Mitsubishi Endeavor 2004-06

Timing Belt, Cover, Sprockets, & Seal

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine under cover and side under cover
     
    Drive belts
     
    Crankshaft pulley, using special tools MB991800 and MB991802
     
    Manifold Differential Pressure (MDP) sensor connector
     
    Knock Sensor (KS) connector
     
    Crankshaft Position (CKP) sensor connector
     
    Control wiring harness and injector wiring harness combination connector
     
    Right bank Heated Oxygen Sensor (HO2S) connectors
     
    Connector bracket
     
    Engine mount stay
     
    Right and left timing belt upper covers
     
    Tensioner pulley
     
    Tensioner bracket
     
    CKP sensor harness clamp
     
    Lower timing belt cover
     
    Engine mount
     
    Engine support bracket
     

  6.  
  7. 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.
  8.  
  9. Loosen the center bolt of the tension pulley, and then remove the timing belt.

    Auto tensioner
     
    Tensioner pulley
     
    Tensioner arm
     
    Shaft
     



    Click image to see an enlarged view

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

  10.  


    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.  
  3. 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.
  4.  
  5. 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.
  6.  


NOTE
If you are installing a new auto-tensioner, the pin will already be inserted into the pin holes of the new tensioner.

  1. Install the auto-tensioner.
  2.  
  3. Align the camshaft and crankshaft TDC timing marks.
  4.  
  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.  
  7. Turn the camshaft sprocket counterclockwise until the tension side of the timing belt is firmly stretched, then, recheck the timing marks.
  8.  
  9. Using the Tension Pulley Socket Wrench tool MD998767, or equivalent, push the tensioner pulley into the timing belt and secure the center bolt.
  10.  
  11. Using the Crankshaft Pulley Spacer tool MD998769, or equivalent, rotate the crankshaft14
  12.  
  13. 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).
  14.  
  15. Remove the setting pin from the auto-tensioner.
  16.  
  17. 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 0.19-0.24 in. (4.8-6.0mm), repeat the adjustment procedure. If the standard value is still not achieved, replace the auto-tensioner.

    Install or connect the following:
     



    Engine support bracket
     
    Engine mount
     
    Lower timing belt cover
     
    CKP sensor harness clamp
     
    Tensioner bracket
     
    Tensioner pulley
     
    Left and right upper timing belt covers
     
    Engine mount stay
     
    Connector bracket
     
    HO2S connectors
     
    Wiring harness and injector connector
     
    CKP sensor connector
     
    KS connector
     
    MDP sensor connector
     

  18.  
  19. Install the crankshaft pulley. Using Pulley Holder MB991800 and the 2 Crankshaft Pulley Holder Pin tools MD991802, or equivalent to hold the crankshaft pulley, and a socket torque wrench, torque the crankshaft pulley bolt to 136 ft. lbs. (185 Nm).

    Drive belts
     
    Side under cover
     
    Under cover
     
    Negative battery cable
     



    Click image to see an enlarged view

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

  20.  
  21. Refill the cooling system.
  22.  

 
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