Mitsubishi Eclipse 1990-1998 Repair Guide

Timing Belt and Sprockets

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It is recommended that the timing belt be replaced periodically to assure correct engine performance. Because of their composition, timing belts wear over a period of time and mileage. To avoid vehicle break down and possible engine damage, the manufacturer recommends timing belt replacement at 60,000 miles.

REMOVAL & INSTALLATION



1.8L Engine

See Figures 1, 2 and 3

  1. If possible, position the engine so the No. 1 piston is at TDC.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the timing belt covers.
  6.  
  7. Remove the timing (outer) belt tensioner and remove the outer timing belt.
  8.  
  9. Remove the outer crankshaft sprocket and flange.
  10.  
  11. Remove the silent shaft (inner) belt tensioner and remove the belt.
  12.  



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Fig. Fig. 1: Silent shaft belt timing marks-1.8L engine



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Fig. Fig. 2: Checking the silent shafts for proper positioning



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Fig. Fig. 3: Timing belt timing mark alignment-1.8L engine

To install:
  1. Align the timing marks of the silent shaft sprockets and the crankshaft sprocket with the timing marks on the front case. Wrap the timing belt around the sprockets so there is no slack in the upper span of the belt and the timing marks are still aligned.
  2.  
  3. Install the tensioner pulley and move the pulley by hand so the long side of the belt deflects about 1 / 4 in.
  4.  
  5. Hold the pulley tightly so the pulley cannot rotate when the bolt is tigthened. Tighten the bolt to 15 ft. lbs. (20 Nm) and recheck the deflection amount.
  6.  
  7. Install the timing belt tensioner fully toward the water pump and tighten the bolts. Place the upper end of the spring against the water pump body.
  8.  
  9. Align the timing marks of the camshaft, crankshaft and oil pump sprockets with their corresponding marks on the front case or rear cover.
  10.  

There is a possibility to align all timing marks and have the oil pump sprocket and silent shaft out of time, causing an engine vibration during operation. If the following step is not followed exactly, there is a 50 percent chance that the silent shaft alignment will be 180 degrees off.

  1. Before installing the timing belt, ensure that the left side (rear) silent shaft (oil pump sprocket) is in the correct position as follows:
    1. Remove the plug from the rear side of the block and insert a tool with shaft diameter of 0.31 in. (8mm) into the hole.
    2.  
    3. With the timing marks still aligned, the shaft of the tool must be able to go in at least 2 1/2 in. If the tool can only go in about 1 in., the shaft is not in the correct orientation and will cause a vibration during engine operation. Remove the tool from the hole and turn the oil pump sprocket 1 complete revolution. Realign the timing marks and insert the tool. The shaft of the tool must go in at least 2 1/3 in.
    4.  
    5. Recheck and realign the timing mark.
    6.  
    7. Leave the tool in place to hold the silent shaft while continuing.
    8.  

  2.  
  3. Install the belt to the crankshaft sprocket, oil pump sprocket, then camshaft sprocket, in that order. While doing so, make sure there is no slack between the sprocket except where the tensioner is installed.
  4.  
  5. Recheck the timing marks' alignment. If all are aligned, loosen the tensioner mounting bolt and allow the tensioner to apply tension to the belt.
  6.  
  7. Remove the tool that is holding the silent shaft and rotate the crankshaft a distance equal to 2 teeth on the camshaft sprocket. This will allow the tensioner to automatically apply the proper tension on the belt. Do not manually overtigthen the belt or it will howl.
  8.  
  9. Tigthen the lower mounting bolt first, then the upper spacer bolt.
  10.  
  11. To verify correct belt tension, check that the deflection at the longest span of the belt is about 1 / 2 in.
  12.  
  13. Install the timing belt covers and all related items.
  14.  
  15. Connect the negative battery cable.
  16.  

2.0L Engine
1990-94 VEHICLES

See Figures 4, 5, 6 and 7

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the timing belt upper and lower covers.
  4.  
  5. Rotate the crankshaft clockwise and align the timing marks so No. 1 piston will be at TDC of the compression stroke. At this time the timing marks on the camshaft sprocket and the upper surface of the cylinder head should coincide, and the dowel pin of the camshaft sprocket should be at the upper side.
  6.  

Always rotate the crankshaft in a clockwise direction. Make a mark on the back of the timing belt indicating the direction of rotation so it may be reassembled in the same direction if it is to be reused.

  1. Remove the auto tensioner and remove the outermost timing belt.
  2.  



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Fig. Fig. 4: Exploded view of the timing belt and sprockets-1990-94 2.0L engines

  1. Remove the timing belt tensioner pulley, tensioner arm, idler pulley, oil pump sprocket, special washer, flange and spacer.
  2.  
  3. Remove the silent shaft (inner) belt tensioner and remove the belt.
  4.  
  5. Remove the crankshaft retaining bolts, then remove the pulley.
  6.  
  7. Remove the crankshaft sprocket retainer bolt and washer from the sprocket, if used, and remove the sprocket. If the sprocket is hard to removed, the proper puller may be used. If no bolts are used on the sprocket. Use the correct puller to remove.
  8.  
  9. Hold the camshaft stationary using the hexagon cast between journals No. 2 and 3 and remove the retainer bolt. Remove the sprocket from the camshaft.
  10.  

To install:
  1. Install the sprockets to their appropriate shafts. Install the retainer bolts and tighten the camshaft sprocket bolt to 65 ft. lbs. (90 Nm).
  2.  
  3. Check both tensioner and idler pulley for bearing wear, and replace if needed.
  4.  
  5. Align the timing marks on the crankshaft sprocket and the silent shaft sprocket. Fit the inner timing belt over the crankshaft and silent shaft sprocket. Ensure that there is no slack in the belt.
  6.  



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Fig. Fig. 5: Align the camshaft sprocket so marks face each other and are in alignment with the top surface of the cylinder head-1990-94 2.0L engine



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Fig. Fig. 6: Align the crankshaft timing mark and the oil pump sprocket timing mark-1990-94 2.0L engine



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Fig. Fig. 7: Timing marks in alignment-1990-94 2.0L engine

  1. While holding the inner timing belt tensioner with your fingers, adjust the timing belt tension by applying a force towards the center of the belt, until the tension side of the belt is taut. Tighten the tensioner bolt.
  2.  

When tightening the bolt of the tensioner, ensure that the tensioner pulley shaft does not rotate with the bolt. Allowing it to rotate with the bolt can cause excessive tension on the belt.

  1. Check belt for proper tension by depressing the belt on its' long side with your finger and noting the belt deflection. The desired reading is 0.20-0.28 in. (5-7mm). If tension is not correct, readjust and check belt deflection.
  2.  
  3. Install the flange, crankshaft and washer to the crankshaft. The flange on the crankshaft sprocket must be installed towards the inner timing belt sprocket. Tighten bolt to 80-94 ft. lbs. (110-130 Nm).
  4.  
  5. To install the oil pump sprocket, insert a Phillips screwdriver with a shaft 0.31 in. (8mm) in diameter into the plug hole in the left side of the cylinder block to hold the left silent shaft. Tighten the nut to 36-43 ft. lbs. (50-60 Nm).
  6.  
  7. Using a wrench, hold the camshaft at its' hexagon between journal No. 2 and 3 and tighten camshaft sprocket mounting bolt, if removed, to 58-72 ft. lbs. (80-100 Nm). If no hexagon is present between journal No. 2 and 3, hold the sprocket stationary with a spanner wrench while tightening the sprocket retainer bolt.
  8.  
  9. Carefully push the auto tensioner rod in until the set hole in the rod aligned up with the hole in the cylinder. Place a wire into the hole to retain the rod.
  10.  
  11. Install the tensioner pulley onto the tensioner arm. Locate the pinhole in the tensioner pulley shaft to the left of the center bolt. Then, tighten the center bolt finger-tight.
  12.  
  13. When installing the timing belt, turn the 2 camshaft sprockets so their dowel pins are located on top. Align the timing marks facing each other and with the top surface of the cylinder head. When you let go of the exhaust camshaft sprocket, it will rotate 1 tooth in the counterclockwise direction. This should be taken into account when installing the timing belts on the sprocket.
  14.  

Both camshaft sprockets are used for the intake and exhaust camshafts and are provided with 2 timing marks. When the sprocket is mounted on the exhaust camshaft, use the timing mark on the right with the dowel pin hole on top. For the intake camshaft sprocket, use the 1 on the left with the dowel pin hole on top.

  1. Align the crankshaft sprocket and oil pump sprocket timing marks.
  2.  
  3. After alignment of the oil pump sprocket timing marks, remove the plug on the cylinder block and insert a Phillips screwdriver with a shaft diameter of 0.31 in. (8mm) through the hole. If the shaft can be inserted 2.4 in. deep, the silent shaft is in the correct position. If the shaft of the tool can only be inserted 0.8-1.0 in. (20-25mm) deep, turn the oil pump sprocket 1 turn and realign the marks. Reinsert the tool making sure it is inserted 2.4 in. deep. Keep the tool inserted in hole for the remainder of this procedure.
  4.  

The above step assures that the oil pump socket is in correct orientation to the silent shafts. This step must not be skipped or a vibration may develop during engine operation.

  1. Install the timing belt as follows:
    1. Install the timing belt around the intake camshaft sprocket and retain it with 2 spring clips or binder clips.
    2.  
    3. Install the timing belt around the exhaust sprocket, aligning the timing marks with the cylinder head top surface using 2 wrenches. Retain the belt with 2 spring clips.
    4.  
    5. Install the timing belt around the idler pulley, oil pump sprocket, crankshaft sprocket and the tensioner pulley. Remove the 2 spring clips.
    6.  
    7. Lift upward on the tensioner pulley in a clockwise direction and tighten the center bolt. Make sure all timing marks are aligned.
    8.  
    9. Rotate the crankshaft 1 / 4 turn counterclockwise. Then, turn in clockwise until the timing marks are aligned again.
    10.  

  2.  
  3. To adjust the timing (outer) belt, turn the crankshaft 1 / 4 turn counterclockwise, then turn it clockwise to move No. 1 cylinder to TDC.
  4.  
  5. Loosen the center bolt. Using tool MD998738 or equivalent and a torque wrench, apply a torque of 1.88-2.03 ft. lbs. (2.6-2.8 Nm). Tighten the center bolt.
  6.  
  7. Screw the special tool into the engine left support bracket until its end makes contact with the tensioner arm. At this point, screw the special tool in some more and remove the set wire attached to the auto tensioner, if the wire was not previously removed. Then remove the special tool.
  8.  
  9. Rotate the crankshaft 2 complete turns clockwise and let it sit for approximately 15 minutes. Then, measure the auto tensioner protrusion (the distance between the tensioner arm and auto tensioner body) to ensure that it is within 0.15-0.18 in. (3.8-4.5mm). If out of specification, repeat Step 1-4 until the specified value is obtained.
  10.  
  11. If the timing belt tension adjustment is being performed with the engine mounted in the vehicle, and clearance between the tensioner arm and the auto tensioner body cannot be measured, the following alternative method can be used:
    1. Screw in special tool MD998738 or equivalent, until its end makes contact with the tensioner arm.
    2.  
    3. After the special tool makes contact with the arm, screw it in some more to retract the auto tensioner pushrod while counting the number of turns the tool makes until the tensioner arm is brought into contact with the auto tensioner body. Make sure the number of turns the special tool makes conforms with the standard value of 2 1 / 2 -3 turns.
    4.  
    5. Install the rubber plug to the timing belt rear cover.
    6.  

  12.  
  13. Install the timing belt covers and all related items.
  14.  
  15. Connect the negative battery cable.
  16.  

1995-98 NON-TURBO ENGINES

See Figures 8 through 25

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the accessory drive belts.
  4.  
  5. Remove the power steering pump from the bracket and position it out of the way. Do not disconnect the hoses.
  6.  



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Fig. Fig. 8: Unfasten the power steering pump retaining bolts

  1. Remove the power steering pump bracket from the engine.
  2.  
  3. Remove the crankshaft pulley.
  4.  
  5. Use a floor jack with a piece of wood on it and jack up the engine to take the weight off of the engine mount.
  6.  
  7. Remove the engine mount and bracket.
  8.  
  9. Unfasten the retainers, then remove the front timing belt cover.
  10.  



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Fig. Fig. 9: Engine timing system parts identification-1995-98 2.0L non-turbo engine

If the timing belt is going to be reused, mark the direction of rotation on the belt with an arrow. Install the belt in the same direction.



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Fig. Fig. 10: If you are going to reinstall the old belt, mark the direction of rotation for installation purposes

  1. Rotate the crankshaft sprocket clockwise until the timing marks are aligned. Loosen the timing belt tensioner and remove the timing belt.
  2.  



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Fig. Fig. 11: Loosen the timing belt tensioner bolts (see arrows) ...



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Fig. Fig. 12: ... then remove the timing belt from the engine



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Fig. Fig. 13: Unfasten the tensioner retaining bolts ...



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Fig. Fig. 14: Remove the timing belt tensioner

  1. Use tool MB995027 or equivalent to hold the crankshaft sprocket while removing the mounting bolt in the center.
  2.  
  3. If available, you can use end yoke holder tool MB990767 or equivalent to hold the camshaft sprocket while removing the mounting bolt in the center.
  4.  



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Fig. Fig. 15: Remove the camshaft sprocket retaining bolt ...



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Fig. Fig. 16: ... then remove the camshaft sprocket from the vehicle


WARNING
Do not rotate the crankshaft or the camshafts while the belt is removed.

  1. If necessary, unfasten the retainers, then remove the idle and tensioner pulleys.
  2.  



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Fig. Fig. 17: If necessary to remove the idle pulley, unfasten the retaining bolt



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Fig. Fig. 18: ... then remove the idle pulley, if necessary



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Fig. Fig. 19: Unfasten the tensioner pulley retaining bolt ...



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Fig. Fig. 20: ... then remove the tensioner pulley

To install:
  1. Use the special tool to hold the camshaft sprocket and install the center bolt. Tighten the bolt to 75 ft. lbs. (101 Nm).
  2.  
  3. Use tool MB995038 and MB995026 or equivalent, to install the crankshaft sprocket.
  4.  
  5. Using a vise, slowly compress the plunger into the body of the tensioner and install a pin through the body of the tensioner to retain the plunger.
  6.  



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Fig. Fig. 21: Compress the tensioner in a vise-1995-98 2.0L non-turbo engine



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Fig. Fig. 22: Once the tensioner is removed from the vehicle, plate it in a suitable vise



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Fig. Fig. 23: Use the vise to carefully compress the plunger into the body



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Fig. Fig. 24: When the plunger of the tensioner is fully compressed, insert a pin through the body to hold it

  1. Make sure the timing marks are still aligned, if not, align the camshaft sprocket timing marks facing each other. Align the crankshaft sprocket timing mark with the mark on the oil pump housing, then turn the crankshaft sprocket backward 1 / 2 notch.
  2.  



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Fig. Fig. 25: Engine timing marks-1995-98 2.0L non-turbo engine

  1. Install the timing belt starting at the crankshaft, go around the water pump sprocket, idler pulley, camshaft sprockets and then around the tensioner pulley.
  2.  
  3. Turn the crankshaft sprocket 1 / 2 notch to TDC to take up the slack in the belt.
  4.  
  5. Install the tensioner on the engine but do not tighten the bolts.
  6.  
  7. Place a torque wrench on the tensioner pulley and apply 21 ft. lbs. (28 Nm) of torque in the direction of the water pump. Push the tensioner up against the tensioner pulley and Tighten the mounting bolts to 23 ft. lbs. (31 Nm).
  8.  
  9. Pull the pin out of the tensioner. Belt tension is correct when the pin can be removed and installed.
  10.  
  11. Rotate the crankshaft two revolutions and check the timing marks for alignment. Repeat the previous steps if necessary.
  12.  
  13. Install the timing belt cover.
  14.  
  15. Install the crankshaft pulley.
  16.  
  17. Install the engine mount and bracket. Remove the jack from under the engine.
  18.  
  19. Install the power steering pump bracket and pump.
  20.  
  21. Install the drive belts.
  22.  
  23. Connect the negative battery cable.
  24.  

1995-98 TURBO ENGINES

See Figures 26, 27, 28, 29, 30, and 31

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine undercover.
  4.  
  5. Remove the engine mount bracket.
  6.  
  7. Remove the drive belts.
  8.  
  9. Remove the belt tensioner pulley.
  10.  
  11. Remove the water pump pulleys.
  12.  
  13. Remove the crankshaft pulley.
  14.  
  15. Remove the stud bolt from the engine support bracket and remove the timing belt covers.
  16.  
  17. Rotate the crankshaft clockwise to line up the camshaft timing marks. Always turn the crankshaft in the forward direction only.
  18.  
  19. Loosen the tension pulley center bolt.
  20.  

If the timing belt is to be reused, mark the direction of rotation on the flat side of the belt with an arrow.

  1. Move the tension pulley towards the water pump and remove the timing belt.
  2.  
  3. Remove the crankshaft sprocket center bolt using special tool MB990767 to hold the crankshaft sprocket while removing the center bolt. Then use MB998778 or equivalent puller to remove the sprocket.
  4.  
  5. Mark the direction of rotation on the timing belt B with a arrow.
  6.  
  7. Loosen the center bolt on the tensioner and remove the belt.
  8.  
  9. To remove the camshaft sprocket, remove the cylinder head cover. Use a wrench to hold the hexagonal part of the camshaft and remove the sprocket mounting bolt.
  10.  


WARNING
Do not rotate the camshafts or the crankshaft while the timing belt is removed.



Click image to see an enlarged view

Fig. Fig. 26: Timing belt routing and component identification-1995-98 2.0L turbo engine

To install:
  1. Use a wrench to hold the camshaft and install the sprocket and mounting bolt. Tighten the bolt(s) to 65 ft. lbs. (88 Nm).
  2.  
  3. Install the cylinder head cover.
  4.  
  5. Place the crankshaft sprocket on the crankshaft. Use tool MB990767 or equivalent to hold the crankshaft sprocket while tightening the center bolt. Tighten the center bolt to 80-94 ft. lbs. (108-127 Nm).
  6.  
  7. Align the timing marks on the crankshaft sprocket B and the balance shaft.
  8.  
  9. Install timing belt B on the sprockets. Position the center of the tensioner pulley to the left and above the center of the mounting bolt.
  10.  
  11. Push the pulley clockwise toward the crankshaft to apply tension to the belt and tighten the mounting bolt to 14 ft. lbs. (19 Nm). Do not let the pulley turn when tightening the bolt because it will cause excessive tension on the belt. The belt should deflect 0.20-0.28 in. (5-7 mm) when finger pressure is applied between the pulleys.
  12.  
  13. Install the crankshaft sensing blade and the crankshaft sprocket. Apply engine oil to the mounting bolt and Tighten the bolt to 80-94 ft. lbs. (108-127 Nm).
  14.  
  15. Use a press or vise to compress the auto tensioner pushrod. Insert a set pin when the holed are lined up.
  16.  


WARNING
Do not compress the pushrod too quickly, damage to the pushrod can occur.

  1. Install the auto tensioner on the engine.
  2.  
  3. Align the timing marks on the camshaft sprocket, crankshaft sprocket and the oil pump sprocket.
  4.  
  5. After aligning the mark on the oil pump sprocket, remove the cylinder block plug and insert a Phillips screwdriver in the hole to check the position of the counter balance shaft. The screwdriver should go in at least 2.36 in. or more, if not, rotate the oil pump sprocket once and realign the timing mark so the screwdriver goes in. Do not remove the screwdriver until the timing belt is installed.
  6.  



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Fig. Fig. 27: After the timing mark on the oil pump sprocket is lined up, remove the block plug and insert a screwdriver to assure proper alignment

  1. Install the timing belt on the intake camshaft and secure it with a clip.
  2.  



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Fig. Fig. 28: Keep the timing belt in position using a bulldog clip

  1. Install the timing belt on the exhaust camshaft. Align the timing marks with the cylinder head top surface using two wrenches. Secure the belt with another clip.
  2.  



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Fig. Fig. 29: Use 2 wrenches to align the marks with the top of the cylinder head

  1. Install the belt around the idler pulley, oil pump sprocket, crankshaft sprocket and the tensioner pulley.
  2.  
  3. Turn the tension pulley so the pinholes are at the bottom. Press the pulley lightly against the timing belt.
  4.  
  5. Screw the special tool into the left engine support bracket until it contacts the tensioner arm, then screw the tool in a little more and remove the pushrod pin from the auto tensioner. Remove the special tool and Tighten the center bolt to 35 ft. lbs. (48 Nm).
  6.  



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Fig. Fig. 30: Use a torque wrench and adapter to apply tension to the timing belt-1995-98 2.0L turbo engine

  1. Turn the crankshaft 1 / 4 turn counterclockwise and then clockwise until the timing marks are aligned.
  2.  



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Fig. Fig. 31: View of the proper timing mark alignment-1995-98 2.0L turbo engine

  1. Loosen the center bolt. Install special tool MD998767 on the tension pulley. Turn the tension pulley counterclockwise with a torque of 2.6 ft. lbs. (3.5 Nm) and tighten the center bolt to 35 ft. lbs. (48 Nm). Do not let the tension pulley turn with the bolt.
  2.  
  3. Turn the crankshaft two revolutions to the right and align the timing marks. After 15 minutes, measure the protrusion of the pushrod on the auto tensioner. The standard measurement is 0.150-0.177 in (3.8-4.5 mm). If the protrusion is out of specification, loosen the tension pulley, apply the proper torque to the belt and retighten the center bolt.
  4.  
  5. Install the crankshaft pulley. Tighten the mounting bolts to 18 ft. lbs. (25 Nm).
  6.  
  7. Install the water pump. Tighten the mounting bolts to 6.5 ft. lbs. (8.8 Nm).
  8.  
  9. Install and adjust the drive belts.
  10.  
  11. Install the engine mount bracket.
  12.  
  13. Install the engine undercover.
  14.  
  15. Connect the negative battery cable.
  16.  

2.4L Engine

See Figures 32, 33, 34, 35 and 36

  1. If possible, position the engine so the No. 1 piston is at TDC.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the splash shield under the engine.
  6.  
  7. Safely support the weight of the engine and remove the engine mount and bracket assembly.
  8.  
  9. Remove the drive belts and the timing belt covers.
  10.  

If timing belts are going to be reused, mark the direction of rotation on the belt. This will ensure the belt is reinstalled in same direction, extending belt life.

  1. To loosen the timing (outer) belt tensioner, install special tool MD998738 or equivalent, to the slot and screw inward to move tensioner toward the water pump. Once the tension has been relieved, remove the outer timing belt.
  2.  
  3. If tensioner replacement is required, align the pin hole in the tensioner rod to the hole in the tensioner cylinder. Insert a 0.055 inch (1.4 mm) wire in the hole and remove the special tool from the slot. With the cylinder tension relieved, remove the auto tensioner cylinder assembly two mounting bolts.
  4.  
  5. Remove the outer crankshaft sprocket and flange.
  6.  
  7. Loosen the silent shaft (inner) belt tensioner and remove the belt. If pulley replacement is required, remove the center adjusting bolt.
  8.  



Click image to see an enlarged view

Fig. Fig. 32: Exploded view of the inner (B) timing belt and related components-2.4L engine

  1. Remove the crankshaft pulley retainer bolts and remove the pulley.
  2.  



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Fig. Fig. 33: You will probably have to use a special tool to remove the crankshaft pulley bolt-2.4L engine

  1. Remove the crankshaft sprocket retainer bolt and washer from the sprocket, if used, and remove sprocket. If sprocket is difficult to remove, the appropriate puller may be used. If no bolts are used on the sprocket, use the appropriate puller to remove.
  2.  



Click image to see an enlarged view

Fig. Fig. 34: If you're having trouble removing the sprocket, you may have to use a suitable puller

  1. Hold the camshaft stationary using the hexagon cast between journals No. 2 and 3 and remove the retainer bolt. Remove the sprocket from the camshaft.
  2.  

To install:
  1. Install the sprockets to their appropriate shafts. Install the retainer bolts and Tighten the camshaft sprocket bolt to 65 ft. lbs. (90 Nm)
  2.  

Inspect the timing belts in detail for any flaw or wear. Check the sprockets and tensioner for wear. The sprocket teeth should be well defined, not rounded and the valleys between the teeth should be clean. Turn both tensioner pulleys and check for any signs of bearing wear. If sprockets or pulleys show any sign of wear, they must be replaced.


WARNING
Do not spray or immerse the sprockets or tensioners in cleaning solvent. The sprocket may absorb the solvent and transfer it to the belt. The tensioners are internally lubricated and the solvent will dilute or dissolve the lubricant.

  1. Align the timing marks of the silent shaft sprockets and the crankshaft sprocket with the timing marks on the front case. Wrap the timing belt around the sprockets so there is no slack in the upper span of the belt and the timing marks are still aligned.
  2.  
  3. Install the tensioner pulley and move the pulley by hand so the long side of the belt deflects about 1 / 4 inch.
  4.  
  5. Hold the pulley tightly so the pulley cannot rotate when the bolt is tigthened. Tighten the bolt to 14 ft. lbs. (19 Nm) and recheck the deflection amount.
  6.  
  7. Align the timing marks of the camshaft, crankshaft and oil pump sprockets with their corresponding marks on the front case or rear cover.
  8.  

There is a possibility to align all timing marks and have the oil pump sprocket and silent shaft out of time, causing an engine vibration during operation. If the following step is not followed exactly, there is a 50 percent chance that the silent shaft alignment will be 180 degrees off.



Click image to see an enlarged view

Fig. Fig. 35: Proper timing component alignment points-2.4L engines

  1. Before installing the timing belt, ensure that the left side (rear) silent shaft (oil pump sprocket) is in the correct position as follows:
    1. Remove the plug from the rear side of the block and insert a tool with shaft diameter of 0.31 inches. (8mm) into the hole.
    2.  
    3. With the timing marks still aligned, the shaft of the tool must be able to go in at least 2 1 / 2 inches. If the tool can only go in about 1 in., the shaft is not in the correct orientation and will cause a vibration during engine operation. Remove the tool from the hole and turn the oil pump sprocket 1 complete revolution. Realign the timing marks and insert the tool. The shaft of the tool must go in at least 2 1 / 4 inches.
    4.  
    5. Recheck and realign the timing mark.
    6.  
    7. Leave the tool in place to hold the silent shaft while continuing.
    8.  

  2.  
  3. If the camshaft belt tensioner was removed, use a vise to carefully push the auto tensioner rod in until the set hole in the rod aligned up with the hole in the cylinder. Place a wire into the hole to retain the rod. Mount the tensioner to the engine block and tighten the mounting bolt to 17 ft. lbs. (23 Nm).
  4.  
  5. Install the belt to the crankshaft sprocket, oil pump sprocket, then camshaft sprocket, in that order. While doing so, make sure there is no slack between the sprocket except where the tensioner is installed.
  6.  
  7. To adjust the timing (outer) belt perform the following steps:
    1. Turn the crankshaft 1 / 4 turn counterclockwise, then turn it clockwise to move No. 1 cylinder to TDC.
    2.  
    3. Loosen the center bolt. Using tool MD998752 or equivalent and a torque wrench, apply a torque of 2.6 ft. lbs. (3.6 Nm). Tighten the center bolt.
    4.  
    5. Screw the special tool into the engine left support bracket until its end makes contact with the tensioner arm. At this point, screw the special tool in some more and remove the set wire attached to the auto tensioner, if the wire was not previously removed. Then remove the special tool.
    6.  
    7. Rotate the crankshaft two complete turns clockwise and let it sit for approximately 15 minutes. Then, measure the auto tensioner protrusion (the distance between the tensioner arm and auto tensioner body) to ensure that it is within 0.15-0.18 inch (3.8-4.5mm). If out of specification, repeat Step 1-4 until the specified value is obtained.
    8.  

  8.  

Do not manually overtigthen the belt or it will howl.

  1. Install the upper and lower timing belt covers. Tighten the bolts to the specifications shown in the accompanying figure.
  2.  



Click image to see an enlarged view

Fig. Fig. 36: Timing belt cover retainer specifications-2.4L engine

  1. Install the drive belts and properly adjust.
  2.  
  3. Reinstall the engine mount and bracket assembly and safely lower the engine.
  4.  
  5. Install the splash shield.
  6.  
  7. Connect the negative battery cable. Start the engine and let it idle.
  8.  
  9. Run engine until thermostat opens. Check and adjust ignition timing.
  10.  

 
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