended position, reset it to the retracted position as follows:
1. Clamp the auto-tensioner in a vise at right angles to the jaws.
2. Push in the rod little by little with the vise until the set hole A in the rod is aligned with the set hole B in the cylinder.
3. Insert a piece of wire [1.4 mm (0.055 inch) diameter] into the set holes.
4. Remove the auto-tensioner from the vise.
2. Install the auto-tensioner in position. Leave the wire installed until the auto-tensioner is completely installed.
]]K[[ TENSIONER PULLEY INSTALLATION
Install the tensioner pulley with its holes aligned as shown in the illustration.
]]L[[ TIMING BELT INSTALLATION
1. Bring the timing mark on the exhaust camshaft sprocket to a point one sprocket tooth away from the timing mark on the rocker cover in the counterclockwise direction.
NOTE: If the timing marks were aligned, the exhaust camshaft would be turned counterclockwise by one sprocket tooth and stay there by the force of the valve springs.
2. Align the timing mark on the intake camshaft sprocket with that on the rocker cover.
NOTE: The intake camshaft will be turned slightly clockwise from where the timing marks are aligned by the force of the valve springs and stay there.
3. Bring the timing mark on the crankshaft sprocket to a point one sprocket tooth away from the mating timing mark in the counterclockwise direction like in the operation with the exhaust camshaft sprocket.
4. Align the timing mark on the oil pump sprocket with that on the cylinder block.
1. Remove the plug from the cylinder block.
2. Insert a crosspoint screwdriver with a shank diameter of 8 mm through the plug hole. If it can be inserted 60 mm (2.36 inches) or more, the sprocket is in the correct phase. If the insertion depth is up to 20 - 25 mm (0.78 - 0.98 inch), the screwdriver is blocked by the counterbalancer shaft. Then turn the oil pump sprocket one turn and realign the timing marks. Then check that the screwdriver can be inserted 60 mm (2.36 inches) or more. Keep the screwdriver inserted until installation of timing belt is finished.
3. Turn the oil pump sprocket counterclockwise by one sprocket tooth.
5. Install the timing belt on the exhaust camshaft sprocket, and hold it in place with a paper clamp at the point indicated in the illustration.
6. Turn the intake camshaft sprocket counterclockwise to bring the timing mark on it one sprocket tooth away from the mating timing mark in the counterclockwise direction. Then install the timing belt on the sprocket and hold it in place with a paper clamp.
NOTE: The timing marks will be aligned when the belt is installed since the intake camshaft is turned slightly clockwise by the force of the valve springs.
7. Turn the exhaust camshaft sprocket clockwise to align the timing marks, and make sure that the intake camshaft sprocket timing marks are also aligned.
8. Install the timing belt on the idler pulley, oil pump sprocket, and crankshaft sprocket, in this order.
NOTE: There should be no slack in the installed portion of the belt.
9. Install the timing belt on the tensioner pulley.
NOTE: Turning slightly the intake camshaft sprocket counterclockwise will facilitate installation of the belt on the tensioner pulley.
10. Turn the crankshaft sprocket slightly clockwise to take up the slack in the idler pulley portion of the timing belt.
11. Check that each of the timing marks on the crankshaft, oil pump, and exhaust camshaft sprockets is one sprocket tooth away from its mating timing mark in the counterclockwise direction.
12. Turn the tensioner pulley counterclockwise using the special tool MD998767 to give tension to the belt and hold the tensioner in position by temporarily tightening the tensioner lock bolt.
NOTE: Take up the slack in the belt portion between the intake and exhaust camshaft sprockets.
13. Turn the crankshaft clockwise to make the timing mark align with the No. 1 cylinder top dead center mark.
14. Install the special tool MD998738 and turn down the tool until the wire (inserted in the auto-tensioner when it was installed) can be moved freely.
CAUTION: Prevent the timing belt from slipping as it becomes loose following rotation of the intake and exhaust camshafts.
15. Loosen the tensioner pulley lock bolt.
16. Turn the torque wrench attached to the special tool MD998767 counterclockwise until the slack in the timing belt is taken up.
17. Turn the torque wrench clockwise from the position of step 16 until the torque wrench reading becomes 3.5 Nm (31 inch lbs.), then tighten the tensioner pulley lock bolt.
18. Remove the special tool that was installed in step 14.
19. Turn the crankshaft clockwise two turns, then let it alone for approximately 15 minutes.
20. Check that the wire (inserted in the auto-tensioner when it was installed) can be moved freely. If the wire can be pulled freely, the belt tensioner is adjusted properly. Remove the wire. Check that the auto-tensioner rod extends by the specified amount.
Standard value: 3.8 - 4.5 mm (0.15 - 0.18 inch)
CAUTION: Be sure to check the tightening torque of the crankshaft bolt anytime the crankshaft has been turned counterclockwise. If the torque lower than specification, tighten the bolt to the specified torque.
21. If the wire cannot be pulled out freely, perform the steps 14 through 18 again to make the belt tension proper.
]]M[[ PLUG CAP INSTALLATION
CAUTION: Do not reuse the washer.
1. Install the washer to the plug cap.
2. Holding the hexagonal portion of the camshaft with a wrench, tighten the plug cap to the specified torque.
Tightening torque: 32 ± 2 Nm (24 ± 1 ft. lbs.)
]]N[[ SEMICIRCULAR PACKING INSTALLATION
1. Remove thoroughly the old sealant remaining on the semicircular packing, cylinder head, and rocker cover.
2. Apply sealant 3M(TM) AAD Part number 8672 or equivalent to the surface indicated in the illustration of the semicircular packing.
3. Install the semicircular packing on the cylinder head.
4. Apply sealant 3M(TM) AAD Part number 8660 or equivalent to the area indicated in the illustration of the semicircular packing and cylinder head.
]]O[[ ROCKER COVER/ROCKER COVER GASKET A INSTALLATION
1. Apply beads of sealant MITSUBISHI Genuine Part number MD970389 or equivalent on the surfaces of the rocker cover indicated in the illustration.
2. Install the rocker cover gasket A on the rocker cover before the FIPG hardens.
3. Apply beads of sealant MITSUBISHI Genuine Part number MD970389 or equivalent to the surfaces of the rocker cover indicated in the illustration.
4. Install the rocker cover on the cylinder head before the FIPG hardens.
INSPECTION
TIMING BELT
Check the timing belt closely. Replace the belt with a new one if any of the following defects are evident:
1. Hardening of rubber backing.
Back side is glossy without resilience and leaves no indent when pressed with fingernail.
2. Surface cracks on the backing rubber.
3. Cracks or peeling of the canvas.
4. Cracks on the tooth bottom.
5. Cracks on the belt sides.
6. Abnormal wear on the belt sides.
NOTE: The sides of the belt are normal if they are sharp as if cut by a knife.
7. Abnormal wear on teeth.
Initial stage: Canvas worn (fluffy canvas fibers, rubbery texture gone, white discoloration, canvas texture indistinct)
Final stage: Canvas worn, exposing rubber (tooth width reduced)
8. Missing teeth.
AUTO-TENSIONER
1. Check the auto-tensioner for leaks from the sealed sections.
Replace it if leaky.
2. Check the rod end for wear and other damage.
Replace the auto-tensioner if the rod is badly worn or damaged.
3. Measure the extension length of the rod.
If it is not within the standard value range, replace the auto-tensioner.
Standard value: 12 mm (0.5 inch)
4. Press the rod with a force of 98 to 196 N (22 to 44) and measure the amount of retraction. If the measurement exceeds the standard value, replace the auto-tensioner.
Standard value: 1.0 mm (0.04 inch) or less