>> J << Timing Belt Installation

WARNING: This page is about a different car, the 2003 Mitsubishi Outlander. However, it is still accessible from the selected car via links, so may be relevant.

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

Fig 1: Identifying Wrench Attaching Holes
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Align the timing mark on the camshaft sprocket with the timing mark on the rocker cover.

Fig 2: Identifying Timing Mark On Camshaft Sprocket Aligned With Timing Mark On Rocker Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Align the timing mark on the crankshaft sprocket with the timing mark on the front case.

Fig 3: Identifying Timing Mark On Crankshaft Sprocket Aligned With Timing Mark On Front Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Align the timing mark on oil pump sprocket with its mating mark.

Fig 4: Aligning Timing Mark On Oil Pump Sprocket With Its Mating Mark
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the plug on the cylinder block and insert a Phillips head screwdriver [shank diameter 8 mm (0.3 inch)] through the hole.
If it can be inserted as deep as 60 mm (2.4 inches) or more, the timing marks are correctly aligned.

If the inserted depth is only 20 to 25 mm (0.8 to 0.9 inch), turn the oil pump sprocket one turn and realign the timing marks. then check to ensure that the screwdriver can be inserted 60 mm (2.4 inches) or more. Keep the screwdriver inserted until the timing belt is completely installed.

Fig 5: Inserting Screwdriver Through Hole
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the timing belt on the crankshaft sprocket, oil pump sprocket, idler pulley, camshaft sprocket, and tensioner pulley in that order.
Lift up the tensioner pulley in the direction of the arrow and tighten the center bolt.
Check that all timing marks are aligned.
Remove the screwdriver inserted in step 5 and install the plug.
Turn the crankshaft a quarter turn counterclockwise. Then, turn it clockwise until the timing marks are aligned again.

Fig 6: Turning Crankshaft Quarter Turn Counterclockwise To Align Timing Marks
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install special tool, MD998767 Socket Wrench and Torque Wrench, onto the tensioner pulley, and loosen the tensioner pulley center bolt.
NOTE: Use a torque wrench that can measure 0 to 5.0 N.m (0 - 50 in-lb).
Torque to 3.5 N.m (30 in-lb) with the torque wrench.
Holding the tensioner pulley with special tool MD998767 and torque wrench, tighten the center bolt to specification.
1. Tightening torque: 48 +/- 6 N.m (35 +/- 4 ft-lb)
  
  Fig 7: Tightening Center Bolt
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Give two clockwise turns to the crankshaft. Wait for 15 minutes, then proceed with the following inspection steps.
Check to see whether the metal wire (inserted when the auto-tensioner was installed) can be removed without any resistance.
If the metal wire can be removed without any resistance, it means that the belt has a proper tension. Therefore, remove the metal wire. In this condition, check that the rod protrusion of the auto-tensioner is within the standard value.
1. Standard value: 3.8 - 4.5 mm (0.15 - 0.17 inch)
  
  Fig 8: Identifying Metal Wire Position (Inserted When Auto-Tensioner Was Installed)
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
If the metal wire offers resistance when removed, repeat the previous steps (10) through (15) until the standard value is obtained as measured by the rod projection of the autotensioner rod.

Fig 9: Identifying Autotensioner Rod Protrusion Dimension
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.