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Removal (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: DO NOT remove tape securing crankshaft position sensor connector and control wiring harness, since control wiring harness may contact power steering oil pump pulley. See Fig 7.
CAUTION: The Set Screw (MD998738) can be gradually installed at a rate of a 30-degrees turn per second. If it is screwed in all at once, timing belt tensioner adjuster rod will not easily retract and Set Screw (MD998738) may bend.
NOTE: To reuse timing belt, draw an arrow indicating rotating direction (clockwise) on back of belt using chalk.
  1. Remove right side under cover. See Fig 1. If reusing drive belt, draw arrow on it indicating direction of rotation before removal. Using 1/2" drive ratchet, turn drive belt autotensioner counterclockwise until it hits stopper. Align hole "A" and hole "B" of drive belt autotensioner. See Fig 2. Inset an L-shaped hexagonal wrench between holes. See Fig 3. This will fix drive belt autotensioner in place to allow drive belt removal. Remove crankshaft pulley. See Fig 4.
  2. Remove power steering oil pressure hose. See Fig 5. Disconnect crankshaft position sensor connector. Remove upper timing belt cover and water pump pulley. Remove drive belt idler pulley. Remove end cap and drive belt autotensioner. Remove lower timing belt cover. Remove engine front mounting bracket. See Fig 6. Turn crankshaft clockwise, align each timing mark to set cylinder No. 1 to TDC of its compression stroke. See Fig 8.
  3. Remove timing belt under cover rubber plug and install Set Screw (MD998738). See Fig 9. Screw in Set Screw (MD998738) until it comes in contact with timing belt tensioner arm. See Fig 10.
  4. Gradually screw in Set Screw (MD998738). Then align timing belt tensioner adjuster rod set hole "A" with timing belt tensioner adjustor cylinder set hole "B". See Fig 11. Insert a wire or pin in set hole. See Fig 12. After removal of Set Screw (MD998738), loosen timing belt tensioner pulley bolt and remove timing belt.
  5. Disconnect power steering pressure switch connector and A/C compressor connector. See Fig 13. Remove A/C compressor connector clamp. Remove power steering oil pump assembly and power steering oil pump bracket. Remove crankshaft position sensor connector bracket and crankshaft position sensor.
Fig 1: Removing Under Covers (Outlander)
G00248054Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Fig 2: Alining Drive Belt Autotensioner Holes (Outlander)
G00248056Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Fig 3: Locking Drive Belt Autotensioner Into Place (Outlander)
G00248057Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Fig 4: Removing Crankshaft Pulley (Outlander)
G00248055Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Fig 5: Removing Timing Belt (Outlander)
G00248065Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Fig 6: Removing Engine Front Mounting Bracket (Outlander)
G00248058Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Fig 7: Identifying Crankshaft Position Sensor Connector Securing Tape (Outlander)
G00248059Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Fig 8: Identifying Timing Belt Alining Marks (Outlander)
G00248060Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Fig 9: Installing Adjusting Bolt Special Tool (Outlander)
G00248061Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Fig 10: Implementing Adjusting Bolt Special Tool (Outlander)
G00248062Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Fig 11: Aligning Timing Belt Tensioner Adjuster Rod With Cylinder (Outlander)
G00248063Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Fig 12: Identifying Timing Belt Tensioner Adjuster Retention Wire Or Pin (Outlander)
G00248064Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Fig 13: Removing Crankshaft Position Sensor (Outlander)
G00248066Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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