Installation (Outlander)
WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2003 Mitsubishi Outlander, 2003 Mitsubishi Montero Sport, 2003 Mitsubishi Montero, 2003 Mitsubishi Lancer, and 2003 Mitsubishi Galant. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION:
Always screw in Set Screw (MD998738) by hand, since use of a spanner or other tools may damage wire or pin inserted in timing belt tensioner adjuster.
NOTE:
Install timing belt. Then apply reverse rotation (counterclockwise rotation) pressure to camshaft sprocket. Recheck to see that each timing mark is in proper location while belt is right.
NOTE:
When tightening timing belt tensioner pulley bolts, ensure that timing belt tensioner pulley does not rotate with bolts. Allowing it to rotate with bolts can cause insufficient tension on belt.
NOTE:
Always check tightening torque of crankshaft pulley center bolt when turning crankshaft pulley center bolt counterclockwise. Retighten if it is loose.
- Install crankshaft position sensor. Align timing marks on camshaft sprocket, crankshaft camshaft drive sprocket and engine oil pump sprocket. See Figure. Adjust timing mark of engine oil pump sprocket. Remove cylinder block plug. See Fig 1. Insert a M6 x 45 mm bolt into plug hole and check if bolt fits. If bolt comes in contact with balancer shaft turn sprocket one rotation. Readjust timing mark and check to see that bolt fits. DO NOT remove bolt until timing belt is assembled.
- Place timing belt on timing belt tensioner pulley and crankshaft cam shaft driver sprocket. See Fig 2. Support it with your hand so it does not slide. Place timing belt on engine oil pump sprocket while pulling it with your other hand. Place timing belt on timing belt idler pulley. Place timing belt on camshaft sprocket.
- Turn timing belt tensioner in direction shown using Timing Belt Tensioner Pulley Adjuster (MD998767) to apply tension to timing belt. See Fig 3. Then pretighten timing belt tensioner pulley. Check that timing marks are aligned. Remove M6 x 45 mm bolt from plug hole and reinstall cylinder block plug. See Fig 1. Tighten cylinder block plug to specification. See TORQUE SPECIFICATIONS . Adjust timing belt tension.
- Install Set Screw (MD998738) when removing timing belt. See Figure. Gradually screw in Set Screw (MD998738) until wire or pin inserted in timing belt tensioner adjuster lightly moves. Turn crankshaft 1/4 turn counterclockwise. Turn crankshaft in clockwise direction until you align each timing mark to set cylinder No. 1 to TDC of its compression stroke. Loosen timing belt tensioner pulley bolt.
- Hold timing belt tensioner adjuster by hand, and press top end of rod onto metal (e.g., cylinder block) under a pressure of 22-44 lbs. (98-196 N) to measure movement of rod. Movement should be within 0.039" (1 mm) of length when it is free (not pressed) and length when it is pressed. See Fig 6. If measured value is out of standard value, replace timing belt tensioner adjuster.
- With Timing Belt Tensioner Pulley Adjuster (MD998767) and torque wrench, apply tension torque of 31 INCH lbs. (3.5 N.m), and tighten timing belt tensioner pulley bolt to specification. See Fig 4. See TORQUE SPECIFICATIONS . Remove wire or pin inserted to timing belt tensioner. See Figure. Remove Set Screw (MD998738), and install rubber plug to timing belt under cover. Rotate crankshaft clockwise two turns, and leave it for about 15 minutes.
- Reinsert wire or pin and ensure that it can be pulled out easily. When wire or pin can be easily removed, appropriate tension is applied on timing belt. In this case, remove wire or pin. If wire or pin cannot be easily pulled out, repeat steps 4- 6 to reach proper timing belt tension. If projection of timing belt tensioner adjuster rod is within standard value, appropriate tension is applied. See Fig 5. Standard value "A" should be 0.15-0.17" (3.8-4.5 mm).
- Check again that timing marks on sprockets are aligned. Check for oil leak from timing belt tensioner adjuster seal, and replace tensioner if leak is detected. Check for wear or damage at top of timing belt tensioner adjuster rod. Replace tensioner, if required.
- Install NEW drive belt autotensioner end cap. To complete installation, reverse removal procedure. Tighten nuts and bolt to specification. See TORQUE SPECIFICATIONS .