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    Mitsubishi Montero, Sport 1998-06

    Timing Belt, Cover, Sprockets, & Seal

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    Removal & Installation



    3.0L & 3.5L Engines
    1. Before servicing the vehicle, refer to the Precautions section.
      2.  
    2. Drain the engine coolant.
      3.  
    3. Remove or disconnect the following:

      Negative battery cable
       
      Upper radiator hose
       
      Cooling fan shroud assembly
       
      Cooling fan-to-clutch bolts and the fan
       
      Cooling fan clutch-to-water pump nuts and the clutch assembly
       
      Drive belts for the alternator, power steering pump and air conditioning compressor
       
      Electrical connectors from the alternator
       
      Alternator-to-engine bolts and the alternator bracket-to-engine bolts
       
      Alternator and bracket from the engine
       
      Power steering pump cover
       
      Power steering pump-to-engine bolts and move the pump aside with the hoses and electrical connector attached
       
      Air conditioning compressor-to-bracket bolts and move the compressor aside with the lines and electrical connector attached
       
      Air conditioning compressor bracket-to-engine bolts and the bracket
       
      Timing indicator bracket (near crankshaft pulley) bolts and the bracket
       
      Accessory mount assembly-to-engine bolts and the mount assembly
       
      Upper timing belt cover assembly
       

      4.  
    4. Using the End Yoke Holder tool MD990767 and 2 Crankshaft Pulley Holder Pin tools MD998715, or equivalent to hold the crankshaft pulley, and a socket wrench, remove the crankshaft pulley bolt and the pulley.

      Lower timing belt cover
       

      5.  
    5. Rotate the crankshaft clockwise to align the timing marks to position the No. 1 cylinder at the Top Dead Center (TDC) of its compression stroke.
      6.  
    6. Use chalk to mark the rotating (clockwise) direction of the timing belt for reinstallation purposes.
      7.  
    7. Loosen the auto-tensioner pulley center bolt and remove the timing bolt.
      8.  
    8. Remove the auto-tensioner pulley and the auto-tensioner arm assembly.
      9.  


      Click image to see an enlarged view

      Fig. Removing or installing the crankshaft pulley bolt-3.0L and 3.5L engines



      Click image to see an enlarged view

      Fig. View of the timing belt alignment marks-3.0L and 3.5L engines



      Click image to see an enlarged view

      Fig. Inspecting the auto-tensioner movement-3.0L and 3.5L engines



      Click image to see an enlarged view

      Fig. Adjusting the timing belt tensioner pulley-3.0L and 3.5L engines



      Click image to see an enlarged view

      Fig. Using crankshaft spacer tool to rotate the crankshaft-3.0L and 3.5L engines


    To install:

    1. Press the end of the auto-tensioner inward with 72-145 ft. lbs. (98-196 Nm) of force and measure the distance that the pushrod is pushed in. If the standard distance is not 0.04 in. (1mm), replace the auto-tensioner.
      2.  
    2. Position the auto-tensioner in a soft-jawed vise and SLOWLY compress the pushrod until the pushrod and housing holes align; then, install a setting pin to secure the auto-tensioner in the retracted position.
      3.  
    3. Align the camshaft and crankshaft TDC timing marks.
      4.  
    4. Install the timing belt (noting its rotational direction) so that there is no deflection between the sprockets and pulleys in the following manner:

      Crankshaft sprocket
       
      Idler pulley
       
      Left camshaft sprocket
       
      Water pump pulley
       
      Right camshaft sprocket
       
      Tension pulley
       

      5.  
    5. Turn the camshaft sprocket counterclockwise until the tension side of the timing belt is firmly stretched, then, recheck the timing marks.
      6.  
    6. Using the Tension Pulley Socket Wrench tool MD998767, or equivalent, push the tensioner pulley into the timing belt and secure the center bolt.
      7.  
    7. Using the Crankshaft Pulley Spacer tool MD998769, or equivalent, rotate the crankshaft14
      8.  
    8. Loosen the timing belt tensioner center bolt. Using the Tension Pulley Socket Wrench tool MD998767, or equivalent, and a torque wrench, apply 39 inch lbs. (4.4 Nm) pressure on the timing belt. Torque the tensioner pulley center bolt to 35 ft. lbs. (48 Nm).
      9.  
    9. Remove the setting pin from the auto-tensioner.
      10.  
    10. Rotate the crankshaft 2 complete revolutions and realign the timing marks. Then, wait for 5 minutes until the auto-tensioner pushrod extends to its standard value. If the standard value is not 0.15-0.20 in. (3.8-5.0mm), repeat the adjustment procedure. If the standard value is still not achieved, replace the auto-tensioner.
      11.  
    11. Install the lower timing belt cover and crankshaft pulley.
      12.  
    12. Using the End Yoke Holder tool MD990767 and 2 Crankshaft Pulley Holder Pin tools MD998715, or equivalent to hold the crankshaft pulley, and a socket torque wrench, torque the crankshaft pulley bolt to 134 ft. lbs. (181 Nm).

      Install or connect the following:
       



      Upper timing belt cover assembly
       
      Remaining items by reversing the removal procedures
       
      Negative battery cable
       

      13.  
    13. Refill the cooling system.
      14.  

    3.8L Engine
    1. Before servicing the vehicle, refer to the Precautions section.
      2.  
    2. Drain the engine coolant.
      3.  
    3. Remove or disconnect the following:

      Negative battery cable
       
      Skid plate and under cover
       
      Battery and battery tray
       
      Air cleaner
       
      Radiator shroud cover
       
      Drive belt
       
      Cooling fan and pulley
       
      Drive belt auto tensioner
       
      Accessory mount stay
       
      Power steering pump. Unbolt and position aside; do not disconnect the fluid lines.
       
      A/C compressor. Unbolt and position aside; do not disconnect the refrigerant lines.
       
      Compressor bracket
       
      Cooling fan bracket assembly
       
      Accessory mount assembly
       
      Timing belt upper cover
       
      Crankshaft pulley, using special tools MB991800 and MB991802
       
      Timing belt indicator bracket
       
      Timing belt lower cover
       
      Auto tensioner
       

      4.  
    4. Turn the crankshaft clockwise to align the timing marks and set the No. 1 cylinder at Top Dead Center (TDC). If you are reusing the timing belt, mark the flat side of the belt with an arrow showing the clockwise direction.
      5.  
    5. Loosen the center bolt of the tension pulley, and then remove the timing belt.
      6.  
    6. Remove or disconnect the following:

      Tension pulley
       
      Tensioner arm assembly
       
      Shaft
       
      Idler pulley
       

      7.  


      Click image to see an enlarged view

      Fig. Installed view of the timing belt and alignment of the timing marks-3.8L engine



      Click image to see an enlarged view

      Fig. Exploded view of the components you need to remove for timing belt removal-3.8L engine



      Click image to see an enlarged view

      Fig. Exploded view of the timing belt and related components-3.8L engine


    To install:

    1. Install or connect the following:

      Idler pulley
       
      Shaft
       
      Tensioner arm assembly
       
      Tension pulley
       

      2.  
    2. Press the end of the auto-tensioner inward with 72-145 ft. lbs. (98-196 Nm) of force and measure the distance that the pushrod is pushed in. If the standard distance is not 0.04 in. (1mm), replace the auto-tensioner.
      3.  
    3. Position the auto-tensioner in a soft-jawed vise and SLOWLY compress the pushrod until the pushrod and housing holes align; then, install a setting pin to secure the auto-tensioner in the retracted position.
      4.  
    4. Align the camshaft and crankshaft TDC timing marks.
      5.  
    5. Install the timing belt (noting its rotational direction) so that there is no deflection between the sprockets and pulleys in the following manner:

      Crankshaft sprocket
       
      Idler pulley
       
      Left camshaft sprocket
       
      Water pump pulley
       
      Right camshaft sprocket
       
      Tension pulley
       

      6.  
    6. Turn the camshaft sprocket counterclockwise until the tension side of the timing belt is firmly stretched, then, recheck the timing marks.
      7.  
    7. Using the Tension Pulley Socket Wrench tool MD998767, or equivalent, push the tensioner pulley into the timing belt and secure the center bolt.
      8.  
    8. Using the Crankshaft Pulley Spacer tool MD998769, or equivalent, rotate the crankshaft14
      9.  
    9. Loosen the timing belt tensioner center bolt. Using the Tension Pulley Socket Wrench tool MD998767, or equivalent, and a torque wrench, apply 39 inch lbs. (4.4 Nm) pressure on the timing belt. Torque the tensioner pulley center bolt to 35 ft. lbs. (48 Nm).
      10.  
    10. Remove the setting pin from the auto-tensioner.
      11.  
    11. Rotate the crankshaft 2 complete revolutions and realign the timing marks. Then, wait for 5 minutes until the auto-tensioner pushrod extends to its standard value. If the standard value is not 0.15-0.20 in. (3.8-5.0mm), repeat the adjustment procedure. If the standard value is still not achieved, replace the auto-tensioner.
      12.  
    12. Install the lower timing belt cover and crankshaft pulley.
      13.  
    13. Using the End Yoke Holder tool MD990767 and 2 Crankshaft Pulley Holder Pin tools MD998715, or equivalent to hold the crankshaft pulley, and a socket torque wrench, torque the crankshaft pulley bolt to 134 ft. lbs. (181 Nm).

      Install or connect the following:
       



      Click image to see an enlarged view

      Fig. Inspecting the auto-tensioner movement-3.8L engines



      Click image to see an enlarged view

      Fig. Adjusting the timing belt tensioner pulley-3.8L engines



      Click image to see an enlarged view

      Fig. Using crankshaft spacer tool to rotate the crankshaft-3.0L and 3.5L engines



      Timing belt upper cover
       
      Accessory mount assembly
       
      Cooling fan bracket assembly
       
      Compressor bracket
       
      A/C compressor
       
      Power steering pump
       
      Accessory mount stay
       
      Drive belt auto tensioner
       
      Cooling fan pulley and fan
       
      Drive belt
       
      Radiator shroud cover
       
      Air cleaner
       
      Battery tray and battery
       
      Under cover and skid plate
       
      Negative battery cable
       

      14.  
    14. Refill the cooling system.
      15.  

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