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

TIMING BELT

REMOVAL AND INSTALLATION
|  |  | Removal steps
--- | --- | --- | ---
|  | 1. | Timing belt front upper cover
|  | 2. | Timing belt front lower cover
|  | 3. | Power steering pump bracket
<<A>> | >>M<< | 4. | Timing belt
| >>L<< | 5. | Tensioner pulley
|  | 6. | Tensioner arm
| >>K<< | 7. | Auto-tensioner
|  | 8. | Idler pulley
|  | 9. | Crankshaft angle sensor
<<B>> | >>J<< | 10. | Oil pump sprocket
<<C>> | >>I<< | 11. | Crankshaft bolt
<<D>> | >>I<< | 12. | Crankshaft sprocket
| >>I<< | 13. | Crankshaft sensing blade
|  | 14. | Tensioner "B"
<<E>> | >>H<< | 15. | Timing belt "B"
<<F>> | >>G<< | 16. | Counterbalancer shaft sprocket
| >>F<< | 17. | Spacer
<<G>> | >>E<< | 18. | Crankshaft sprocket "B"
|  | 19. | Crankshaft key
|  | 20. | Breather hose
|  | 21. | PCV hose
|  | 22. | PCV valve
|  | 23. | PCV valve gasket
|  | 24. | Oil filler cap
| >>D<< | 25. | Rocker cover
| >>D<< | 26. | Rocker cover gasket "A"
|  | 27. | Rocker cover gasket "B"
| >>C<< | 28. | Semicircular packing
| >>B<< | 29. | Engine support bracket
<<H>> | >>A<< | 30. | Camshaft sprocket bolt
|  | 31. | Camshaft sprocket
|  | 32. | Timing belt rear cover, right
|  | 33. | Timing belt rear upper cover, left
|  | 34 | Timing belt rear lower cover, left
| 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.
| 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. 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. Loosen the lock nut of the tensioner pulley, then remove the timing belt.
| <<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 bolt. Remove the oil pump sprocket.
| <<C>> CRANKSHAFT BOLT REMOVAL
| Hold the drive plate with the special tool Fly wheel 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
| 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. Mark the belt running direction for reinstallation. Loosen the tensioner "B" bolt, and then remove the timing belt "B."
| <<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
| 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 BOLT INSTALLATION
| Tighten the camshaft sprocket bolt to 88 ± 10 N·m while preventing the camshaft from rotation using a wrench fitted on the hexagonal portion of the camshaft.
| >>B<< ENGINE SUPPORT BRACKET INSTALLATION
| Remove thoroughly the old sealant remaining on the indicated bolt and in its hole. Coat the bolt with sealant, then install and tighten it. Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent
| >>C<< SEMICIRCULAR PACKING INSTALLATION Remove thoroughly the old sealant and FIPG remaining on the semicircular packing, cylinder head, and rocker cover.
| Apply sealant to the surface indicated in the drawing of the semicircular packing. Specified sealant: 3M ATD No.8660 or equivalent Install the semicircular packing on the cylinder head.
| Apply sealant to the area indicated in the drawing of the semicircular packing and cylinder head. Specified sealant: 3M ATD No.8660 or equivalent
| >>D<< ROCKER COVER/ROCKER COVER GASKET "A" INSTALLATION
| Apply beads of FIPG on the surfaces of the rocker cover indicated in the drawing. Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent Install the rocker cover gasket "A" on the rocker cover before the FIPG hardens.
| Apply beads of FIPG to the surfaces of the rocker cover indicated in the drawing. Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent Install the rocker cover on the cylinder head before the FIPG hardens.
| >>E<< 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.
| >>F<< SPACER INSTALLATION
| CAUTION If the spacer is opposite in direction to that shown in the drawing when installed, it will damage the oil seal lip. 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.
| >>G<< COUNTERBALANCER SHAFT SPROCKET INSTALLATION
| Use the special tool Sprocket stopper (MD998785) as shown in the drawing to prevent the counterbalancer shaft sprocket from rotating. Tighten the sprocket mounting bolt to 45 ± 3 N·m.
| >>H<< 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.
| >>I<< 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 then 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 Fly wheel stopper (MD998781). Tighten the crankshaft bolt to a torque of 167 N·m.
| >>J<< 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 thin coat of engine oil to the seating surface of the nut. Tighten the flange nut to 54 ± 5 N·m.
| >>K<< 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.
| >>L<< TENSIONER PULLEY INSTALLATION
| Install the tensioner pulley with its holes aligned as shown in the drawing.
| >>M<< TIMING BELT INSTALLATION
| 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.
| 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.
| 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.
| Align the timing mark on the oil pump sprocket with that on the cylinder block. Remove the plug from the cylinder block. Insert a crosspoint screwdriver with a shank diameter of 8 mm through the plug 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.
| Turn the oil pump sprocket counterclockwise by one sprocket tooth.
| Install the timing belt on the exhaust camshaft sprocket, and hold it in place with a paper clip at the point indicated in the drawing.
| 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 clip. 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.
| Turn the exhaust camshaft sprocket clockwise to align the timing marks, and make sure that the intake camshaft sprocket timing marks are also aligned.
| 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.
| 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.
| Turn slightly the crankshaft sprocket clockwise to take up the slack in the idler pulley portion of the timing belt. 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.
| Turn the tensioner pulley counterclockwise using the special tool Tension pulley socket wrench (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. Turn the crankshaft clockwise to make the timing mark align with the No.1 cylinder top dead center mark.
| Install the special tool Set screw (MD998738) and turn down the tool until the wire (inserted in the auto-tensioner when it was installed) can be moved freely. Loosen the tensioner pulley lock bolt.
| CAUTION Prevent the timing belt from slipping as it becomes loose following rotation of the intake and exhaust camshafts. Turn the torque wrench attached to the special tool Tension pulley socket wrench (MD998767) counterclockwise until the slack in the timing belt is taken up. Turn the torque wrench clockwise from the position of step 16 until the torque wrench reading becomes 3.5 N·m, then tighten the tensioner pulley lock bolt. Remove the special tool Set screw (MD998738) that was installed in step 14. Turn the crankshaft clockwise two turns, then let it alone for approx. 15 minutes.
| 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. At that time, check that the auto-tensioner rod extends by the specified amount. Standard value: 3.8 - 4.5 mm 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. If the wire cannot be pulled out freely, perform the steps 14 through 18 again to make the belt tension proper.

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

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