1995 Mitsubishi Montero LS. Ensure timing marks are aligned. Mark timing belt direction of rotation.

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Dwayne Powell
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1 TIMING BELT NOTE: Ensure timing marks are aligned. Mark timing belt direction of rotation. Removal 1. Disconnect negative battery cable. Drain engine coolant. Remove engine coolant reservoir tank, fan shroud and radiator. 2. Remove generator with wires attached, and secure out of way. Remove battery and battery tray. Remove engine lower splash shields. 3. Remove accessory drive belts. Remove cooling fan clutch assembly. See Fig. 1. Remove cooling fan pulley. Remove A/C compressor with hoses attached, and secure out of way. Remove A/C compressor bracket. 4. Remove power steering pump mount cover. Remove power steering pump with hoses attached, and secure out of way. Remove accessory mount. See Fig Remove timing belt upper cover. See Fig. 2. Disconnect crankshaft position sensor connector. Using Holder (MB990767) and Bolts (MB998754) or equivalent, hold crankshaft stationary while remove crankshaft pulley center bolt. 6. If reusing timing belt, place arrow on belt to indicate running direction. Rotate crankshaft to align all timing marks. See Fig. 3. Loosen timing belt tensioner center bolt. Remove timing belt and timing belt automatic tensioner. Page 1

2 Fig. 1: Exploded View Of Accessory Mount Components Page 2

3 Fig. 2: Exploded View Of Timing Belt & Components Page 3

4 Fig. 3: Aligning Timing Marks Inspection NOTE: Revised auto-tensioner procedure is from Mitsubishi technical service bulletin ; June, Inspect timing belt for wear on edges of drive teeth. Inspect belt for signs of oil contamination, cracks, separation, worn or missing teeth, or hardened black surface. Replace belt if worn, damaged or contaminated. Inspect belt tensioner pulley for smooth rotation. 2. Check timing belt automatic tensioner for leaks. Hold timing belt auto-tensioner upright. Measure rod protrusion above edge of housing. Length should be " ( mm). Apply lbs. (18-20 kg) of force to end of rod. If automatic tensioner rod moves more than 0.39" (1 mm), replace the automatic tensioner. Installation Page 4

5 1. Place automatic tensioner assembly in a soft-jawed vise. SLOWLY close vise to press rod back into tensioner until both rod and housing holes are aligned. Install a.055" (1.40 mm) diameter wire or drill bit through both holes. 2. Remove automatic tensioner from vise, and install assembly on engine with wire in place. Install crankshaft sprocket (if removed). Align timing marks on crankshaft and camshaft sprockets. See Fig. 3. CAUTION: Turning camshaft sprockets while No. 1 piston is at TDC may damage valve and piston. Use care when aligning timing marks. 3. To lower No. 1 piston from TDC and prevent valve and piston contact, turn crankshaft back 3 sprocket teeth (measured at timing mark). See Fig Starting with left (driver's side) bank of cylinders, verify intake and exhaust camshaft timing marks are correctly aligned with marks on rear timing belt cover. See Fig. 3. Rotate either camshaft sprocket clockwise to align timing marks. WARNING: Use care when aligning timing marks. Camshaft is under valve spring pressure and may rotate suddenly, pinching hand between sprockets. 5. Align camshaft timing marks on right (passenger's side) camshaft sprockets. See Fig. 3. Using box end wrenches, hold camshaft sprocket center bolts to prevent sprockets from turning. With right bank camshaft sprocket timing marks aligned with marks on rear timing belt cover, install timing belt on right bank camshaft sprockets. Hold camshaft sprockets in place with spring clips. See Fig Install timing belt around water pump pulley. With left bank camshaft sprockets correctly aligned, install timing belt on left hand camshaft sprocket. Secure timing belt onto sprockets with spring clips. 7. Install timing belt on the idler pulley. Realign the crankshaft sprocket timing mark with mark on oil pump housing. Turn crankshaft ONE turn counterclockwise (as viewed from front of engine). Set timing belt on crankshaft sprocket, then onto tensioner pulley. 8. Rotate timing belt tensioner pulley until pin holes are located above center bolt. See Fig. 6. Push tensioner pulley against belt, and temporarily tighten center bolt. Ensure all timing marks are still aligned, and remove spring clips. 9. Rotate crankshaft 1/4 revolution counterclockwise. Rotate crankshaft clockwise until timing marks are realigned. Loosen tensioner center bolt. 10. Using Tensioner Pulley Socket (MD998767) or equivalent, apply approximately 83 INCH lbs. (9.4 N.m) torque to tensioner pulley in a clockwise direction. Holding tensioner pulley to prevent it from turning, final tighten center bolt to 35 ft. lbs. (48 N.m). Ensure tensioner pulley does not rotate while tightening center bolt. 11. Remove set pin or drill bit from automatic tensioner. Rotate crankshaft 2 revolutions clockwise. Wait 5 minutes. Verify wire or drill bit can still be easily removed and installed. 12. Even if set pin or drill bit cannot be easily installed, the automatic tensioner is normal if its push rod protrusion is within " ( mm). Measure push rod protrusion between top of tensioner body and lever arm of tensioner pulley lever. See Fig If push rod protrusion is out of specification, timing belt tension adjustment will have to be repeated. Page 5

14. Install timing belt covers. Install crankshaft pulley. Tighten crankshaft pulley bolt to specification. See TORQUE SPECIFICATIONS. 15. Install generator. Install accessory mount.

6 14. Install timing belt covers. Install crankshaft pulley. Tighten crankshaft pulley bolt to specification. See TORQUE SPECIFICATIONS. 15. Install generator. Install accessory mount. Install power steering pump and A/C compressor. Install cooling fan. Install accessory drive belts. CAUTION: On later model years, the sealing washer under the cooling system air bleed bolt was reduced to.85 mm from 2.0 mm. The.85 mm washer CANNOT be reused. Replace washer if bolt is loosened or removed. This information is from Mitsubishi technical service bulletin ; February, Install radiator. Before refilling cooling system, remove air bleed bolt on top of thermostat housing. Refill cooling system with 50/50 mix of water and coolant until it overflows from air bleed bolt hole. Install air bleed bolt with new.85 mm washer (if equipped). 17. Start engine and run to normal operating temperature. Race engine to 3000 RPM several times. Stop engine. After engine cools, refill radiator. 18. To complete installation, reverse removal procedure. Tighten all nuts and bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. Fig. 4: Positioning Crankshaft For Timing Belt Installation Page 6

7 Fig. 5: Securing Timing Belt With Spring Clips Page 7

8 Fig. 6: Adjusting Timing Belt Tension Page 8

9 Fig. 7: Measuring Push Rod Protrusion TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Accessory Mount Bolts 10 x 80 mm (38-41) 10 x 100 mm (43-46) 12 x 100 mm (72-75) Automatic Tensioner Bolt 17 (24) Camshaft Sprocket Bolt 64 (88) Crankshaft Pulley Center Bolt ( ) Power Steering Pump Bolt (38-41) Timing Belt Tensioner Arm Pivot Bolt 33 (44) Timing Belt Tensioner Pulley Bolt 35 (48) INCH Lbs. (N.m) Coolant Air Bleed Bolt (9-11) Cooling Fan-To-Pulley Bolt (10-12) Page 9

10 Crankshaft Position Sensor 80 (9) Radiator Mounting Bolt/Nut 62 (7) Timing Belt Cover Bolt (10-12) Page 10

2002 Mitsubishi Montero Limited

2002 Mitsubishi Montero Limited Fig. 9: Removing Drive Belt Auto Tensioner (2001-02 Montero) Sunday, December 07, 2008 2:19:07 2:19:11 PM Page 1 2005 Mitchell Repair Information Company, LLC. Fig. 10: Exploded View Of Timing Belt Components