Removal and installation the timing belt cover and timing belt (Mitsubishi Galant 6)

The timing belt maintenance procedure is described in Chapter Settings and ongoing maintenance.

1.5L engines

Models produced in 1990÷1994.

Removal

1. The installation details of the timing belt cover and components on 1.5L models produced in 1990–1994 are shown in the illustration.

2. Disconnect the negative cable from the battery.

If your car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!

3. Remove the crankcase protection elements.

4. Support the engine with a trolley jack (to distribute the load, place a wooden block between the jack head and the engine oil pan). Remove the accessory drive belts.



5. If necessary, remove the expansion tank of the cooling system.

6. Raise the engine slightly with a jack and remove the front engine mount bracket. Remove the tensioner brackets and the water pump and crankshaft pulleys.

7. Remove the mounting screws and remove the upper and lower sections of the front timing cover.

8. Mark the direction of rotation of the timing belt with chalk or paint, loosen the tensioner and remove the belt.

Try to prevent coolant or engine oil from getting on the surfaces of the timing belt or timing gear!

9. Remove the spacer sleeve, spring and tensioner assembly.

10. Carefully inspect the belt from all sides for cracks, abrasions, traces of oil contamination and other defects. Manually assess the freedom of rotation of the tension roller.

Installation

1. Install the tensioner assembly with spring and spacer sleeve onto the engine block.



2. Ensure that the timing marks of the camshaft and crankshaft gears are correctly aligned, which should ensure that the engine is brought to the TDC position at the end of the compression stroke of the piston of the first cylinder.

3. Keeping the appropriate side of the belt taut, place it over the camshaft and crankshaft timing gears.



4. To tension the belt, apply force to the camshaft gear in a counterclockwise direction and make sure that the timing marks are correctly aligned.

5. Loosen the tensioner axle and lock bolts - the belt slack should be released due to the force developed by the tensioner spring.

6. Tighten the tensioner lock bolt first, then the tensioner axle bolt.

Tightening the axle bolt first may cause the tensioner to unwind and therefore weaken the belt!

7. Turn the crankshaft clockwise. Loosen first the axial and then the locking bolts of the tensioner, allowing the spring to take up the remaining slack in the belt. Retighten the bolts in the appropriate order (see above), this time with the required force (20÷27 Nm).

8. Check that the belt tension is correct by holding the tension roller and pressing the straight run of the belt in the middle with your thumb - when pressed firmly, the belt should bend by an amount approximately equal to 1/4 of the size of the head of the locking bolt (see ibid.).

Remember that overtightening the belt may cause a howling sound when the engine is running!

9. Reinstall the timing belt covers and all other components removed for access.

10. Connect the negative cable to the battery.

Models produced in 1995÷2000.

Removal

1. Disconnect the negative cable from the battery.

If your car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!

2. Remove the crankcase protection elements.



3. Turn the engine clockwise until it reaches the TDC position at the end of the compression stroke of the piston of the first cylinder.

4. Support the engine with a trolley jack (to distribute the load, place a wooden block between the jack head and the engine oil pan). Remove the crankcase retainer, front powertrain support bracket, and accessory drive belts.

5. Remove the crankshaft pulley.

6. Remove the mounting screws and remove the upper and lower sections of the front timing cover.

7. Mark the direction of rotation of the timing belt with chalk or paint. Loosen the tensioner and fix it in this position.

8. Remove the belt.

Try to prevent coolant or engine oil from getting on the surfaces of the timing belt or timing gear!

9. If necessary, remove the spacer sleeve, spring and tensioner assembly.

10. Carefully inspect the belt from all sides for cracks, abrasions, traces of oil contamination and other defects. Manually assess the freedom of rotation of the tension roller.

11. Install the tensioner assembly with spring and spacer sleeve onto the engine block.



12. Ensure that the timing marks of the camshaft and crankshaft gears are correctly aligned, which should ensure that the engine is brought to the TDC position at the end of the compression stroke of the piston of the first cylinder.



13. Keeping the appropriate side of the belt taut, place it over the camshaft and crankshaft timing gears.

14. To tension the belt, apply force to the camshaft gear in a counterclockwise direction and make sure that the timing marks are correctly aligned.

15. Loosen the tensioner axle and lock bolts - the belt slack should be released due to the force developed by the tensioner spring.

16. Tighten the tensioner lock bolt first, then the tensioner axle bolt.

Tightening the axle bolt first may cause the tensioner to unwind and therefore weaken the belt!

17. Turn the crankshaft clockwise. Loosen first the tensioner pivot bolt, then the tensioner lock bolt, allowing the spring to take up the remaining slack in the belt. Retighten the bolts in the correct order (see above), this time to the required torque (24 Nm).

18. Install the timing belt covers, screw in the mounting bolts and tighten them to the required torque (10÷11 Nm).

19. Reinstall all other components removed for access purposes.

20. Connect the negative cable to the battery.

1.6L and 2.0L DOHC Non-Turbocharged Engines

On 1.6 l engines there are no balance shafts, so the corresponding points in the instructions should be omitted.

Removal

1. Disconnect the negative cable from the battery.

If your car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!

2. Remove the crankcase protection elements.

3. If necessary, remove the expansion tank of the cooling system.

4. Support the engine with a trolley jack (to distribute the load, place a wooden block between the jack head and the engine oil pan) and remove the power unit support bracket.

5. Remove the accessory drive belts, tensioner brackets, and water pump and crankshaft pulleys.

6. Remove the mounting screws and remove the upper and lower sections of the front timing cover.



7. Turn the engine clockwise, bring it to the TDC position of the end of the compression stroke of the piston of the first cylinder - the gear wheels of the camshafts should turn with the mounting pins upward (the installation marks will be at the level of the mating surface of the cylinder head). Mark the direction of rotation of the timing belt with chalk or paint.

8. Remove the automatic tensioner and outer timing belt.

9. Remove the tensioner roller and lever, idler roller, oil pump gear, special washer, flange and spacer sleeve.

10. Remove the inner tensioner of the inner toothed belt of the balance shaft drive. Then remove the belt.

Installation

1. Ensure that the timing marks of the crankshaft and balance shaft gears are correctly aligned, then install the balance shaft drive toothed belt (inner).

2. While holding the tensioner with your fingers, press the belt at the center to completely remove any slack, then tighten the tensioner bolt.

3. Check the correct adjustment of the belt tension: when pressing firmly on the middle part of the longest run, the deflection should be approximately 5÷7 mm. Repeat the adjustment if necessary.

4. Place the flange, timing belt toothed wheel and washer on the crankshaft journal.

The flange is installed on the side of the internal toothed belt toothed wheel. Screw in the fastening bolt and tighten it to the required force (110÷130 Nm).

5. To install the oil pump gear, insert a Phillips screwdriver with an 8 mm diameter blade into the special hole in the left wall of the cylinder block (remove the plug first). After locking the balancing shaft with the screwdriver, tighten the fastening nut with the required force (50÷60 N·m).

6. Using an open-end wrench placed on the flats provided between the journals of the 2nd and 3rd bearings, secure the camshaft from turning and tighten the bolt securing its gear wheel with the required force (80÷100 N·m).

If there are no chamfers between the journals of the specified bearings, the gear wheel can be locked using a fork wrench.

7. Carefully press the automatic tensioner rod inward so that the mounting hole in it aligns with the hole in the cylinder block. To secure the rod, thread a wire through the hole.

8. Place the roller on the tensioner arm. Ensure that the pin hole in the tension roller axle is to the left of the central bolt and tighten the latter manually.

9. When installing the timing belt, turn the camshaft gears with the mounting pins facing up and the alignment marks facing each other (the marks should be level with the mating surface of the head).

When the exhaust camshaft gear is released, it will rotate one tooth counterclockwise, which must be taken into account when fitting the belt!

The camshaft gears are provided with a sensor-switch for the installation marks. When installing the exhaust shaft gear, you should focus on the mark located on the right with the pin in the upper position, when installing the intake shaft gear, you should focus on the mark located on the left (the pin is also at the top).

10. Ensure that the timing marks on the crankshaft and oil pump gears are correctly aligned.

11. Remove the plug and insert a Phillips screwdriver with an 8 mm diameter blade into the hole in the cylinder block wall. If the screwdriver can be inserted approximately 60 mm, the balance shaft is in the correct position. If the screwdriver cannot be inserted deeper than 20-25 mm, turn the oil pump gear wheel one full revolution and try again. Leave the screwdriver inserted into the hole.

Failure to correctly position the balancing shaft may result in vibrations during engine operation.

12. Place the timing belt over the intake camshaft timing gear and secure it with two spring clips.

13. Place the belt on the toothed wheel of the exhaust camshaft - using two keys, achieve the correct alignment of the installation marks. To fix the belt, use a pair of clamps again.

14. Thread the belt under the idler pulley, then pull it over the oil pump and crankshaft gears, finally threading it under the tensioner pulley. Remove the clamps.

15. Rotate the tensioner clockwise and tighten the center bolt. Make sure that the timing marks are aligned correctly.

16. Turn the crankshaft 1/4 turn counterclockwise, then return it to its original position, achieving the required alignment of all timing marks, the engine should be in the TDC position of the end of the compression stroke of the piston of the first cylinder.

17 Loosen the central bolt, then using tool MD998738 and a torque wrench, apply a torque of 2.6÷2.8 Nm to the tensioner and retighten the bolt.

18 Screw the special tool into the left powertrain support bracket until it is pressed against the tensioner lever. Screw the tool in a little more and pull out the wire securing the automatic tensioner. Remove the special tool.

19 Turn the crankshaft two full turns clockwise, allow the components to settle for about 15 minutes, then measure the protrusion of the automatic tensioner (the distance between the tensioner lever and the automatic tensioner housing). The required value is 3.8÷4.5 mm. Repeat the adjustment if necessary.

20 If the timing belt tension is adjusted with the engine installed on the vehicle, it is not possible to measure the specified gap. In this situation, an alternative method should be used:

• Screw in the MD998738 tool, pressing its end against the tensioner lever;
• Screw the tool in a little more, pressing the tensioner pusher, count the number of tool turns required for the tensioner lever to press against the automatic tensioner body - the nominal value is 2.5÷3 turns;
• Install the rubber plug into the rear timing cover.

21 Reinstall the front cover sections and other components removed for access.

22 Connect the negative cable to the battery.

1.8L and 2.0L SOHC engines

Removal

1. Bring the engine to the TDC position of the end of the compression stroke of the piston of the first cylinder.

2. Disconnect the negative cable from the battery.

If your car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!

3. Remove the crankcase protection elements.

4. Support the engine with a trolley jack (to distribute the load, place a wooden block between the jack head and the engine oil pan). Remove the powertrain suspension support bracket.

5. Remove the accessory drive belts, tensioner pulley brackets, and water pump and crankshaft pulleys.

6. Remove the mounting screws and remove the upper and lower sections of the front timing cover.

7. Remove the timing belt, crankshaft outer gear and spacer flange.

8. Remove the balance shaft drive toothed belt tensioner, then the inner belt itself.

9. Remove the crankshaft pulley.

10. Mark the direction of rotation of the timing belt with chalk or paint. Loosen the tensioner and fix it in this position.

Installation

1. Ensure that the timing marks on the balance shaft and crankshaft gears are correctly aligned with the matching marks on the front casing.

2. Place the belt on the toothed wheels so that its upper part is taut. Check that the installation marks are aligned correctly.

3. Install the tension roller and move it manually so that the long belt run is deflected by approximately 6 mm.

4. After locking the pulley from turning, tighten the mounting bolt to the required torque (20 Nm) and check the deflection again.

5. Move the timing belt tensioner all the way toward the water pump and tighten the bolts. Press the upper end of the spring against the water pump housing.

6. Align the timing marks on the camshaft, crankshaft and oil pump gears with the corresponding marks on the front casing.

There is a 50% chance that the balance shaft will be misaligned (180-degree offset) despite all marks being correctly aligned, which will result in a noticeable increase in vibration levels during engine operation. To avoid this, please follow the procedures below with the utmost care!



7. Before installing the timing belt, make sure that the left (rear) balance shaft (oil pump gear) is correctly oriented:

• Remove the plug from the rear wall of the cylinder block and insert a rod with a diameter of 8 mm into the opened hole;
• When the marks are correctly aligned, the rod should enter to a depth of about 60 mm. If the rod cannot be inserted deeper than 25 mm, the oil pump gear should be turned one full revolution;
• Make sure the marks are aligned correctly;
• Leave the rod inserted into the hole to secure the balance shaft.

8. Place the belt on the toothed wheels first of the crankshaft, then of the oil pump, making sure that all the slack is on the side where the tensioner is located.

9. Make sure that the timing marks are aligned correctly. If everything is in order, loosen the tensioner mounting bolt, allowing the latter to take up the slack in the belt.

10. Remove the balance shaft retaining pin and turn the crankshaft so that the camshaft gear advances two teeth - the tensioner will automatically adjust the belt tension force.

Attempts to adjust the belt manually may result in a howling sound when the engine is running!

11. Tighten the lower mounting/spacer bolts first, then the upper mounting/spacer bolts.

12. Check that the belt tension is adjusted correctly - the deflection of the longest run when pressed firmly with your thumb should be about 13 mm.

13. Install the timing belt covers and other components removed to provide access in the reverse order of their removal. Make sure that all the sealing elements provided are seated in the groove on the mating surfaces of the covers.

14. Connect the negative cable to the battery.

2.0L DOHC Turbocharged Engines

Removal

1. Disconnect the negative cable from the battery.

If your car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!

2. Remove the crankcase protection elements.

3. Support the engine with a trolley jack (to distribute the load, place a wooden block between the jack head and the engine oil pan). Remove the powertrain suspension support bracket.

4. Remove the accessory drive belts.

5. Remove the drive belt tension roller.

6. Remove the water pump and crankshaft pulleys.

7. Unscrew the threaded stud from the powertrain suspension support bracket and remove the timing belt drive covers.



8. Turn the engine clockwise until the timing marks are aligned.

9. Loosen the center bolt of the tension roller.

10. Mark the direction of rotation of the timing belt with chalk or paint. Move the tensioner towards the water pump and remove the belt.

11. Using the special tool МВ9g67, block the crankshaft gear from turning and loosen the central bolt of its fastening. Using the puller МВ998778, remove the gear.

12. Mark the direction of rotation of toothed belt B with chalk or paint.

13. Loosen the tensioner center bolt and remove the belt.

Installation

1. Place the toothed wheel on the crankshaft journal, lock it from turning using the МВ9g67 tool and tighten the central mounting bolt with the required force (108÷127 N·m).



2. Ensure that the timing marks on the crankshaft timing gear B and the balance shaft gear are correctly aligned.

3. Place the inner belt B on the toothed wheels. Move the tension roller to the left, positioning it in the center above the mounting bolt.

4. Turn the roller clockwise towards the crankshaft, select the slack in the belt and tighten the fastening bolt with a force of 19 N·m, - to avoid excessive tension of the belt, try not to allow the roller to move while tightening the bolt. When the tension is adjusted correctly, the belt should deflect by approximately 5-7 mm when you press it firmly with your thumb in the area in the middle between the toothed wheels.

5. Install the crankshaft outer gear. Lightly lubricate the mounting bolt with oil, screw it in and tighten it to 108÷127 N·m.

6. Using a vice, press the automatic tensioner pusher and fix it in this position by inserting a special pin into the aligned holes.

7. Install the automatic tensioner assembly onto the engine.

8. Ensure that the timing marks on the camshaft, crankshaft and oil pump gears are correctly aligned.

9. After the oil pump gear mark is correctly aligned, remove the plug from the cylinder block wall and insert a rod of approximately 8 mm in diameter into the vacated hole - the rod should enter the hole at least 60 mm, otherwise the pump gear should be turned once and the rod should be inserted again. Leave the rod inserted into the hole until the belt installation procedure is complete.

10. Place the timing belt on the intake camshaft sprocket and secure it with a clamp.

11. Place the belt on the exhaust camshaft sprocket.

12. Check that the timing marks are correctly positioned relative to the mating surface of the cylinder head - if necessary, make the appropriate adjustments using a pair of wrenches. Secure the belt to the second wheel with another clamp.

13. Place the belt under the idler pulley, then pull it over the oil pump and crankshaft gears, finally tucking it under the tensioner pulley.

14. Turn the tension roller so that the pin holes are at the bottom and press it lightly against the belt tape.

15. Screw the special tool into the left powertrain suspension bracket until its end rests against the tensioner lever. Screw the tool in a little more and remove the pin locking the automatic tensioner. Remove the special tool and tighten the central bolt to the required torque (48 N·m).

16. Turn the crankshaft 1/4 turn counterclockwise, then return it to its original position, achieving correct alignment of the timing marks.

17. Loosen the center bolt and install the special tool MD998767 on the tensioner roller. Apply a counter-clockwise torque of 3.5 N·m to the roller and tighten the center bolt to the required torque (48 N·m), - try not to allow the roller to move while tightening the bolt.

18. Turn the crankshaft two full turns clockwise and again ensure that the timing marks are correctly aligned.

19. After allowing the components to settle for at least 15 minutes, measure the protrusion of the automatic tensioner pushrod - the required value is 2.8÷4.8 mm. If necessary, loosen the central bolt again and repeat the adjustment procedure.

20. Reinstall the timing belt covers and any other components that were removed to provide access.

21. Connect the negative cable to the battery.

2.4L engines

Removal

1. Disconnect the negative cable from the battery.

If your car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!

2. Remove the high voltage wires from the bracket on the top cover.

3. Drain the cooling system.

To avoid burns, proceed with the above work only after the system has completely cooled down! Do not allow antifreeze to come into contact with exposed areas of the body or painted surfaces of the car. Wash off any accidental splashes immediately with plenty of water. Remember that antifreeze is a highly toxic liquid and its ingestion, even in small quantities, can have the most serious consequences (even fatal). Never leave antifreeze stored in a loosely closed container and immediately collect any coolant spilled on the floor. Remember that the sweet smell of antifreeze can attract the attention of children and animals. Consult any car service station for information on how to dispose of used coolant. In many regions of the world, special collection points for various types of waste have been set up. Never pour old coolant down the drain or onto the ground!

4. Remove the cooling fan(s) assembly with shrouds (see Section Removal and installation the engine cooling system fan) and drive belts of auxiliary units.

5. If necessary, remove the radiator (see Section Removal and installation the cooling system radiator (all models)).



6. Remove the upper powertrain mount assembly.





7. Remove the upper section of the front timing cover.







8. Remove the steering pump, alternator, air conditioning compressor, tensioner pulley and associated support brackets.

9. Remove the water pump and crankshaft pulleys.

10. Remove the mounting screws and remove the lower section of the timing belt cover.



11. If the belt(s) is to be reused, mark its direction of rotation.

12. Remove the outer toothed (timing) belt. Unbolt from the block and remove the tensioner assembly.









13. Remove the crankshaft outer gear and spacer flange.







14. Unbolt from the block and remove the tensioner of the internal toothed belt (balance shaft drive belt). Remove the internal belt.





15. To remove the camshaft gear, you will need special tools such as SST MB9g67-01 and MIT308239.

Installation

1. Install the camshaft timing gear. The required tightening torque for the central bolt is 90 Nm.

2. Align the timing marks on the balance shaft drive belt gears with the matching indicators on the front casing. Place the belt on the gears so that all the slack is collected at the bottom. Check again that the marks are aligned correctly.

3. Install the tensioner so that the axis of its roller is above and to the left of the installation bolt.

4. Use your hands to move the roller upwards so that the long belt run, when pressed firmly with your thumb, bends approximately 6 mm.

5. Having locked the roller in this position to prevent it from turning, tighten the bolt to the required torque (20 Nm). If the roller moves when released, the belt is therefore too tight.



6. Install the timing belt tensioner, move it all the way to the water pump and temporarily tighten the bolts. Press the upper end of the spring against the pump housing. Align the timing marks on the timing gear wheels with the corresponding indicators on the front casing.

There is a 50% chance that the balance shaft will be misaligned (180-degree offset) despite all marks being correctly aligned, which will result in a noticeable increase in vibration levels during engine operation. To avoid this, please follow the procedures below with the utmost care!

7. Before installing the timing belt, make sure that the left balance shaft (oil pump gear) is correctly oriented:

• Check that the oil pump gear mark is correctly aligned with the counter indicator on the front casing;
• Remove the plug from the left wall of the cylinder block in the area where the starter is mounted;
• Insert a rod with a diameter of 8 mm into the opened hole;
• When the marks are correctly aligned, the rod should enter to a depth of about 60 mm. If the rod cannot be inserted deeper than 25 mm, the oil pump gear should be turned one full revolution;
• Make sure the marks are aligned correctly;
• Leave the rod inserted into the hole to secure the balance shaft.

8. Place the belt on the toothed wheels first of the crankshaft, then of the oil pump and finally of the camshaft. Make sure that all the slack is collected on the side where the tension roller is located - the opposite run of the belt must remain taut.

9. Check the correct alignment of the timing marks; if everything is in order, loosen the tensioner mounting bolt, allowing the roller to press against the belt tape and remove any slack.

10. Remove the rod that holds the balance shaft, then turn the crankshaft clockwise so that the camshaft gear moves two teeth, and the belt tension force should be automatically adjusted.

Attempts to adjust the belt manually are fraught with overtightening it, which usually leads to the occurrence of a howling sound when the engine is running!

11. Tighten the mounting bolts (first the lower one, then the upper spacer bolt).

The material was borrowed from the website [MITSUBISHIMAN]

If you feel any resistance when turning the crankshaft while adjusting the belt tension, stop the procedure immediately to avoid damaging the valves by accidental contact with the pistons.

12. Check the correct adjustment of the belt tension - when pressing firmly with your thumb in the middle of the straight run of the belt (between the camshaft and oil pump wheels), the latter should bend by approximately 13 mm.

13. Install the lower section of the timing drive, making sure that all the provided sealing gaskets are seated.

14. Install the water pump and crankshaft pulleys.

15. Install the upper section of the front timing cover.

16. Install the steering pump, alternator, air conditioning compressor, tensioner pulley, support brackets and other components removed for access.

17. Install the radiator and cooling fan assembly with the protective shroud (see Sections Removal and installation the cooling system radiator (all models) и Removal and installation the engine cooling system fan).

18. Secure the spark plug wires to the support bracket on the top cover.

19. Fill the engine with fresh coolant of the required grade (see Chapter Settings and ongoing maintenance).

20. Connect the negative cable to the battery.

21. Start the engine and check it for signs of developing leaks.

Engines 3.0L SOHC

Models produced in 1992÷1994.

Removal

1. The installation details of the timing belt cover and components on 3.0L models produced in 1990–1994 are shown in the illustration.

2. Disconnect the negative cable from the battery.

If your car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!

3. Remove the crankcase protection elements.

4. Remove the speed control system actuator (tempostat).

5. Remove the accessory drive belts (see Chapter Settings and ongoing maintenance).

6. Remove the air conditioning compressor drive belt tensioner assembly.

7. Remove the tensioner support bracket.

8. Support the engine with a trolley jack (to distribute the load, place a wooden block between the jack head and the engine oil pan) and remove the powertrain suspension support bracket.

9. Disconnect the wiring from the steering pump pressure switch. Remove the pump, move it to the side without disconnecting the hydraulic lines, and tie it with wire.

10. Remove the crankshaft pulley.

11. Remove the timing belt side cover.

12. Remove the upper and lower sections of the front timing cover.

13. Mark the direction of rotation of the timing belt with chalk or paint, loosen the tensioner and remove the belt.

Try to prevent coolant or engine oil from getting on the surfaces of the timing belt or timing gear!

14. Make sure that the TDC marks on the timing gear drive are correctly aligned.

15. Loosen the tensioner bolt and remove the timing belt. If the tensioner does not need to be removed, move it to the side as far away from the engine as possible and secure it in this position by tightening the bolt.

16. If the tensioner is to be removed, mark the correct installation position of its spring - it must be installed similarly during assembly. Unbolt the tensioner and remove it together with the spring.

Installation

1. If removed, install the tensioner, connect the upper end of the spring to the pin on the water pump housing, secure the lower end in the original position. Install the gear wheels of both camshafts - make sure the timing marks are aligned. Turn the crankshaft until the timing mark is aligned with the corresponding pointer on the oil pump housing.

2.Put the timing belt on the crankshaft toothed wheel and, keeping the corresponding side taut, place the belt strap on the front camshaft wheel.

3. Place the belt under the water pump drive face, then pull it onto the rear camshaft sprocket and tuck it under the tensioner roller.

4. Turn the front camshaft counterclockwise, achieving belt tension in the area between the gear wheels of this shaft and the crankshaft. If the timing marks are misaligned during belt installation, repeat the procedure.

5. Install the guide flange on the crankshaft gear.

6. Loosen the tensioner bolt and allow the spring to take up the slack in the belt.

7. Rotate the crankshaft two full turns clockwise, again aligning the timing marks, then tighten the tensioner lock bolt to the required torque (29 N·m). Check the correct adjustment of the belt tension using a special measuring device. When connecting the device to the belt tape in the middle between the gears of the rear camshaft and crankshaft, the reading should be (230÷310 N·m).

8. Install the timing belt drive covers - make sure that all sealing gaskets provided by the design are seated on the mating surfaces of the sections.

9. Install the crankshaft pulley. Screw in the mounting bolt and tighten it to the required torque (150÷160 Nm).

10. Install the engine support bracket.

11. Install the steering pump and connect the wiring to the power steering pressure switch sensor.

12. Install the powertrain suspension support bracket and remove the jack from under the engine.

13. Install the tension rollers and accessory drive belts.

14. Install the cruise control actuator.

15. Install the crankcase protection elements.

16. Connect the negative cable to the battery.

17. Conduct road tests of the vehicle.

Other models

Removal

1. Bring the piston of the first cylinder to the TDC position at the end of the compression stroke.

2. Disconnect the negative cable from the battery.

If your car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!

To avoid unauthorized deployment of the airbags, begin the procedure at least 90 seconds after disconnecting the battery!

3. Remove the crankcase protection element.

4. Remove the pump and the cruise control drive rod.

5. Remove the generator.

6. Support the engine with a trolley jack (to distribute the load, place a wooden block between the jack head and the engine oil pan) and remove the powertrain suspension support bracket.

7. Remove the front timing belt covers.

8. Mark the direction of rotation of the timing belt with chalk or paint, loosen the tensioner and remove the belt.

Try to prevent coolant or engine oil from getting on the surfaces of the timing belt or timing gear!

9. Make sure the engine is still at TDC and the timing marks are properly aligned.

10. Loosen the center bolt of the tension roller and unbolt the automatic tensioner assembly.

The automatic tensioner needs to be reinstalled!

11. Remove the timing belt.

12. Using a wrench, lock the camshaft from turning and remove the gear wheel from it.

13. Clamp the automatic tensioner assembly in a vice with soft jaws.

There is a protruding plug on the rear side of the tensioner assembly - to avoid accidental damage, place a washer of the appropriate thickness under the jaws of the vice.

14. Slowly push the tensioner rod in until the mounting holes align.

15. Thread a 1.4 mm thick wire through the aligned holes, release the tensioner assembly from the vice and install it on the engine. Screw in the mounting bolts and tighten them to the required torque (24 N·m).

before installing, the mating surface of the tensioner should be thoroughly cleaned, the threaded part of the old bolts should be lubricated with sealant. When replacing bolts, sealant is applied only to those whose heads are not marked with white paint.

Installation

1. If removed, install the tensioner. Connect the upper end of the spring to the pin on the water pump housing, secure the lower end to the tensioner assembly, bringing it strictly to the previous installation position.

2. Make sure that the timing marks on both camshafts are correctly aligned.

3. Turn the crankshaft so that its timing mark is aligned with the counter indicator on the front cover.

4. Place the timing belt on the crankshaft toothed wheel, then, holding the corresponding side taut, place the belt tape on the front (left) camshaft toothed wheel.

5. Thread the belt under the water pump drive roller, then tighten it onto the rear (right) camshaft sprocket. Finally, thread the belt tape under the tension roller.

6. Loosen the adjuster lock bolt and lightly press the tensioner onto the belt webbing. Make sure all timing marks are aligned correctly.

7. Turn the crankshaft two full turns clockwise, finally aligning the marks again.

8. Tighten the tensioner lock bolt to the required torque (26 N·m).

9. Install the timing cover sections and all other components removed for access.

10. Connect the negative cable to the battery.

11. Conduct road tests of the vehicle.

Engines 3.0L DOHC

Models produced in 1992÷1994.

Removal

1. Bring the engine to the TDC position of the end of the compression stroke of the piston of the first cylinder.

2. Disconnect the negative cable from the battery.

If your car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!

3. Remove the crankcase protection elements.

4. Remove the speed control system actuator (tempostat).

5. Remove the generator.

6. Remove the air hose and tube.

7. Remove the tensioner assembly and the steering pump drive belt.

8. Remove the crankshaft pulley.

9. Disconnect the electrical wiring from the brake fluid level sensor.

10. Remove the upper section of the timing belt cover.

11. Support the engine with a trolley jack (to distribute the load, place a wooden block between the jack head and the engine oil pan) and remove the powertrain suspension support bracket.

12. Remove the intermediate roller of the generator/compressor drive belt.

13. Remove the engine support bracket.

The mounting bolts have different lengths and must be installed strictly in their original places during assembly.

14. Remove the lower section of the front timing cover - try to remember the installation position of the mounting bolts.

15. Mark the direction of rotation of the timing belt with chalk or paint, loosen the tensioner and remove the belt.

Make sure that no coolant or engine oil gets on the surfaces of the timing belt or timing gears! Make sure that the engine is still in the TDC position.

16. Loosen the tensioner bolt and remove the belt.

17. Remove the tensioner assembly.

Installation

1. If the automatic tensioner rod is fully extended, reinstall it:

• Place the tensioner assembly in a vice with soft jaws;
• Slowly squeezing the jaws of the vice, press the rod to align its hole with the hole in the cylinder;
• By inserting a piece of rigid wire into the aligned holes, fix the rod in the recessed position;
• Remove the assembly from the vice.

2. Without removing the wire, install the tensioner on the engine.

3. If the alignment of the installation marks is not correct, perform the manipulations described below.

• Try not to put your fingers between the spokes of the gear wheels, as the latter may suddenly turn under the force developed by the valve springs!
• Ensure that the timing mark on the crankshaft gear is correctly positioned, then turn the gear 2 teeth clockwise to eliminate the risk of piston-valve contact when turning the camshafts;
• Alternately achieve the correct positioning of the timing marks on the gear wheels of each of the camshafts.
• When opening the intake and exhaust valves of one cylinder at the same time, they can cling to each other, therefore, if the slightest resistance occurs, the position of the second camshaft should be immediately adjusted;
• Again, align the timing marks on the crankshaft, then turn the latter one more tooth counterclockwise, thereby preparing the wheels for installing the timing belt.

4. Install the timing belt in the following order (immediately secure the belt to the camshaft gears with spring clamps):

• 1 - front cylinder head exhaust camshaft gear;
• 2 - front cylinder head intake camshaft gear;
• 3 - water pump drive roller;
• 4 - toothed wheel of the intake camshaft of the rear cylinder head;
• 5 - toothed wheel of the exhaust camshaft of the rear cylinder head;
• 6 - intermediate roller;
• 7 - crankshaft gear;
• 8 - tensioner roller.

5. Rotate the tensioner pulley so that the holes in its pin are directly above the center bolt, then press the pulley against the belt webbing and tighten the center bolt at the same time.

6. Make sure that the timing marks are aligned correctly and remove the belt retaining clips.

7. Turn the crankshaft 1/4 turn counterclockwise, then return it back, again achieving correct alignment of the marks.

8. Loosen the tension roller center bolt. Using the special tool type MD998767 and a torque wrench, apply a torque of 10 Nm to the roller and tighten the bolt again (make sure that the tensioner does not turn while tightening the bolt).

9. Remove the wire that secures the automatic tensioner rod.

10. Rotate the crankshaft two full turns clockwise and allow the components to settle for at least 5 minutes. Check the free movement of the installation pin in the tensioner hole.

11. Measure the protrusion of the automatic tensioner (the distance between the tensioner lever and its housing). The required value is 3.8÷4.5 mm. If the measurement result is outside the permissible range, repeat the adjustment procedure.

12. Install the lower section of the front timing cover onto the engine, making sure that all sealing gaskets provided by the design are installed.

13. Install the engine support bracket, - make sure that all bolts are installed strictly in their original places, - pre-lubricate the working surface of the countersunk bolt, tighten the bolt slowly.

14. Install the intermediate roller.

15. Install the powertrain suspension support bracket, lower the jack and remove it from under the engine.

16. Reinstall the upper section of the front timing cover, making sure that all sealing gaskets provided by the design are installed.

17. Connect the wiring to the brake fluid level sensor.

18. Install the crankshaft pulley. Screw in the mounting bolt and tighten it to the required torque (180÷190 Nm).

19. Install the tensioner assembly and steering pump drive belt.

20. Install the air hose and tube.

21. Install the generator.

22. Install the cruise control actuator.

23. Install the crankcase protection elements.

24. Connect the negative cable to the battery.

25. Conduct road tests of the vehicle.

Models produced in 1995 and 1996.

Removal

1. Bring the engine to the TDC position of the end of the compression stroke of the piston of the first cylinder.

2. Disconnect the negative cable from the battery.

If your car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!

To avoid unauthorized deployment of the airbags, start the procedure at least 90 seconds after disconnecting the battery!

3. Remove the crankcase protection elements.

4. Remove the speed control system actuator (tempostat).

5. Remove the generator.

6. Remove the air hose and tube.

7. Remove the tensioner assembly and the steering pump drive belt.

8. Remove the crankshaft pulley.

9. Disconnect the electrical wiring from the brake fluid level sensor.

10. Remove the upper section of the timing belt cover.

11. Support the engine with a trolley jack (to distribute the load, place a wooden block between the jack head and the engine oil pan) and remove the powertrain suspension support bracket.

12. Remove the intermediate roller of the generator/compressor drive belt.

13. Remove the engine support bracket.

The mounting bolts have different lengths and must be installed strictly in their original places during assembly.

14. Remove the lower section of the front timing cover - try to remember the installation position of the mounting bolts.

15. Mark the direction of rotation of the timing belt with chalk or paint, loosen the tensioner and remove the belt.

Make sure that no coolant or engine oil gets on the surfaces of the timing belt or timing gears! Make sure that the engine is still in the TDC position.

16. Loosen the tension roller bolt and remove the belt.

To avoid damaging the valves when they hit the piston bottoms, do not allow the camshaft gears to turn when the timing belt is removed!

17. Remove the mounting bolts and the automatic tensioner assembly.

Installation

1. Cock the automatic tensioner rod:

• Place the tensioner assembly in a vice with soft jaws;
• Slowly squeezing the jaws of the vice, press the rod to align its hole with the hole in the cylinder;
• By inserting a piece of rigid wire with a diameter of 1.4 mm into the aligned holes, fix the rod in the recessed position;
• Remove the assembly from the vice.

2. Without removing the wire, install the tensioner on the engine. Screw in the mounting bolts and tighten them to the required torque (24 N·m).

3. Ensure that the timing mark on the crankshaft timing gear is correctly positioned, then turn the gear 1 tooth counterclockwise.

4. Align the timing marks on the camshafts.

5. Install the timing belt in the following order (immediately secure the belt to the toothed wheels with spring clamps):

• 2 - toothed wheel of the intake camshaft of the front cylinder head;
• 3 - water pump drive roller;
• 4 - toothed wheel of the intake camshaft of the rear cylinder head;
• 5 - toothed wheel of the exhaust camshaft of the rear cylinder head;
• 6 - tensioner roller;
• 7 - crankshaft gear;
• 8 - intermediate roller.

6. Make sure the crankshaft marks are aligned correctly, then press the tensioner roller against the belt tape. After the belt slack has been taken up, tighten the tensioner bolt.

7. Rotate the tensioner pulley so that the holes in its pin are directly above the center bolt.

8. Make sure that the timing marks are aligned correctly and remove the belt retaining clips.

9. Turn the crankshaft 1/4 turn counterclockwise, then return it back, again achieving correct alignment of the marks.

10. Loosen the tensioner pulley centre bolt. Using the special tool type MD998767 and a torque wrench, apply a torque of 10 Nm to the pulley and tighten the bolt again, this time to the required force (49 Nm) (ensure that the tensioner does not turn while tightening the bolt).

11. Rotate the crankshaft two full revolutions clockwise and allow the components to settle for at least 5 minutes. Check the free movement of the installation pin in the hole of the automatic tensioner.

12. Remove the tensioner rod retaining wire.

13. Measure the automatic tensioner protrusion (distance between the tensioner lever and its housing). The required value is 3.8÷4.5 mm. If the measurement result is outside the permissible range, repeat the adjustment procedure.

14. Install the lower section of the front timing cover onto the engine, making sure that all sealing gaskets provided by the design are installed.

15. Install the engine support bracket, - make sure that all bolts are installed strictly in their original places, - pre-lubricate the working surface of the countersunk bolt, tighten the bolt slowly.

16. Install the intermediate roller.

17. Install the powertrain suspension support bracket, lower the jack and remove it from under the engine.

18. Reinstall the upper section of the front timing cover, making sure that all sealing gaskets provided by the design are installed.

19. Connect the wiring to the brake fluid level sensor.

20. Install the crankshaft pulley. Screw in the mounting bolt and tighten it to the required torque (180÷190 Nm).

21. Install the tensioner assembly and steering pump drive belt.

22. Install the air hose and tube.

23. Install the generator.

24. Install the cruise control actuator.

25. Install the crankcase protection elements.

26. Connect the negative cable to the battery.

27. Conduct road tests of the vehicle.

3.5L engines

Removal

1. Disconnect the negative cable from the battery.

If your car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!

2. Drain the cooling system.

To avoid burns, proceed with the above work only after the system has completely cooled down! Do not allow antifreeze to come into contact with exposed areas of the body or painted surfaces of the car. Wash off any accidental splashes immediately with plenty of water. Remember that antifreeze is a highly toxic liquid and its ingestion, even in small quantities, can have the most serious consequences (even fatal). Never leave antifreeze stored in a loosely closed container and immediately collect any coolant spilled on the floor. Remember that the sweet smell of antifreeze can attract the attention of children and animals. Consult any car service station for information on how to dispose of used coolant. In many regions of the world, special collection points for various types of waste have been set up. Never pour old coolant down the drain or onto the ground!

3. Remove the accessory drive belts.

4. Remove the upper radiator shroud.

5. Remove the fan assembly with the drive pulley.

6. Unbolt the steering pump from its support bracket, without disconnecting the hydraulic hoses, move the pump to the side and secure it with wire. Remove the pump support bracket.

7. Remove the cooling fan support bracket.

8. On some models, to gain access to the bolts securing the lower section of the front timing cover, it is necessary to remove the crankshaft pulley.

9. Unscrew the mounting bolts and remove the upper and lower timing belt drive covers.

10. Disconnect the wiring from the crankshaft position (CKP) sensor.

11. Using special tools MB9g67-01 and MD998754, remove the pulley from the crankshaft journal.



12. Carefully wipe the timing marks on the timing gear wheels with a clean rag. And ensure that they are correctly aligned.

13. Mark the direction of rotation of the timing belt with chalk or paint, loosen the tensioner and remove the belt.

Make sure that no coolant or engine oil gets on the surfaces of the timing belt or timing gears! Make sure that the placemarks are aligned correctly.

14. Loosen the center bolt of the tension roller and remove the timing belt.

15. Remove the automatic tensioner assembly, tension roller and tensioner arm.

16. While holding the camshafts from turning with a suitable wrench, loosen the mounting bolts and remove the corresponding gears.

Installation

1. Install the crankshaft pulley in place and turn the crankshaft gear three teeth clockwise, thereby bringing the engine to a position slightly beyond TDC of the end of the compression stroke of the piston of the first cylinder.

2. If removed, reinstall the camshaft sprockets. Tighten the mounting bolts to the specified torque (88 N·m).

3. Align the timing marks of the camshaft gears on the left and right cylinder heads. Use a wrench to prevent the gears from turning.

4. Place the belt on the camshaft sprockets of the right cylinder head and secure it with a pair of paper clips.

5. Place the timing belt under the water pump drive roller.

6. Make sure that the timing marks on the camshaft gears of the left cylinder head are correctly aligned, put the belt on the wheels and secure it with a pair of spring clips.

7. Place the belt under the idler roller.

8. Turn the crankshaft one full revolution counterclockwise and again align the timing marks.

9. Place the belt under the tension roller.

10. Turn the roller with the pin hole facing up, press it against the belt webbing and tighten the locking bolt to 48 Nm.

11. Slowly rotate the crankshaft two full turns clockwise until the timing marks are aligned. Remove the four clamps securing the belt to the camshaft gears.

12. Reinstall the timing belt covers.

13. Install the crankshaft pulley. Screw in the mounting bolt and tighten it to the required torque (150 Nm).

14. Install all components removed for safety purposes onto the engine in the reverse order of their removal.

15. Fill the cooling system with fresh mixture of the required grade (see Chapter Settings and ongoing maintenance).

16. Connect the negative cable to the battery.

17. Start the engine and check for signs of developing leaks.