REMOVAL & INSTALLATION CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. TIMING BELT & BALANCE SHAFT BELT Removal (Eclipse & Galant) 1. Raise and support vehicle. Remove engine splash shield from right side wheelwell. 2. Lower vehicle. Support weight of engine with floor jack. If necessary, remove coolant reservoir. Remove upper engine mount located near timing belt cover. Remove all drive belts. If necessary, remove drive belt tensioner pulley bracket and power steering pump pulley. See Fig. 1. Remove water pump pulley. 3. Remove crankshaft pulley. Noting bolt lengths and locations, remove upper and lower timing belt cover with gasket. CAUTION: DO NOT rotate crankshaft counterclockwise (as viewed from timing belt end of engine). If timing belt is to be reused, mark direction of rotation before removing. 4. Rotate crankshaft clockwise (as viewed from timing belt end of engine) until cylinder No. 1 is at TDC of compression stroke. Align timing mark on camshaft sprocket with timing mark on cylinder head. See Fig. 2. 5. Loosen timing belt tensioner center bolt, and move tensioner pulley toward water pump. Tighten center bolt to secure tensioner. Remove front timing belt. Remove tensioner pulley and timing belt auto tensioner. 6. To remove balance shaft belt, remove left balance shaft access plug from cylinder block. Insert.31" (8.0 mm) diameter Phillips screwdriver to block left silent shaft. See Fig. 3. Ensure screwdriver can be inserted at least 2.36" (59.9 mm). Remove screwdriver if it cannot be inserted at least 2.36" (59.9 mm). Rotate balance shaft one revolution and realign timing mark. 7. If reusing old balance shaft timing belt, mark belt with arrow to indicate rotation direction. Holding crankshaft stationary, remove front crankshaft sprocket bolt. Use gear puller to remove crankshaft sprocket from crankshaft. 8. Noting direction of installation, remove crankshaft sensing blade. Loosen balance shaft tensioner pulley center bolt. Remove balance shaft timing belt. Inspect timing belt. See TIMING BELT INSPECTION. Wednesday, March 24, 2010 4:06:38 4:06:41 PM Page 1 2005 Mitchell Repair Information Company, LLC.
Fig. 1: Exploded View Of Drive Belts & Timing Belt Components (Eclipse & Galant - 1994-98 Shown; 1999 & Up Is Similar) Wednesday, March 24, 2010 4:06:38 PM Page 2 2005 Mitchell Repair Information Company, LLC.
Fig. 2: Aligning Front Timing Belt Marks Wednesday, March 24, 2010 4:06:38 PM Page 3 2005 Mitchell Repair Information Company, LLC.
Fig. 3: Locking Balance Shaft Installation (Eclipse & Galant) 1. Align crankshaft rear sprocket and balance shaft sprocket timing marks. See Fig. 4. Install balance shaft timing belt. Ensure there is no slack in belt. If reusing old belt, install in original direction of rotation. 2. Ensure crankshaft components are clean. Install crankshaft sensing blade in correct direction. See Fig. 6. Install crankshaft sprocket. Apply engine oil to threads of crankshaft sprocket bolt. Install and tighten bolt to specification. See TORQUE SPECIFICATIONS. 3. Move the balance shaft tensioner pulley so that the center of the tensioner pulley is above and to the left of the centerline of the tensioner center bolt. See Fig. 5. The tensioner pulley flange should face toward the front of the engine. CAUTION: When tightening balance shaft tensioner pulley center bolt, ensure tensioner pulley shaft does not rotate with bolt. This will place excessive tension on bolt. 4. Using your hand, place pressure on balance shaft tensioner pulley in direction of balance shaft timing belt. Loosen balance shaft tensioner pulley center bolt. Ensure balance shaft timing belt is taut (no slack), and tighten balance shaft tensioner pulley center bolt. Wednesday, March 24, 2010 4:06:38 PM Page 4 2005 Mitchell Repair Information Company, LLC.
5. Press balance shaft belt on side opposite tensioner to check belt deflection. See Fig. 4. Balance shaft belt deflection should be.20-.28" (5.0-7.0 mm). Adjust as necessary. NOTE: DO NOT remove Phillips screwdriver from side of engine block until camshaft timing belt is installed. 6. Using a soft-jawed vise, SLOWLY compress the timing belt auto tensioner push rod until rod pin hole aligns with pin hole in tensioner body. Insert a locking pin through tensioner body and tensioner push rod pin holes to lock auto tensioner in position. Install auto tensioner on engine with locking pin in place. Install tensioner pulley. 7. Ensure all timing marks are still aligned. See Fig. 2. Install timing belt on crankshaft sprocket, oil pump sprocket, then camshaft sprocket. If reusing old timing belt, ensure belt is installed in original direction of rotation. Make sure there is no slack in timing belt between sprockets. 8. Set the timing belt tensioner pulley so that pin holes are at the bottom of the pulley. See Fig. 7. Press tensioner pulley lightly against the timing belt. Temporarily tighten tensioner pulley center bolt. CAUTION: To prevent breaking auto tensioner push rod, turn Set Screw (MD998738) by hand only. 9. Install Set Screw (MD998738) into rear timing belt cover. See Fig. 7. Screw in set screw by hand until tensioner bracket arm makes contact with auto tensioner push rod end. 10. Remove Phillips screwdriver from engine block and install plug. To adjust timing belt tension, turn crankshaft 1/4 revolution counterclockwise. Turn crankshaft clockwise until all timing marks are aligned. 11. Loosen the tensioner pulley center bolt. Install Adapter (MD998767) and torque wrench on tensioner pulley. See Fig. 8. Apply 31 INCH lbs. (3.5 N.m) of torque while tightening tensioner pulley center bolt to specification. See TORQUE SPECIFICATIONS. DO NOT let tensioner pulley turn while tightening center bolt. 12. Remove locking pin from auto tensioner. Remove set screw. 13. Turn crankshaft 2 revolutions clockwise. Align all timing marks. Let vehicle sit for 15 minutes. Measure auto tensioner rod protrusion between auto tensioner housing and point where it contacts tensioner arm. Protrusion should be.150-.177" (3.8-4.5 mm). If protrusion is not as specified, repeat timing belt tensioning procedure. 14. Install timing belt covers. Ensure bolts are installed in original locations. See Fig. 9. Continue installation in reverse order of removal procedure. Adjust drive belts to proper tension. Wednesday, March 24, 2010 4:06:38 PM Page 5 2005 Mitchell Repair Information Company, LLC.
Fig. 4: Aligning Balance Shaft Timing Marks Wednesday, March 24, 2010 4:06:38 PM Page 6 2005 Mitchell Repair Information Company, LLC.
Fig. 5: Adjusting Balance Shaft Timing Belt Tensioner Wednesday, March 24, 2010 4:06:38 PM Page 7 2005 Mitchell Repair Information Company, LLC.
Fig. 6: Installing Crankshaft Sensing Blade (Eclipse & Galant) Wednesday, March 24, 2010 4:06:38 PM Page 8 2005 Mitchell Repair Information Company, LLC.
Fig. 7: Installing Set Screw On Tensioner Pulley Wednesday, March 24, 2010 4:06:38 PM Page 9 2005 Mitchell Repair Information Company, LLC.
Fig. 8: Adjusting Timing Belt Tension Fig. 9: Timing Belt Cover Bolt Installation Locations Removal (Montero Sport) 1. Drain engine coolant. Remove upper radiator hose. Loosen the cooling fan clutch-to-pulley nuts. Remove accessory drive belts. Remove fan shroud and cooling fan clutch with pulley. CAUTION: Never rotate crankshaft counterclockwise. 2. Rotate crankshaft clockwise so that No. 1 piston is at TDC of compression stroke. Leaving secondary wires attached, remove distributor cap and set aside. 3. Note installed position of distributor and distributor rotor. Unplug distributor electrical connector. Remove distributor housing and set aside. 4. Disconnect ignition power transistor and ignition coil connector. Remove ignition coil. Remove timing Wednesday, March 24, 2010 4:06:38 PM Page 10 2005 Mitchell Repair Information Company, LLC.
belt upper cover. 5. Holding crankshaft stationary, remove crankshaft pulley bolt. Remove crankshaft pulley. Remove distributor bracket. See Fig. 10. 6. Remove timing belt lower cover. Align timing mark on camshaft sprocket with timing mark on cylinder head. See Fig. 2. 7. Loosen timing belt tensioner center bolt, and remove tensioner toward water pump. Tighten center bolt to secure tensioner. If reusing old timing belt, mark belt with arrow to indicate original direction of rotation. Remove timing belt. Remove timing belt auto tensioner. 8. To remove balance shaft timing belt, remove left balance shaft access plug from cylinder block. Insert.31" (8.0 mm) diameter Phillips screwdriver to block left silent shaft. See Fig. 3. Ensure screwdriver can be inserted at least 2.36" (59.9 mm). Remove screwdriver if it cannot be inserted at least 2.36" (59.9 mm). Rotate balance shaft one revolution and realign timing mark. 9. If reusing old balance shaft timing belt, mark belt with arrow to indicate rotation direction. Loosen balance shaft tensioner pulley center bolt. Remove balance shaft timing belt. Inspect timing belt. See TIMING BELT INSPECTION. Wednesday, March 24, 2010 4:06:38 PM Page 11 2005 Mitchell Repair Information Company, LLC.
Fig. 10: Exploded View Of Timing Belt & Components (Montero Sport) Installation (Montero Sport) 1. Align crankshaft sprocket and balance shaft sprocket timing marks. See Fig. 4. Install balance shaft timing belt. If reusing old belt, install in original direction of rotation. 2. Move the balance shaft tensioner pulley so that the center of the tensioner pulley is above and to the left of the centerline of the tensioner center bolt. See Fig. 5. The tensioner pulley flange should face toward the front of the engine. 3. Using your hand, place pressure on balance shaft tensioner pulley in direction of balance shaft timing belt. Loosen balance shaft tensioner pulley center bolt. Ensure balance shaft timing belt is taut (no slack), and tighten balance shaft tensioner pulley center bolt. Wednesday, March 24, 2010 4:06:38 PM Page 12 2005 Mitchell Repair Information Company, LLC.
NOTE: When tightening balance shaft tensioner pulley center bolt, ensure tensioner pulley shaft does not rotate with bolt. This will place excessive tension on belt. 4. Press balance shaft belt on side opposite tensioner to check belt deflection. See Fig. 4. Balance shaft belt deflection should be.20-.28" (5.0-7.0 mm). Adjust as necessary. 5. Using a soft-jawed vise, SLOWLY compress the timing belt auto tensioner push rod until rod pin hole aligns with pin hole in tensioner body. Insert a locking pin through tensioner body and tensioner push rod pin holes to lock auto tensioner in position. Install auto tensioner on engine with locking pin in place. 6. Ensure all timing marks are still aligned. See Fig. 2. Install timing belt on engine. If reusing old timing belt, ensure belt is installed in original direction of rotation. Make sure there is no slack in timing belt between sprockets. NOTE: DO NOT remove Phillips screwdriver from side of engine block until camshaft timing belt is installed. 7. Set the timing belt tensioner pulley so that pin holes are at the bottom of the pulley. See Fig. 7. Press tensioner pulley lightly against the timing belt. Temporarily tighten tensioner pulley center bolt. CAUTION: To prevent breaking auto tensioner push rod, turn Set Screw (MD998738) by hand only. 8. Install Set Screw (MD998738) into rear timing belt cover. See Fig. 7. Screw in set screw until tensioner bracket arm makes contact with auto tensioner push rod end. 9. Remove Phillips screwdriver from engine block and install plug. To adjust timing belt tension, turn crankshaft 1/4 revolution counterclockwise. Turn crankshaft clockwise until all timing marks are aligned. 10. Loosen the tensioner pulley center bolt. Install Adapter (MD998767) and torque wrench on tensioner pulley. See Fig. 8. Apply 31 INCH lbs. (3.5 N.m) of torque while tightening tensioner pulley center bolt to specification. See TORQUE SPECIFICATIONS. DO NOT let tensioner pulley turn while tightening center bolt. 11. Remove locking pin from auto tensioner. Remove set screw. 12. Turn crankshaft 2 revolutions clockwise. Align all timing marks. Let vehicle sit for 15 minutes. Measure auto tensioner rod protrusion between auto tensioner housing and point where it contacts tensioner arm. See Fig. 11, Dimension "A". Protrusion should be.150-.177" (3.8-4.5 mm). If protrusion is not as specified, repeat timing belt tensioning procedure. 13. Install timing belt lower cover, distributor bracket, and timing belt upper cover. Install distributor, distributor cap, and ignition coil. 14. Install cooling fan clutch, pulley, fan shroud, and upper radiator hose. Continue installation in reverse order of removal procedure. Fill and bleed cooling system. Adjust ignition timing. Wednesday, March 24, 2010 4:06:38 PM Page 13 2005 Mitchell Repair Information Company, LLC.
Fig. 11: Measuring Timing Belt Auto Tensioner Protrusion TIMING BELT INSPECTION 1. Inspect back of belt for being hard, non-elastic and having a glossy surface. Check for rounded sides on belt. Sides of belt should be straight and clear-cut. Flaking, peeling, cracking rubber from canvas also indicates that belt should be replaced. Cracks are most evident at base of tooth. 2. Abnormal wear most often occurs on load side of tooth. Fluffy canvas, unclear canvas texture, belt color changed to White from rubber missing, reduced tooth width or a missing tooth warrant belt replacement. 3. Check timing belt and balance shaft belt tensioner pulleys for worn bearings. Replace as necessary. 4. Check timing belt auto tensioner for leaks. Hold timing belt auto tensioner upright. Measure rod protrusion above edge of housing. See Fig. 12. Length should be.47" (12 mm). Apply 22-44 lbs. (20 kg) of force to end of rod. If auto tensioner rod moves more than 0.39" (1 mm), replace the auto tensioner. Wednesday, March 24, 2010 4:06:38 PM Page 14 2005 Mitchell Repair Information Company, LLC.
Fig. 12: Inspecting Timing Belt Auto Tensioner Wednesday, March 24, 2010 4:06:38 PM Page 15 2005 Mitchell Repair Information Company, LLC.