Timing Cover and Belt

REMOVAL & INSTALLATION

NOTE: Refer to Section 1 for the proper timing belt service interval.

1.5L Engine

1990 — 94 MODELS

1. Disconnect the negative battery cable.
2. Remove the engine under cover.
3. Raise and safely support the weight of the engine using the appropriate equipment. Remove the front engine mount bracket and accessory drive belts.
4. If necessary, remove the coolant reservoir tank.
5. Using the proper equipment, slightly raise the engine to take the weight off the side engine mount. Remove the engine mount bracket.
6. Remove the drive belts, tension pulley brackets, water pump pulley and crankshaft pulley.
7. Remove all attaching screws and remove the upper and lower timing belt covers.
8. 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. Loosen the timing belt tensioner and remove the timing belt.

   NOTE: If coolant or engine oil comes in contact with the timing belt, they will drastically shorten its life. Also, do not allow engine oil or coolant to contact the timing belt sprockets or tensioner assembly.

9. Remove the tensioner spacer, tensioner spring and tensioner assembly.
10. Inspect the timing belt for cracks on back surface, sides, bottom and check for separated canvas. Check the tensioner pulley for smooth rotation.

    To install:

11. Position the tensioner, tensioner spring and tensioner spacer on engine block.

    Fig. 1: Exploded view of the timing belt covers, timing belt and related parts — 1990–94 1.5L engine

    Fig. 2: Camshaft and crankshaft sprocket mark alignment for proper timing belt installation — 1990–94 1.5L engine

12. Align the timing marks on the camshaft sprocket and crankshaft sprocket. This will position No. 1 piston on TDC on the compression stroke.
13. Position the timing belt on the crankshaft sprocket and keeping the tension side of the belt tight, set it on the camshaft sprocket.
14. Apply counterclockwise force to the camshaft sprocket to give tension to the belt and make sure all timing marks are aligned.
15. Loosen the pivot side tensioner bolt and the slot side bolt. Allow the spring to take up the slack.
16. Tighten the slot side tensioner bolt and then the pivot side bolt. If the pivot side bolt is tightened first, the tensioner could turn with bolt, causing over tension.
17. Turn the crankshaft clockwise. Loosen the pivot side tensioner bolt and then the slot side bolt to allow the spring to take up any remaining slack. Tighten the slot bolt and then the pivot side bolt to 14–20 ft. lbs. (20–27 Nm).
18. Check the belt tension by holding the tensioner and timing belt together by hand and give the belt a slight thumb pressure at a point level with tensioner center. Make sure the belt cog crest comes as deep as about ¹⁄₄ of the width of the slot side tensioner bolt head. Do not manually overtighten the belt or it will make a howling noise.
19. Install the timing belt covers and all related items.
20. Connect the negative battery cable.

1995–00 MODELS

1. Disconnect the negative battery cable.
2. Remove the engine undercover.
3. Rotate the crankshaft clockwise and position the engine at TDC of the compression stroke.
4. Raise and safely support the weight of the engine using the appropriate equipment. Remove the A/C clamp, front engine mount bracket and accessory drive belts.
5. Remove the crankshaft pulley.
6. Remove timing belt upper and lower covers.
7. 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. Loosen the timing belt tensioner and move the tensioner to provide slack to the timing belt. Tighten the tensioner in this position.
8. Remove the timing belt.

   WARNING
   Coolant and engine oil will damage the rubber in the timing belt, drastically reducing its life. Do not allow engine oil or coolant to contact the timing belt, the sprockets or tensioner assembly.

9. If defective, remove the tensioner spacer, tensioner spring and tensioner assembly.

   Fig. 3: Align the timing belt sprockets as indicated before removing the timing belt — 1995–00 1.5L engine

   To install:

10. Position the tensioner, tensioner spring and tensioner spacer on engine block.
11. Align the timing marks on the camshaft sprocket and crankshaft sprocket. This will position No. 1 piston on TDC on the compression stroke.
12. Position the timing belt on the crankshaft sprocket and keeping the tension side of the belt tight, set it on the camshaft sprocket, then the tensioner.
13. Apply slight counterclockwise force to the camshaft sprocket to give tension to the belt and be sure all timing marks are aligned.
14. Loosen the pivot side tensioner bolt and the slot side bolt. Allow the spring to remove the slack.
15. Tighten the slot side tensioner bolt, then the pivot side bolt. If the pivot side bolt is tightened first, the tensioner could turn with bolt, causing over tension.
16. Turn the crankshaft clockwise. Loosen the pivot side tensioner bolt, then the slot side bolt to allow the spring to take up any remaining slack. Tighten the slot bolt, then the pivot side bolt to 17 ft. lbs. (24 Nm).
17. Install the timing belt covers and tighten the cover bolts to 84–96 inch lbs. (10–11 Nm). Install all other applicable components.

1.6L & 2.0L (Non-Turbo) DOHC Engines

NOTE: The 1.6L engine is not equipped with silent shafts. Disregard all instructions pertaining to silent shafts if working on that engine.

1. Disconnect the negative battery cable.
2. Remove the engine undercover.
3. If necessary, remove the coolant reservoir.
4. Using the proper equipment, slightly raise the engine to take the weight off the side engine mount. Remove the engine mount bracket.
5. Remove the drive belts, tension pulley brackets, water pump pulley and crankshaft pulley.
6. Remove all attaching screws and remove the upper and lower timing belt covers.
7. 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.

   NOTE: 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.

8. Remove the auto tensioner and remove the outermost timing belt.
9. Remove the timing belt tensioner pulley, tensioner arm, idler pulley, oil pump sprocket, special washer, flange and spacer.
10. Remove the silent shaft (inner) belt tensioner and remove the belt.

    To install:

11. 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.

    Fig. 4: Camshaft and crankshaft timing belt sprocket alignment marks — 1990–94 Mitsubishi 1.6L and 2.0L DOHC engines

12. 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.

    NOTE: 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.

13. Check belt for proper tension by depressing the belt on it's 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.
14. 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).
15. 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).
16. Using a wrench, hold the camshaft at it's hexagon between journal No. 2 and 3, then tighten the bolt 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 retainer bolt.
17. Carefully push the auto tensioner rod in until the set hole in the rod aligns with the hole in the cylinder. Place a wire into the hole to retain the rod.
18. 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.
19. 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 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.

    NOTE: 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.

20. Align the crankshaft sprocket and oil pump sprocket timing marks.
21. 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.

    NOTE: 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.

22. 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. 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.
    3. Install the timing belt around the idler pulley, oil pump sprocket, crankshaft sprocket and the tensioner pulley. Remove the 2 spring clips.
    4. Lift upward on the tensioner pulley in a clockwise direction and tighten the center bolt. Make sure all timing marks are aligned.
    5. Rotate the crankshaft ¹⁄₄ turn counterclockwise. Then, turn in clockwise until the timing marks are aligned again.
23. To adjust the timing (outer) belt, turn the crankshaft ¹⁄₄ turn counterclockwise, then turn it clockwise to move No. 1 cylinder to TDC.
24. Loosen the center bolt. Using tool MD998738 or equivalent and a torque wrench, apply a torque of 22–25 inch. lbs. (2.6–2.8 Nm). Tighten the center bolt.
25. 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.
26. 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.
27. 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. 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.
    3. Install the rubber plug to the timing belt rear cover.
28. Install the timing belt covers and all related items.
29. Connect the negative battery cable.

1.8L & 2.0L SOHC Engines

1. Position the engine so the No. 1 piston is at TDC of the compression stroke.
2. Disconnect the negative battery cable.
3. Remove the engine undercover.
4. Using the proper equipment, slightly raise the engine to take the weight off the side engine mount. Remove the engine mount bracket.
5. Remove the drive belts, tension pulley brackets, water pump pulley and crankshaft pulley.
6. Remove all attaching screws and remove the upper and lower timing belt covers.
7. Remove the timing belt covers.
8. Remove the outer crankshaft sprocket and flange.
9. Remove the silent shaft (inner) belt tensioner and remove the belt.

   To install:

10. Align the timing marks of the silent shaft sprockets and the crankshaft sprocket with the timing marks on the front case.
11. 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.
12. Install the tensioner pulley and move the pulley by hand so the long side of the belt deflects about ¹⁄₄ in. (6mm).

    Fig. 5: Camshaft and crankshaft sprocket alignment for proper timing belt replacement — 1.8L and 2.0L SOHC engines

    Fig. 6: Silent shaft sprocket alignment marks for belt replacement — 1.8L and 2.0L SOHC engines

    Fig. 7: Checking the rear silent shaft for proper positioning — 1.8L and 2.0L SOHC engines

13. Hold the pulley tightly so the pulley cannot rotate when the bolt is tightened. Tighten the bolt to 15 ft. lbs. (20 Nm) and recheck the deflection amount.
14. 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.
15. Align the timing marks of the camshaft, crankshaft and oil pump sprockets with their corresponding marks on the front case or rear cover.

    NOTE: 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.

16. 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. With the timing marks still aligned, the shaft of the tool must be able to go in at least 2 ¹⁄₃ in. (59mm). If the tool can only go in about 1 in. (25mm), 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. (59mm).
    3. Recheck and realign the timing marks.
    4. Leave the tool in place to hold the silent shaft while continuing.
17. 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.
18. Recheck the timing marks' alignment. If all are aligned, loosen the tensioner mounting bolt and allow the tensioner to apply tension to the belt.
19. 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 overtighten the belt or it will howl.
20. Tighten the lower mounting bolt first, then the upper spacer bolt.
21. To verify correct belt tension, check that the deflection at the longest span of the belt is about ¹⁄₂ in. (13mm).
22. The installation of the timing belt covers and all related items, is the reverse of the removal procedure. Make sure all pieces of packing are positioned in the inner grooves of the covers when installing.
23. Connect the negative battery cable.

2.0L (Turbo) DOHC Engine

1. Disconnect the negative battery cable.
2. Remove the engine undercover.
3. Remove the engine mount bracket.
4. Remove the drive belts.
5. Remove the belt tensioner pulley.
6. Remove the water pump pulleys.
7. Remove the crankshaft pulley.
8. Remove the stud bolt from the engine support bracket and remove the timing belt covers.
9. Rotate the crankshaft clockwise to line up the camshaft timing marks. Always turn the crankshaft in the normal direction of rotation only.
10. Loosen the tension pulley center bolt.

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

11. Move the tension pulley towards the water pump and remove the timing belt.
12. 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.
13. Mark the direction of rotation on the timing belt B with a arrow.
14. Loosen the center bolt on the tensioner and remove the belt.

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

    Fig. 8: Camshaft and crankshaft timing belt sprocket TDC alignment mark positioning for timing belt removal and installation — 2.0L turbo engine

    To install:

15. 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).
16. Align the timing marks on the crankshaft sprocket B and the balance shaft.
17. 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.
18. 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. (5–7mm) when finger pressure is applied between the pulleys.
19. 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).
20. Use a press or vise to compress the auto-tensioner pushrod. Insert a set pin when the holes are lined up.

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

21. Install the auto-tensioner on the engine.
22. Align the timing marks on the camshaft sprocket, crankshaft sprocket and the oil pump sprocket.
23. After aligning the mark on the oil pump sprocket, remove the cylinder block plug and insert a prytool in the hole to check the position of the counterbalance shaft. The prytool should go in at least 2.36 in. (60mm) or more, if not, rotate the oil pump sprocket once and realign the timing mark so the prytool goes in. Do not remove the prytool until the timing belt is installed.
24. Install the timing belt on the intake camshaft and secure it with a clip.
25. Install the timing belt on the exhaust camshaft.

    Fig. 9: Timing belt B installation mark alignment — 2.0L turbo

26. Align the timing marks with the cylinder head top surface using two wrenches. Secure the belt with another clip.
27. Install the belt around the idler pulley, oil pump sprocket, crankshaft sprocket and the tensioner pulley.
28. Turn the tensioner pulley so the pinholes are at the bottom. Press the pulley lightly against the timing belt.
29. 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).
30. Turn the crankshaft ¹⁄₄ turn counterclockwise, then clockwise until the timing marks are aligned.
31. Loosen the center bolt. Install Mitsubishi Special Tool MD998767, or equivalent, on the tensioner pulley. Turn the tensioner 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 tensioner pulley turn when tightening the bolt.
32. Turn the crankshaft clockwise two revolutions and align the timing marks.
33. After 15 minutes, measure the protrusion of the pushrod on the auto-tensioner. The standard measurement is 0.150–0.177 in (3.8–4.5mm). If the protrusion is out of specification, loosen the tensioner pulley, apply the proper torque to the belt and retighten the center bolt.
34. Install the timing belt covers and all applicable components.

2.4L Engine

1. Be sure that the engine's No. 1 piston is at TDC in the compression stroke.

   CAUTION
   Wait at least 90 seconds after the negative battery cable is disconnected to prevent possible deployment of the air bag.

2. Disconnect the negative battery cable.
3. Remove the spark plug wires from the tree on the upper cover.
4. Drain the cooling system.

   CAUTION
   Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

5. Remove the shroud, fan and accessory drive belts.
6. Remove the radiator as required.
7. Remove the power steering pump, alternator, air conditioning compressor, tension pulley and accompanying brackets, as required.
8. Remove the upper front timing belt cover.
9. Remove the water pump pulley and the crankshaft pulley(s).
10. Remove the lower timing belt cover mounting screws and remove the cover.
11. If the belt(s) are to be reused, mark the direction of rotation on the belt.
12. Remove the timing (outer) belt tensioner and remove the belt. Unbolt the tensioner from the block and remove.
13. Remove the outer crankshaft sprocket and flange.
14. Remove the silent shaft (inner) belt tensioner and remove the inner belt. Unbolt the tensioner from the block and remove it.
15. To remove the camshaft sprockets, use SST MB990767–01 and MIT308239, or their equivalents.

    Fig. 26: Silent shaft alignment marks. Notice the tension side of the inner (silent shaft) belt — 2.4L engine

    Fig. 27: Timing belt pulley alignment marks — 2.4L engine

    To install:

16. Install the camshaft sprockets and tighten the center bolt to 65 ft. lbs. (90 Nm).
17. Align the timing mark of the silent shaft belt sprockets on the crankshaft and silent shaft with the marks on the front case. Wrap the silent shaft belt around the sprockets so there is no slack in the upper span of the belt and the timing marks are still in line.
18. Install the tensioner initially so the actual center of the pulley is above and to the left of the installation bolt.
19. Move the pulley up by hand so the center span of the long side of the belt deflects about ¹⁄₄ in. (6mm).
20. Hold the pulley tightly so it does not rotate when the bolt is tightened. Tighten the bolt to 15 ft. lbs. (20 Nm). If the pulley has moved, the belt will be too tight.
21. Install the timing belt tensioner fully toward the water pump and temporarily tighten the bolts. Place the upper end of the spring against the water pump body. Align the timing marks of the cam, crankshaft and oil pump sprockets with the corresponding marks on the front case or head.

    NOTE: If the following steps are not followed exactly, there is a chance that the silent shaft alignment will be 180 degrees off. This will cause a noticeable vibration in the engine and the entire procedure will have to be repeated.

22. Before installing the timing belt, ensure that the left side silent shaft is in the correct position.

    NOTE: It is possible to align the timing marks on the camshaft sprocket, crankshaft sprocket and the oil pump sprocket with the left balance shaft out of alignment.

23. With the timing mark on the oil pump pulley aligned with the mark on the front case, check the alignment of the left balance shaft to assure correct shaft timing.
    1. Remove the plug located on the left side of the block in the area of the starter.
    2. Insert a tool having a shaft diameter of 0.3 in. (8mm) into the hole.
    3. With the timing marks still aligned, the tool must be able to go in at least 2 ¹⁄₃ in. (59mm). If it can only go in about 1 in. (25mm), turn the oil pump sprocket one complete revolution.
    4. Recheck the position of the balance shaft with the timing marks realigned. Leave the tool in place to hold the silent shaft while continuing.
24. Install the belt to the crankshaft sprocket, oil pump sprocket and the camshaft sprocket, in that order. While doing so, be sure there is no slack between the sprockets except where the tensioner will take it up when released.
25. Recheck the timing marks' alignment.
26. If all are aligned, loosen the tensioner mounting bolt, and allow the tensioner to apply tension to the belt.
27. Remove the tool that is holding the silent shaft in place and turn the crankshaft clockwise a distance equal to two teeth of the camshaft sprocket. This will allow the tensioner to automatically tension the belt the proper amount.

    WARNING
    Do not manually apply pressure to the tensioner. This will overtighten the belt and will cause a howling noise.

28. First tighten the lower mounting bolt and then tighten the upper spacer bolt.

    WARNING
    If any binding is felt when adjusting the timing belt tension by turning the crankshaft,

    STOP turning the engine, because the pistons may be hitting the valves.

29. To verify that belt tension is correct, check that the deflection of the longest span (between the camshaft and oil pump sprockets) is ¹⁄₂ in. (13mm).
30. Install the lower timing belt cover. Be sure the packing is properly positioned in the inner grooves of the covers when installing.
31. Install the water pump pulley and the crankshaft pulley(s).
32. Install the upper front timing belt cover.
33. Install the power steering pump, alternator, air conditioning compressor, tension pulley and accompanying brackets, as required.
34. Install the radiator, shroud, fan and accessory drive belts.
35. Install the spark plug wires to the tree on the upper cover.
36. Refill the cooling system.
37. Connect the negative battery cable. Start the engine and check for leaks.

3.0L SOHC Engine

1992–94 MODELS

1. Disconnect the negative battery cable.
2. Remove the engine undercover.
3. Remove the cruise control actuator.
4. Remove the accessory drive belts.
5. Remove the air conditioner compressor tension pulley assembly.
6. Remove the tension pulley bracket.
7. Using the proper equipment, slightly raise the engine to take the weight off the side engine mount. Remove the engine mounting bracket.
8. Detach the power steering pump pressure switch connector. Remove the power steering pump and wire aside.
9. Remove the engine support bracket.
10. Remove the crankshaft pulley.
11. Remove the timing belt cover cap.
12. Remove the timing belt upper and lower covers.
13. If the same timing belt will be reused, mark the direction of the timing belt's rotation for installation in the same direction. Make sure the engine is positioned so the No. 1 cylinder is at the TDC of its compression stroke and the sprockets' timing marks are aligned with the engine's timing mark indicators.

    Fig. 28: Exploded view of the timing belt covers, timing belt and related parts — 1992–94 Mitsubishi 3.0L SOHC engine

    Fig. 29: Crankshaft and camshaft sprocket alignment for proper timing belt replacement — 1992–94 Mitsubishi 3.0L SOHC engine

14. Loosen the timing belt tensioner bolt and remove the belt. If the tensioner is not being removed, position it as far away from the center of the engine as possible and tighten the bolt.
15. If the tensioner is being removed, paint the outside of the spring to ensure that it is not installed backwards. Unbolt the tensioner and remove it along with the spring.

    To install:

16. Install the tensioner, if removed, and hook the upper end of the spring to the water pump pin and the lower end to the tensioner in exactly the same position as originally installed. If not already done, position both camshafts so the marks align with those on the rear. Rotate the crankshaft so the timing mark aligns with the mark on the oil pump.
17. Install the timing belt on the crankshaft sprocket and while keeping the belt tight on the tension side, install the belt on the front camshaft sprocket.
18. Install the belt on the water pump pulley, then the rear camshaft sprocket and the tensioner.
19. Rotate the front camshaft counterclockwise to tension the belt between the front camshaft and the crankshaft. If the timing marks became misaligned, repeat the procedure.
20. Install the crankshaft sprocket flange.
21. Loosen the tensioner bolt and allow the spring to apply tension to the belt.
22. Turn the crankshaft 2 full turns in the clockwise direction until the timing marks align again. Now that the belt is properly tensioned, torque the tensioner lock bolt to 21 ft. lbs. (29 Nm). Measure the belt tension between the rear camshaft sprocket and the crankshaft with belt tension gauge. The specification is 46–68 lbs. (210–310 N).
23. Install the timing covers. Make sure all pieces of packing are positioned in the inner grooves of the covers when installing.
24. Install the crankshaft pulley. Tighten the bolt to 108–116 ft. lbs. (150–160 Nm).
25. Install the engine support bracket.
26. Install the power steering pump and reconnect wire harness at the power steering pump pressure switch.
27. Install the engine mounting bracket and remove the engine support fixture.
28. Install the tension pulleys and drive belts.
29. Install the cruise control actuator.
30. Install the engine undercover.
31. Connect the negative battery cable.
32. Road test the vehicle.

EXCEPT 1992–94 MODELS

1. Position the engine so the No. 1 cylinder is at TDC of its compression stroke.
2. Disconnect the negative battery cable.

   CAUTION
   Wait at least 90 seconds after the negative battery cable is disconnected to prevent possible deployment of the air bag.

3. Remove the engine undercover.
4. Remove the front undercover panel.
5. Remove the cruise control pump and the link assembly.
6. Remove the alternator.
7. Raise and suspend the engine so that force is not applied to the engine mount.
8. Remove the timing covers from the engine.
9. If the same timing belt will be reused, mark the direction of the timing belt's rotation for installation in the same direction. Make sure the engine is positioned so the No. 1 cylinder is at the TDC of its compression stroke and the timing marks are aligned with the engine's timing mark indicators on the valve covers or head.
10. Loosen the center bolt of tensioner pulley and unbolt auto-tensioner assembly. The auto-tensioner assembly must be reset to correctly adjust belt tension. Remove the timing belt.
11. Using a wrench, hold the camshaft at its hexagon and remove the camshaft sprocket bolt.
12. Remove and position the auto-tensioner into a vise with soft jaws. The plug at the rear of tensioner protrudes, be sure to use a washer as a spacer to protect the plug from contacting vise jaws.
13. Slowly push the rod into the tensioner until the set hole in rod is aligned with set hole in the auto-tensioner.
14. Insert a 0.055 in. (1.4mm) wire into the aligned set holes. Unclamp the tensioner from the vise and install it on the engine. Tighten tensioner to 17 ft. lbs. (24 Nm).
15. Clean and inspect both auto tensioner mounting bolts. Coat the threads of the old bolts with thread sealer. If new bolts are installed, inspect the heads of the new bolts. If there is white paint on the bolt head, no sealer is required. If there is no paint on the head of the bolt, apply a coat of thread sealer to the bolt. Install both bolts and tighten to 17 ft. lbs. (24 Nm).

    Fig. 30: Align the sprockets properly before removing or installing the timing belt — 1995–96 Diamante with the 3.0L (6G72) SOHC engine

    To install:

16. Install the tensioner, if removed, and hook the upper end of the spring to the water pump pin and the lower end to the tensioner in exactly the same position as originally installed.
17. Ensure both camshafts are still positioned so the timing marks align with those on the rear timing covers.
18. Rotate the crankshaft so the timing mark aligns with the mark on the front cover.
19. Install the timing belt on the crankshaft sprocket and while keeping the belt tight on the tension side, install the belt on the front (left) camshaft sprocket.
20. Install the belt on the water pump pulley, then the rear (right) camshaft sprocket and the tensioner.
21. Loosen the bolt that secures the adjustment of the tensioner and lightly press the tensioner against the timing belt.
22. Check that the timing marks are in alignment.
23. Rotate the crankshaft 2 full turns in the clockwise direction only, then realign the timing marks.
24. Tighten the bolt that secures the tensioner to 19 ft. lbs. (26 Nm).
25. Install the lower and the upper timing belt covers, along with all other applicable components.

3.0L DOHC Engine

1992–94 MODELS

1. Position the engine so the No. 1 cylinder is at TDC of its compression stroke.
2. Disconnect the negative battery cable.
3. Remove the engine undercover.
4. Remove the cruise control actuator.
5. Remove the alternator. Remove the air hose and pipe.
6. Remove the belt tensioner assembly and the power steering belt.
7. Remove the crankshaft pulley.
8. Disconnect the brake fluid level sensor.
9. Remove the timing belt upper cover.
10. Using the proper equipment, slightly raise the engine to take the weight off the side engine mount. Remove the engine mount bracket.
11. Remove the alternator/air conditioner idler pulley.
12. Remove the engine support bracket. The mounting bolts are different lengths; mark them for proper installation.
13. Remove the timing belt lower cover. Timing bolt cover mounting bolts are different in length, note their position during removal.
14. If the same timing belt will be reused, mark the direction of the timing belt's rotation for installation in the same direction. Make sure the engine is positioned so the No. 1 cylinder is at the TDC of its compression stroke and the sprockets' timing marks are aligned with the engine's timing mark indicators on the valve covers or head.

    Fig. 31: Crankshaft and camshaft sprocket alignment for proper timing belt replacement — 1992–94 Mitsubishi 3.0L DOHC engine

15. Loosen the timing belt tensioner bolt and remove the belt.
16. Remove the tensioner assembly.

    To install:

17. If the auto tensioner rod is fully extended, reset it as follows:
    1. Clamp the tensioner in a soft-jaw vice in level position.
    2. Slowly push the rod in with the vice until the set hole in the rod is aligned with the hole in the cylinder.
    3. Insert a stiff wire into the set holes to retain the position.
    4. Remove the assembly from the vice.
18. Leave the retaining wire in the tension and install to the engine.
19. If the timing marks of the camshaft sprockets and crankshaft sprocket are not aligned at this point, proceed as follows:

    NOTE: Keep fingers out from between the camshaft sprockets. The sprockets may move unexpectedly because of valve spring pressure and could pinch fingers.

    1. Align the mark on the crankshaft sprocket with the mark on the front case. Then move the sprocket 2 teeth clockwise to lower the piston so the valve can't touch the piston when the camshafts are being moved.
    2. Turn each camshaft sprocket 1 at a time to align the timing marks with the mark on the valve cover or head. If the intake and exhaust valves of the same cylinder are opened simultaneously, they could interfere with each other. Therefore, if any resistance is felt, turn the other camshaft to move the valve.
    3. Align the timing mark of the crankshaft sprocket, then continue 1 tooth farther in the counterclockwise direction to facilitate belt installation.
20. Using 4 spring loaded paper clips to hold the belt on the cam sprockets, install the belt to the sprockets in the following order:
    • 1st  — exhaust camshaft sprocket for the front head
    • 2nd  — intake camshaft sprocket for the front head
    • 3rd  — water pump pulley
    • 4th  — intake camshaft sprocket for the rear head
    • 5th  — exhaust camshaft sprocket for the rear head
    • 6th  — idler pulley
    • 7th  — crankshaft sprocket
    • 8th  — tensioner pulley
21. Turn the tensioner pulley so its pin holes are located above the center bolt. Then press the tensioner pulley against the timing belt and simultaneously tighten the center bolt.
22. Make certain that all timing marks are still aligned. If so, remove the 4 clips.
23. Turn the crankshaft ¹⁄₄ turn counterclockwise, then turn it clockwise until all timing marks are aligned.
24. Loosen the center bolt on the tensioner pulley. Using tool MD998767 or equivalent and a torque wrench, apply a torque of 7 ft. lbs. (10 Nm). Tighten the tensioner bolt; make sure the tensioner doesn't rotate with the bolt.
25. Remove the set wire attached to the auto tensioner, if the wire was not previously removed.
26. Rotate the crankshaft 2 complete turns clockwise and let it sit for approximately 5 minutes. Then, make sure the set pin can easily be inserted and removed from the hole in the tensioner.
27. 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 Steps 1–4 until the specified value is obtained.
28. Make sure all pieces of packing are positioned in the inner grooves of the lower cover, position cover on engine and install mounting bolts in their original location.
29. Install the engine support bracket and secure using mounting bolts in their original location. Lubricate the reaming area of the reamer bolt and tighten slowly.
30. Install the idler pulley.
31. Install the engine mount bracket. Remove the engine support fixture.
32. Make sure all pieces of packing are positioned in the inner grooves of the upper cover and install.
33. Connect the brake fluid level sensor.
34. Install the crankshaft pulley. Tighten the bolt to 130–137 ft. lbs. (180–190 Nm).
35. Install the belt tensioner assembly and the power steering belt.
36. Install the air hose and pipe.
37. Install the alternator.
38. Install the cruise control actuator.
39. Install the engine undercover.
40. Connect the negative battery cable.

1995–96 MODELS

1. Position the engine so the No. 1 cylinder is at TDC of its compression stroke.
2. Disconnect the negative battery cable.
3. Remove the engine undercover.
4. Remove the cruise control actuator.
5. Remove the alternator. Remove the air hose and pipe.
6. Remove the belt tensioner assembly and the power steering belt.
7. Remove the crankshaft pulley.
8. Disconnect the brake fluid level sensor.
9. Remove the timing belt upper cover.
10. Using the proper equipment, slightly raise the engine to take the weight off the side engine mount. Remove the engine mount bracket.
11. Remove the alternator/air conditioner idler pulley.
12. Remove the engine support bracket. The mounting bolts are different lengths; mark them for proper installation.
13. Remove the timing belt lower cover. Timing bolt cover mounting bolts are different in length, note their position during removal.

    CAUTION
    Be sure to disconnect the negative battery cable. Wait at least 90 seconds after the negative battery cable is disconnected to prevent possible deployment of the air bag.

14. If the same timing belt will be reused, mark the direction of the timing belt's rotation for installation in the same direction. Be sure the engine is positioned so the No. 1 cylinder is at the TDC of its compression stroke and the timing marks are aligned with the engine's timing mark indicators on the rear timing covers.

    WARNING
    Turning the camshaft sprocket when the timing belt is removed could cause the valves to contact with the pistons, resulting in severe engine damage.

15. Remove the bolts that secure the auto-tensioner to the engine block and remove the tensioner.

    Fig. 32: Sprocket alignment for timing belt installation — 1995–96 Diamante with the 3.0L (6G72) DOHC engine

    To install:

    NOTE: The auto-tensioner assembly must be reset to correctly adjust belt tension.

16. Loosen the center bolt of tensioner pulley to provide timing belt slack.
17. Remove the timing belt assembly.
18. Position the auto-tensioner into a vise with soft jaws. The plug at the rear of tensioner protrudes, be sure to use a washer as a spacer to protect the plug from contacting vise jaws.
19. Slowly push the rod into the tensioner until the set hole in rod is aligned with set hole in the auto-tensioner.
20. Insert a 0.055 in. (1.4mm) wire into the aligned set holes. Remove the tensioner from the vise and install it on the engine.
21. Tighten tensioner mounting bolts to 17 ft. lbs. (24 Nm).

    WARNING
    DO NOT rotate or turn the camshafts when removing the sprockets or severe engine damage will result from internal component interference.

22. Align the mark on the crankshaft sprocket with the mark on the front case. Then, move the crankshaft sprocket 1 tooth counterclockwise.
23. Align the timing marks of the camshafts with the marks on the rear covers.
24. Using large paper clips to secure the timing belt to the sprockets, install the timing belt in the following order. Be sure camshafts-to-cylinder heads and crankshaft-to-front cover timing marks are aligned. Install the timing belt around the pulleys in the following order:
    1. Exhaust camshaft sprocket (front bank).
    2. Intake camshaft sprocket (front bank).
    3. Water pump pulley.
    4. Intake camshaft sprocket (rear bank).
    5. Exhaust camshaft sprocket (rear bank).
    6. Tensioner pulley.
    7. Crankshaft pulley.
    8. Idler pulley.

       NOTE: Since the camshaft sprockets turn easily, secure them with box wrenches when installing the timing belt.

25. Align all timing marks on the crankshaft and raise the tensioner pulley against the belt to remove slack, snug tensioner bolt.
26. Check the alignment of all the timing marks and remove the clips that secure the timing belt to the camshaft sprockets.
27. Rotate the engine ¹⁄₄ turn counterclockwise, then rotate the engine clockwise to align the timing marks. Check that all the timing marks are in alignment.
28. Loosen the center bolt on the tensioner pulley.
29. Using tool MD998752 or equivalent and a torque wrench, apply 84 inch lbs. (10 Nm) to the tool on the tensioner. Tighten the tensioner bolt to 35 ft. lbs. (49 Nm) and be sure the tensioner does not rotate with the bolt.
30. Rotate the crankshaft two complete turns clockwise and let it sit for approximately five minutes. Then, check that the set pin can easily be inserted and removed from the hole in the auto-tensioner.
31. Remove the set wire attached to the auto-tensioner.
32. 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 adjustment procedure until the specified value is obtained.
33. Check again that the timing marks on all sprockets are in proper alignment.
34. Install the timing belt covers and all other applicable components.

3.5L Engine

1. Disconnect the negative battery cable.
2. Drain the cooling system.

   CAUTION
   Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

3. Remove the drive belts.
4. Remove the upper radiator shroud.
5. Remove the fan and fan pulley.
6. Without disconnecting the lines, remove the power steering pump from its bracket and position it to the side. Remove the pump brackets.
7. Remove the belt tensioner pulley bracket.
8. Without releasing the refrigerant, remove the air conditioning compressor from its bracket and position it to the side.
9. Remove the bracket.
10. Remove the cooling fan bracket.
11. On some vehicles it may be necessary to remove the pulley from the crankshaft to access the lower cover bolts.
12. Remove the timing belt cover bolts and the upper and lower covers from the engine.
13. Detach the crankshaft position sensor connector.
14. Using SST MB990767–01 and MD998754, or their equivalents, remove the crankshaft pulley from the crankshaft.
15. Use a shop rag to clean the timing marks to assist in properly aligning the timing marks.
16. Loosen the center bolt on the tension pulley and remove the timing belt.

    NOTE: If the same timing belt will be reused, mark the direction of timing belt's rotation, for installation in the same direction. Be sure engine is positioned so No. 1 cylinder is at the TDC of it's compression stroke and the sprockets timing marks are aligned with the engine's timing mark indicators.

17. Remove the auto-tensioner, the tension pulley and the tension arm assembly.
18. Remove the sprockets by holding the hexagonal portion of the camshaft with a wrench while removing the sprocket bolt.

    Fig. 33: Clean the timing marks to verify their position when aligning — 3.5L engine

    To install:

19. Install the crankshaft pulley and turn the crankshaft sprocket timing mark forward (clockwise) three teeth to move the piston slightly past No. 1 cylinder top dead center.
20. If removed, install the camshaft sprockets and tighten the bolts to 64 ft. lbs. (88 Nm).
21. Align the timing mark of the left bank side camshaft sprocket.
22. Align the timing mark of the right bank side camshaft sprocket, and hold the sprocket with a wrench so that it doesn't turn.
23. Set the timing belt onto the water pump pulley.
24. Check that the camshaft sprocket timing mark of the left bank side is aligned and clamp the timing belt with double clips.
25. Set the timing belt onto the idler pulley.

    WARNING
    If any binding is felt when adjusting the timing belt tension by turning the crankshaft, STOP turning the engine, because the pistons may be hitting the valves.

26. Turn the crankshaft one turn counterclockwise and set the timing belt onto the crankshaft sprocket.
27. Set the timing belt on the tension pulley.
28. Place the tension pulley pin hole so that it is towards the top. Press the tension pulley onto the timing belt, and then provisionally tighten the fixing bolt. Tighten the bolt to 35 ft. lbs. (48 Nm).
29. Slowly turn the crankshaft two full turns in the clockwise direction until the timing marks align. Remove the four double clips.
30. Install the crankshaft position sensor connector.
31. Install the upper and lower covers on the engine and secure them with the retaining screws. Be sure the packing is properly positioned in the inner grooves of the covers when installing.
32. Install the crankshaft pulley if it was removed. Tighten the bolt to 110 ft. lbs. (150 Nm).
33. Install the air conditioning bracket and compressor on the engine. Install the belt tensioner.
34. Install the power steering pump into position. Install the fan pulley and fan.
35. Install the fan shroud on the radiator.
36. Refill the cooling system.
37. Connect the negative battery cable.
38. Start the engine and check for fluid leaks.