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REMOVAL & INSTALLATION

Mitsubishi Montero Sport
1997 2.4L (VIN G) ENGINE
  1. Be sure that the engine's No. 1 piston is at Top Dead Center (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.
  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. 1: Silent shaft alignment marks. Notice the tension side of the inner (silent shaft) belt — Mitsubishi Montero Sport 2.4L engine

    Fig. 2: Timing belt pulley alignment marks — Mitsubishi Montero Sport 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 aligned.
  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. If it can only go in about 1 inch, 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 2 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 over tighten 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.
Mitsubishi Montero
1997–98 3.0L (VIN P) ENGINES
  1. Position the engine with No. 1 cylinder at Top Dead Center (TDC) of the compression stroke.
  2. Disconnect the negative battery cable.
  3. Drain the cooling system. Remove the drive belts.

    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.

  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 aside. 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 aside. Remove the bracket.
  9. Remove the cooling fan bracket.
  10. On some vehicles, it may be necessary to remove the pulley from the crankshaft to access the lower cover bolts.
  11. Remove the timing belt cover bolts, and the upper and lower covers from the engine.
  12. 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 engine is positioned so that the No. 1 cylinder is at TDC of its compression stroke and the sprockets timing marks are aligned with the engine's timing mark indicators.
  13. Loosen the timing belt tensioner bolt and remove the belt. If not removing the tensioner, position it as far away from the center of the engine as possible and tighten the bolt.
  14. If tensioner is being removed, mark outside of the spring to ensure that it is not installed backwards. Unbolt the tensioner and remove it along with the spring.
  15. Using SST MB990767-01 and MIT308239 or their equivalents, remove the camshaft sprockets.

    Fig. 3: Be sure to align the timing marks before removing or installing the timing belt — Mitsubishi 1999 3.0L (VIN H), 1997–98 3.0L (VIN P) and 1997–01 3.5L engines

    To install:

  16. Hold the hexagonal portion of the camshaft with a wrench when tightening the camshaft sprocket bolt and tighten to 64 ft. lbs. (88 Nm).
  17. If removed, install the tensioner and hook the upper end of the spring to the water pump pin. Install the lower end of the spring to the tensioner in exactly the same position as originally installed.
  18. Position both camshafts so the timing marks align with those on the alternator bracket (rear bank) and inner timing cover (front bank). Rotate the crankshaft so the timing mark aligns with the mark on the oil pump.
  19. Install the timing belt on the crankshaft sprocket, and while keeping the belt tight on the tension side (right side), install the belt on the front camshaft sprocket.
  20. Install the belt on the water pump pulley, then the rear camshaft sprocket and the tensioner.
  21. Rotate the front camshaft counterclockwise to tension the belt between the front camshaft and the crankshaft. If the timing marks came out of line, repeat the procedure.
  22. Install the crankshaft sprocket flange.
  23. Loosen the tensioner bolt and allow the spring to tension the belt.

    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.

  24. Slowly turn the crankshaft 2 full turns in the clockwise direction until the timing marks align. Now that the belt is properly tensioner, tighten the tensioner lockbolt to 35 ft. lbs. (48 Nm).
  25. Install the upper and lower covers to the engine and secure with the retaining screws. Be sure the packing is positioned in the inner grooves of the covers properly when installing.
  26. Install the crankshaft pulley if it was removed. Tighten the bolt to 110 ft. lbs. (150 Nm).
  27. Install the air conditioning bracket and compressor on the engine. Install the belt tensioner.
  28. Install the power steering pump into position. Install the fan pulley and fan.
  29. Install the fan shroud to the radiator.
  30. Refill the cooling system.
  31. Connect the negative battery cable. Start the engine and check for fluid leaks.
1999–01 3.0L (VIN H), 1997–98 3.5L (VIN M) and 1999–01 3.5L (VIN R) ENGINES
  1. Disconnect the negative battery cable.
  2. Drain the engine coolant and store it for reinstallation. Remove the upper radiator hose.
  3. Remove the cooling fan shroud assembly.
  4. Remove the cooling fan-to-clutch bolts and the fan.
  5. Remove the cooling fan clutch-to-water pump nuts and the clutch assembly.
  6. Remove the drive belts for the alternator, power steering pump and air conditioning compressor.
  7. Disconnect the electrical connectors from the alternator.
  8. Remove the alternator-to-engine bolts and the alternator bracket-to-engine bolts; then, remove the alternator and bracket from the engine.
  9. Remove the power steering pump cover. Remove the power steering pump-to-engine bolts and move the pump aside with the hoses and electrical connector attached.
  10. Remove the air conditioning compressor-to-bracket bolts and move the compressor aside with the lines and electrical connector attached.
  11. Remove the air conditioning compressor bracket-to-engine bolts and the bracket.
  12. Remove the timing indicator bracket (near crankshaft pulley) bolts and the bracket.
  13. Remove the accessory mount assembly-to-engine bolts and the mount assembly.
  14. Remove the upper timing belt cover assembly.
  15. Using the End Yoke Holder tool MD990767 and 2 Crankshaft Pulley Holder Pin tools MD998715, or equivalent to hold the crankshaft pulley, and a socket wrench, remove the crankshaft pulley bolt and the pulley.
  16. Remove the lower timing belt cover.
  17. Rotate the crankshaft clockwise to align the timing marks to position the No. 1 cylinder at the Top Dead Center (TDC) of its compression stroke.
  18. Use chalk to mark the rotating (clockwise) direction of the timing belt for reinstallation purposes.
  19. Loosen the auto-tensioner pulley center bolt and remove the timing bolt.
  20. Remove the auto-tensioner pulley and the auto-tensioner arm assembly.

    Fig. 4: Removing or installing the crankshaft pulley bolt — Mitsubishi 1999–01 3.0L (VIN H), 1997–98 3.5L (VIN M) and 1999–01 3.5L (VIN R) engines

    Fig. 5: View of the timing belt alignment marks — Mitsubishi 1999–01 3.0L (VIN H), 1997–98 3.5L (VIN M) and 1999–01 3.5L (VIN R) engines

    Fig. 6: Inspecting the auto-tensioner movement — Mitsubishi 1999–01 3.0L (VIN H), 1997–98 3.5L (VIN M) and 1999–01 3.5L (VIN R) engines

    Fig. 7: Adjusting the timing belt tensioner pulley — Mitsubishi 1999–01 3.0L (VIN H), 1997–98 3.5L (VIN M) and 1999–01 3.5L (VIN R) engines

    Fig. 8: Using crankshaft spacer tool to rotate the crankshaft — Mitsubishi 1999–01 3.0L (VIN H), 1997–98 3.5L (VIN M) and 1999–01 3.5L (VIN R) engines

    To install:

  21. 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.
  22. 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.
  23. Align the camshaft and crankshaft TDC timing marks.
  24. Install the timing belt (noting its rotational direction) so that there is no deflection between the sprockets and pulleys in the following manner:
  25. Turn the camshaft sprocket counterclockwise until the tension side of the timing belt is firmly stretched, then, recheck the timing marks.
  26. Using the Tension Pulley Socket Wrench tool MD998767, or equivalent, push the tensioner pulley into the timing belt and secure the center bolt.
  27. Using the Crankshaft Pulley Spacer tool MD998769, or equivalent, rotate the crankshaft 1⁄4 turn counterclockwise, then, turn it again clockwise to align the timing marks.
  28. 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).
  29. Remove the setting pin from the auto-tensioner.
  30. Rotate the crankshaft 2 complete revolutions and realign the timing marks. Then, wait for 5 minutes until the auto-tensioner's pushrod extends to its standard value. If the standard value is not 0.15–0.20 in. (3.8–5.0mm), repeat the adjustment procedure. If the standard value is still not achieved, replace the auto-tensioner.
  31. Install the lower timing belt cover and crankshaft pulley.
  32. Using the End Yoke Holder tool MD990767 and 2 Crankshaft Pulley Holder Pin tools MD998715, or equivalent to hold the crankshaft pulley, and a socket torque wrench, torque the crankshaft pulley bolt to 134 ft. lbs. (181 Nm).
  33. Install the upper timing belt cover assembly.
  34. Install the remaining items by reversing the removal procedures.
  35. Refill the cooling system.
  36. Connect the negative battery cable.

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