Mitsubishi Outlander 2003-06

Timing Belt & Sprockets

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Engine undercover
     
    Drive belt
     
    Crankshaft damper pulley
     
    Control wiring harness connection
     
    Battery wiring harness connection
     
    Connector
     
    Engine front mounting bracket
     
    Harness bracket
     
    Upper timing belt cover
     
    Water pump pulley
     
    Idler pulley
     
    Auto-tensioner
     
    Lower timing belt cover
     

  4.  
  5. Position the engine so that the No. 1 piston is at Top Dead Center (TDC).
    NOTE
    If the 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.



    Click image to see an enlarged view

    Fig. Timing mark alignment

  6.  
  7. To loosen the timing (outer) belt tensioner, remove the rubber plug, then install Mitsubishi Special tool MD998738 to the slot and screw inward until the it contacts the timing belt tensioner arm.
  8.  
  9. Gradually screw in the tool, then align the timing belt tensioner adjuster rod set hold A with the timing belt tensioner adjusted cylinder set hole B.
  10.  
  11. Insert a wire or pin in the set hole aligned.
  12.  
  13. Loosen the timing belt tensioner pulley bolts and remove the outer timing belt.
  14.  
  15. Remove or disconnect the following:

    Timing belt tensioner pulley
     
    Timing belt tensioner arm
     
    Timing belt tensioner adjuster
     
    Timing belt idler pulley
     
    Timing belt lower cover bracket
     
    Crankshaft Position (CKP) sensor
     

  16.  
  17. Hold the crankshaft/camshaft drive sprocket with Mitsubishi Special tools MD991367 and MD991385. Loosen the crankshaft pulley center bolt, then remove the crankshaft pulley washer and sprocket.

    Crankshaft angle sensing blade
     
    Balancer timing belt tensioner and balancer timing (inner) belt.

    Click image to see an enlarged view

    Fig. Outer timing belt and related components



    Click image to see an enlarged view

    Fig. Inner timing belt and related components

     

  18.  

To install:

Click image to see an enlarged view

Fig. Proper alignment of the timing belt sprocket marks for belt service


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 balancer shaft sprockets and the crankshaft sprocket with the timing marks on the front case. Route 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.

    Click image to see an enlarged view

    Fig. Timing belt -B- (balancer belt) installation mark alignment

  2.  
  3. Assemble and temporarily hold the center of the balancer timing belt tensioner pulley so it is at the top left from the center of the assembling bolt, and the pulley flange is at the front side of the engine.
    NOTE
    When tightening the mounting bolts, make sure the tensioner does not turn with the bolts.



    Click image to see an enlarged view

    Fig. Assemble and temporarily hold the center of the balancer belt tensioner pulley so it-s at the top left from the center of the assembling bolt, and the pulley flange is at the front side of the engine

  4.  
  5. Adjust the balancer belt tension as follows:
    1. Use your fingers to lift the tensioner in the direction of the arrow shown in the accompanying figure. Apply 22-30 inch lbs. (2.6-3.4 Nm) to the timing belt so the belt is taut without any looseness.
    2.  
    3. Tighten the assembling bolt to 12-16 ft. lbs. (16-22 Nm). Then, fix the timing belt tensioner.
    4.  
    5. Turn the crankshaft clockwise 2 revolutions to set the No. 1 cylinder to TDC of its compression stroke and check that the timing marks are still aligned.
    6.  
    7. Apply about 22 lbs. (100 N) of pressure to the center area between the sprockets, then check the belt deflection. It should measure 0.20-0.27 in. (5-7mm). If not within specifications, adjust the belt tension again.

      Click image to see an enlarged view

      Fig. Lift the tensioner in the direction of the arrow, then apply 22-30 inch lbs. (2.6-3.4 Nm) of pressure to the timing belt so the it is taut without any looseness

    8.  

  6.  
  7. Clean the crankshaft, crankshaft angle sensing blade, drive sprocket and crankshaft pulley washer, as shown.
  8.  
  9. Install the crankshaft angle sending blade and drive sprocket in the direction shown in the accompanying figure.

    Click image to see an enlarged view

    Fig. Crankshaft, sensing blade, drive sprocket and pulley washer cleaning and installation direction

  10.  
  11. Place the larger chamfer side of the pulley washer in the direction shown, and then assemble on the crankshaft pulley center bolt.
  12.  
  13. Apply a small amount of engine oil to the crankshaft pulley center bolt bearing surface and screw.
  14.  
  15. Hold the drive sprocket with Mitsubishi Special tool nos. MB991367 and MD991385, then torque the center bolt to 123 ft. lbs. (167 Nm).
  16.  
  17. Install or connect the following:

    CKP sensor
     
    Timing belt lower cover bracket
     
    Timing belt idler pulley
     

  18.  
  19. Install the timing belt tensioner arm as follows:
    1. If the adjuster rod is fully extended, use a vise to slowly compress the timing belt adjuster rod and align set hole -A-. Insert a pin or wire into the holes. If installing a new tensioner, it will already be set with a pin.
    2.  
    3. Install the tensioner and tighten the bolts 15-19 ft. lbs. (20-26 Nm). Do not remove the pin until the timing belt is tensioned.
    4.  

  20.  
  21. Install the timing belt tensioner arm.
  22.  
  23. Install the timing belt tensioner pulley. Temporarily tighten the pulley as shown in the accompanying figure.

    Click image to see an enlarged view

    Fig. Temporary alignment of the timing belt tensioner pulley

  24.  
  25. Align the timing marks on the camshaft sprocket, crankshaft camshaft drive sprocket and engine oil pump sprocket.

    Click image to see an enlarged view

    Fig. Timing mark and sprocket alignment

  26.  
  27. Adjust the timing mark of the engine oil pump sprocket as follows:
    1. Unplug the cylinder block plug.
    2.  
    3. Insert a bolt (M6, section width 10mm, 45mm long) into the plug hole.
    4.  
    5. If the bolt contacts the balancer shaft, turn the oil sprocket 1 rotation.
    6.  
    7. Re-adjust the timing mark, and then check to make sure the bolt fits. Do not remove the bolt until the timing belt is assembled.
    8.  

  28.  
  29. Install the timing belt as follows:
    1. Place the belt on the timing belt tensioner pulley and cam/crank drive sprocket, then support it with your left hand so it does not slide.
    2.  
    3. Place the timing belt on the engine oil pump sprocket while pulling it with your right hand.
    4.  
    5. Place the belt on the timing belt idler pulley.
      WARNING
      Rotate the camshaft sprocket counter-clockwise. Make sure the timing marks are properly aligned, while the tension side of the belt is correct.

    6.  
    7. Place the timing belt on the camshaft sprocket.
    8.  
    9. Turn the timing belt tensioner pulley in the direction shown, using Mitsubishi special tool MD998767 to apply tension to the timing belt. Temporarily tighten and fix the tensioner pulley mounting bolt.
    10.  
    11. Make sure the timing marks and still aligned.
    12.  
    13. Remove the bolt from the cylinder block plug hole.
    14.  
    15. Install the plug and tighten to 21-25 ft. lbs. (27-33 Nm).
    16.  

  30.  
  31. Adjust the timing belt tension as follows:
    1. Set Mitsubishi Special tool no. MD998738, used during belt removal.
    2.  
    3. Gradually screw the special tool to a position in which the wire or pin inserted in the tensioner adjuster moves slightly.
    4.  
    5. Rotate the crankshaft counter-clockwise 1 / 4 -turn.
    6.  
    7. Rotate the crankshaft clockwise, aligning each timing mark to set the No. 1 cylinder to TDC.
    8.  
    9. Loosen the tensioner pulley mounting bolt.
      WARNING
      When tightening the mounting bolt, make sure the pulley does not rotate with the bolt.

    10.  
    11. Using a torque wrench and Mitsubishi Special tool no. MD998767, apply 31 inch lbs. (3.5 Nm) of pressure to the timing belt, then install the tensioner pulley bolt and tighten to 33-39 ft. lbs. (43-53 Nm).
    12.  
    13. Remove the wire or pin from the tensioner adjuster.
    14.  
    15. Remove Mitsubishi Special tool no. MD998738, and install the rubber plug to the timing belt undercover.
    16.  
    17. Rotate the crankshaft 2 full rotations in the clockwise direction, then wait 15 minutes to continue the procedure.
    18.  
    19. Insert the wire or pin removed in Step G, and make sure it can be pulled out with a light load. When it can be lightly removed, the timing belt is tensioned properly. If so, remove the pin.
    20.  
    21. If the projection of the timing belt tensioner adjuster rod is within 0.15-0.17 inch. (3.8-4.5mm), proper tension is applied.
    22.  
    23. If the wire or pin cannot be removed easily, the timing belt tension must be readjusted.
      NOTE
      Always check the torque of the crankshaft pulley center bolt when turning the crankshaft pulley center bolt counterclockwise. Retighten the bolt if it becomes loose.

    24.  
    25. Make sure the timing marks are aligned.
    26.  

  32.  
  33. Install or connect the following:

    Timing belt lower cover
     
    Auto-tensioner
     
    Idler pulley and tighten the bolt to 56-62 ft. lbs. (74-84 Nm)
     
    Water pump pulley. Torque the bolt to 69-87 inch lbs. (7.8-9.8 Nm).
     
    Timing belt upper cover
     
    Harness bracket
     
    Connector bracket
     
    Battery wiring harness connection
     
    Control wiring harness connection
     
    Crankshaft damper pulley. Torque the bolt to 18 ft. lbs. (25 Nm).
     
    Engine undercover
     

  34.  

 
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