[11B] ENGINE OVERHAUL <4G6-SOHC> - - TIMING BELT - REMOVAL AND INSTALLATION | PRINT PAGE / INDEX / PRIOR / NEXT

TIMING BELT

REMOVAL AND INSTALLATION
|  |  | Removal steps
--- | --- | --- | ---
|  | 1. | Timing belt front upper cover
|  | 2. | Connector bracket
|  | 3. | Timing belt front lower cover
|  | 4. | Power steering pump bracket
|  | 5. | Crankshaft angle sensor
<<A>> | >>K<< | 6. | Timing belt
| >>J<< | 7. | Tensioner pulley
|  | 8. | Tensioner arm
| >>I<< | 9. | Auto-tensioner
|  | 10. | Idler pulley
<<B>> | >>H<< | 11. | Oil pump sprocket
<<C>> | >>G<< | 12. | Crankshaft bolt
|  | 13. | Crankshaft sprocket washer
<<D>> | >>G<< | 14. | Crankshaft sprocket
| >>G<< | 15. | Crankshaft sensing blade
|  | 16. | Tensioner B
<<E>> | >>F<< | 17. | Timing belt B
<<F>> | >>E<< | 18. | Counterbalancer shaft sprocket
| >>D<< | 19. | Spacer
<<G>> | >>C<< | 20. | Crankshaft sprocket B
|  | 21. | Crankshaft key
| >>B<< | 22. | Engine support bracket
<<H>> | >>A<< | 23. | Camshaft sprocket bolt
|  | 24. | Camshaft sprocket
|  | 25. | Timing belt rear cover
| REMOVAL SERVICE POINTS
| <<A>> TIMING BELT REMOVAL
| 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.
| <<B>> OIL PUMP SPROCKET REMOVAL
| Remove the plug on the left side of cylinder block. Insert a crosspoint screwdriver (shank diameter: 8 mm) to prevent the counterbalancer shaft from rotating. Remove the flange nut. Remove the oil pump sprocket.
| <<C>> CRANKSHAFT BOLT REMOVAL
| Hold the drive plate with the special tool Flywheel stopper (MD998781). Remove the crankshaft bolt.
| <<D>> CRANKSHAFT SPROCKET REMOVAL
| Use the special tool Crankshaft sprocket puller (MD998778) if the sprocket is stuck and hard to remove.
| <<E>> TIMING BELT B REMOVAL
| If the timing belt is to be used, make an arrow mark with something like chalk on the back of the timing belt indicating the direction of rotation so it may be reinstalled in the same direction.
| <<F>> COUNTERBALANCER SHAFT SPROCKET REMOVAL
| Use the special tool Sprocket stopper (MD998785) to prevent the counterbalancer shaft sprocket from rotating. Remove the counterbalancer shaft mounting bolt.
| <<G>> CRANKSHAFT SPROCKET B REMOVAL
| Use the special tool Crankshaft sprocket puller (MD998778) if the sprocket is stuck and hard to remove.
| <<H>> CAMSHAFT SPROCKET BOLT REMOVAL
| Use the special tools to prevent the camshaft sprocket from rotating. End yoke holder (MB990767) Pulley holder pin (MD998719) Remove the camshaft sprocket bolt.
| INSTALLATION SERVICE POINTS
| >>A<< CAMSHAFT SPROCKET BOLT INSTALLATION
| Use the special tools to prevent the camshaft sprocket from rotating. End yoke holder (MB990767) Pulley holder pin (MD998719) Tighten the camshaft sprocket bolt to the specified torque.
| >>B<< ENGINE SUPPORT BRACKET INSTALLATION
| Coat the bolt indicated in the drawing with sealant before it is installed. Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent
| >>C<< CRANKSHAFT SPROCKET B INSTALLATION
| Clean and then degrease the crankshaft sprocket B and the sprocket fitting surface of the crankshaft. NOTE: Degreasing is necessary to prevent lack of frictional coefficient between the mating surfaces.
| >>D<< SPACER INSTALLATION
| Smear slightly oil on the outer surface of the spacer that comes into contact with the oil seal. Install the spacer with the chamfered end toward the oil seal. Reversing the direction will cause damage to the oil seal lip.
| >>E<< COUNTERBALANCER SHAFT SPROCKET INSTALLATION
| Use the special tool Sprocket stopper (MD998785) as shown in the drawing to prevent the counterbalancer shaft sprocket from rotating, then tighten the sprocket mounting bolt to the specified torque.
| >>F<< TIMING BELT B INSTALLATION
| Align the timing marks on the crankshaft sprocket B and counterbalancer shaft sprocket with the corresponding timing marks on the oil pump case. Install the timing belt B on the crankshaft sprocket B and counterbalancer shaft sprocket. There should be no slack in the tension section of the belt.
| Make sure that the tensioner B center is positioned as shown in the drawing relative to the mounting bolt center.
| Lift the tensioner B with fingers to move it in the direction of the arrow until the tension section of the timing belt becomes taut. While keeping the tensioner B in this position, tighten its bolt. NOTE: When the bolt is tightened, prevent the tensioner B shaft from turning. If the shaft turns, the belt will be overtightened. Make sure that the timing marks on the oil pump case and those of the sprockets are all aligned with each other.
| Push a central point of the timing belt B tension section lightly with an index to see if it deflects 5 - 7 mm.
| >>G<< CRANKSHAFT BOLT /CRANKSHAFT SPROCKET /CRANKSHAFT SENSING BLADE INSTALLATION
| Clean and then degrease the crankshaft sprocket, sprocket fitting surface of the crankshaft, and crankshaft sensing blade. Install the crankshaft sprocket and crankshaft sensing blade on the crankshaft. Clean the bolt hole in the crankshaft, and the washer. Apply a necessary minimum amount of oil to the threads and seating surface of the crankshaft bolt.
| Hold the drive plate using the special tool Flywheel stopper (MD998781). Tighten the crankshaft bolt to a torque of 162 ± 5 N·m.
| >>H<< OIL PUMP SPROCKET INSTALLATION
| Prevent the counterbalancer shaft from rotating in the same method as in the removal procedure. Install the oil pump sprocket. Apply a necessary minimum amount of engine oil to the seating surface of the flange nut. Tighten the flange nut to the specified torque.
| >>I<< AUTO-TENSIONER INSTALLATION
| If the auto-tensioner rod remains in its fully extended position, reset it to the retracted position as follows: Clamp the auto-tensioner in a vise at right angles to the jaws. 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. Insert a piece of wire (1.4 mm diameter) into the set holes. Remove the auto-tensioner from the vise.
| Install the auto-tensioner in position. Leave the wire installed until the auto-tensioner is completely installed.
| >>J<< TENSIONER PULLEY INSTALLATION
| Install the tensioner pulley with its holes aligned as shown in the drawing.
| >>K<< TIMING BELT INSTALLATION
| Check that the tensioner pulley is installed with its holes correctly aligned. (See >>J<< ) Align the timing mark on the camshaft sprocket with that on the cylinder head.
| Align the timing mark on the crankshaft sprocket with that on the front case.
| Align the timing mark on the oil pump sprocket with that on the front case.
| Check that the oil pump sprocket is in the correct phase as follows: Remove the plug from the cylinder block and insert a crosspoint screwdriver with a shank diameter of 8 mm through the hole. If it can be inserted 60 mm or more, the sprocket is in the correct phase. If the insertion depth is up to 20 - 25 mm, 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 or more. Keep the screwdriver inserted until installation of timing belt is finished.
| Install the timing belt on the crankshaft sprocket, idler pulley, camshaft sprocket, and tensioner pulley in that order. Lift the tensioner pulley in the direction of the arrow and tighten the tensioner pulley bolt. Check that all the timing marks are aligned. Rotate the crankshaft counterclockwise a quarter (1/4) turn.
| Install the special tool Tension pulley socket wrench (MD998767) on the tensioner pulley and attach a torque wrench to the tool. Apply a torque of 3.5 N·m to the tensioner pulley using the torque wrench. While holding the tensioner pulley to prevent it from rotating, tighten the center bolt to the specified torque. Turn the crankshaft clockwise two turns, then let it alone for approx. 15 minutes.
| Check that the wire that was 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. At that time, check that the auto-tensioner rod extends by the specified amount. Standard value: 3.8 - 4.5 mm If the wire cannot be pulled out freely, perform the steps 10. through 13. again to make the belt tension proper.

[11B] ENGINE OVERHAUL <4G6-SOHC> - - TIMING BELT - REMOVAL AND INSTALLATION | PRINT PAGE / INDEX / PRIOR / NEXT

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