External Components
GENERATOR AND IGNITION SYSTEM
Removal
Follow removal steps outlined in illustration.
Installation
Installation in reverse order as removal.
Installation Service Points
]A[ Camshaft Position Sensor Support Installation.
1. Apply a 3 mm bead of form-in-place gasket (FIPG) to the area shoving.
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or equivalent.
TIMING BELT
Removal
Follow removal steps outlined in illustration.
Removal Service Points
[A] Timing Belt Removal.
Mark belt running direction for reinstallation.
NOTE:
1. Water or oil on the belt shorten its life drastically, so the removed timing belt, sprocket, and tensioner must be free from oil and water. These parts should not be washed. Replace parts if seriously contaminated.
2. If there is oil or water on each part check front case oil seals, camshaft oil seal and water pump for leaks.
[B] Oil Pump Sprocket Removal.
[C] Crankshaft Bolt Loosening.
[D] Crankshaft Sprocket Removal.
[E] Timing Belt "B" Removal.
1. 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.
NOTE:
1. Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and tension_ must be free from oil and water. These parts should not be washed. Replace parts if seriously contaminated.
2. If there is oil or water on each part check front case oil seals, camshaft oil seal and water pump for leaks.
[F] Counterbalance Shaft Sprocket Removal.
[G] Crankshaft Sprocket "B" Removal.
[H] Camshaft Sprocket Bolt Loosening.
Installation
Installation in reverse order as removal.
Installation Service Points
]A[ Camshaft Sprocket Tightening.
]B[ Engine Support Bracket Installation.
Coat the bolts illustrated with sealant before tightening.
Specified sealant:
3M ATD Part No. 8660 or equivalent
]C[ Spacer Installation.
Install the spacer with the chamfered end toward the oil seal.
]D[ Counterbalance Shaft Sprocket Installation.
]E[ Timing Belt "B" Installation.
1. Align timing marks on the crankshaft sprocket "B" and counterbalance shaft sprocket with the marks on the front case respectively.
2. Install the timing belt "B" on the crankshaft sprocket "B" and counterbalance shaft sprocket. There should be no slack on the tension side.
3. Make sure that the relationship between the tensioner pulley center and the bolt center is as shown in the illustration.
4. Move the tensioner "B" in the direction of arrow while lifting with a finger to give a sufficient tension to the tension side of timing belt. In this condition, tighten bolt to secure tensioner "B". When the bolt is tightened, use care to prevent shaft from turning together. If shaft is turned together, belt will be overtensioned.
5. Check to ensure that timing marks on sprockets and front case are in alignment.
6. Press with index finger the center of span on tension side of timing belt "B". The bolt must deflect 5 - 7 mm (0.20 - 0.28 inch) .
]F[ Crankshaft Bolt Tightening.
]G[ Oil Pump Sprocket Installation.
1. Insert a Phillips screwdriver [shank diameter 8 mm (0.31 inch) shaft] through the plug hole on the left side of the cylinder block to block the left counterbalance shaft.
2. Install the oil pump sprocket.
3. Apply a proper amount of engine oil to the bearing surfaces of the nuts.
4. Tighten the nuts to the specified torque.
]H[ Auto Tensioner Installation.
1. If the auto tensioner rod is in its fully extended position, reset it as follows.
2. Clamp the auto-tensioner in the vise with soft jaws.
3. Push in the rod little by little with the vise until the see. hole A in the rod is aligned with the hole B in the cylinder.
4. Insert a wire [1.4 mm (0.055 inch) in diameter] into the set holes.
5. Unclamp the auto tensioner from the vise.
6. Install the auto tensioner to front case and tighten to the specified torque.
CAUTION: Leave the wire installed in the auto tensioner.
]I[ Tensioner Pulley Installation.
Install the tensioner pulley in such direction that its two small holes are arranged vertically.
]J[ Timing Belt Installation.
1. Check that the timing belt tensioner and have been installed in position.
2. Align timing mark on camshaft sprocket with timing mark on cylinder head.
3. Align timing mark on crankshaft sprocket with timing mark on front case.
4. Align the timing mark on oil pump sprocket with its mating mark.
5. Remove the plug on cylinder block and insert a Phillips screwdriver [shank diameter 8 mm (0.31 inch) ] through the hole (Engine with counterbalance shafts).
If it can be inserted as deep as 60 mm (2.4 inch) or more, the timing marks are correctly aligned. If the inserted depth is only 20 - 25 mm (0.8 - 1.0 inch) , turn the oil pump sprocket one turn and realign timing marks. Then check to ensure that the screwdriver can be inserted 60 mm (2.4 inch) or more. Keep the screwdriver inserted until installation of timing belt is finished.
6. Install the timing belt on the crankshaft sprocket, idler pulley, camshaft sprocket, and tensioner pulley in that order.
7. Lift up the tensioner pulley in the direction of arrow and tighten the center bolt.
8. Check that all timing marks are lined up.
9. Remove the screwdriver inserted in step (5) and fit the plug.
10. Give the crankshaft a quarter counterclockwise turn. Then, turn it clockwise until the timing marks are lined up again.
11. Install the special tools, Socket Wrench and Torque Wrench, on the tensioner pulley, and loosen the tensioner pulley center bolt.
NOTE: If the special tool is not available, use a commercially available torque wrench that is capable of measuring 0 - 5 Nm (0 - 3.6 ft. lbs.) .
12. Torque to 3.5 Nm (2.5 ft.lbs.) with the torque wrench.
13. Holding the tensioner pulley with the special tool and torque wrench, tighten the center bolt to specification.
14. After giving two clockwise turns to the crankshaft, ie: it alone for approximately 15 minutes. Then, make sure that the auto tensioner setting wire moves freely.
NOTE: If the wire does not move freely, repeat step (10) above until it moves freely.
15. Remove the auto tensioner setting wire.
16. Measure the distance "A" (between the tensioner arm and auto tensioner body).
Standard Value: 3.8 - 4.5 mm (0.15 - 0.18 inch)
Inspection
Timing Belt
Replace belt if any of the following conditions exist.
1. Hardening of back rubber. Back side is glossy without resilience and leaves no indent when pressed with fingernail.
2. Cracks on rubber back.
3. Cracks or peeling of canvas.
4. Cracks on rib root.
5. Cracks on belt sides.
6. Abnormal wear of belt sides. The sides are normal if they are sharp as if cut by a knife.
7. Abnormal wear on teeth.
8. Missing tooth.
Auto Tensioner
1. Check the auto tensioner for possible leaks and replace as necessary.
2. Check the rod end for wear or damage and replace as necessary.
3. Measure the rod protrusion. If it is out of specification, replace the auto tensioner.
Standard Value: 12 mm (0.47 inch)
4. Press the rod with a force of 98 to 196 N (22 to 44 lbs.) and measure its protrusion.
5. If the measured value is 1 mm (0.39 inch) or more shorter than the value obtained in step (3), replace the auto tensioner.
FUEL AND EMISSION CONTROL PARTS
Removal
Follow removal steps outlined in illustration.
Installation
Installation in reverse order as removal.
Installation Service Points
]A[ Injectors / Injector Clip Installation.
1. Before installing an injector, the rubber O-ring must be lubricated with a drop of clean engine oil to aid in installation.
2. Install injector top end into fuel rail. Be careful not to damage O-ring during installation.
]B[ Fuel Pressure Regulator Installation.
Before installing the pressure regulator, the O-ring must be lubricated with a drop of clean engine oil to aid in installations.
INTAKE MANIFOLD
Removal
Follow removal steps outlined in illustration.
Installation
Installation in reverse order as removal.
Installation Service Points
]A[ Sealant Application To Thermostat Housing.
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or equivalent
NOTE:
1. Be sure to install the housing quickly while the sealant is wet (within 15 minutes).
2. After installation, keep the sealed area away from the oil and coolant for approximately one hour.
]B[ Sealant Application To Water Outlet Fitting.
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or equivalent
NOTE:
1. Be sure to install the housing quickly while the sealant is wet (within 15 minutes).
2. After installation, keep the sealed area away from the oil and coolant for approximately one hour.
]C[ Sealant Application To Engine Coolant
Temperature Sensor.
Specified sealant:
3M Nut Locking Part No. 4171 or equivalent
]D[ Sealant Application To Engine Coolant Temperature Gauge Unit.
Specified sealant:
3M ATD Part No. 8660 or equivalent
EXHAUST MANIFOLD AND WATER PUMP
Removal
Follow removal steps outlined in illustration.
Installation
Installation in reverse order as removal.
Installation Service Point
]A[ Water Pipe/O-ring Installation.
1. Wet the O-ring (with water) to ease assembly.
CAUTION: Keep the O-ring free of oil or grease.