Timing Belt Replacement (4G93 Engine) (Mitsubishi Lancer 9)

Removal

Before you begin removing parts, perform the following operations:

• a) Remove the decorative engine cover.
• b) Remove the engine crankcase protective cover.
• c) Remove the support bracket and engine mount assembly.
• d) Remove the generator adjusting bar.

The parts are removed in the order of numbers indicated in the figures "Removing the crankshaft pulley" and "Replacing the timing belt".

When removing parts, pay attention to the following operations:

1. Removing the power steering pump and air conditioning compressor drive belt.

a) Loosen the lock nut of the power steering pump and air conditioning compressor drive belt tensioner roller.



b) Loosen the adjusting bolt to release the belt tension, then remove the belt.

Caution: If the power steering pump and air conditioning compressor drive belt is reused, an arrow indicating the direction of rotation (clockwise) must be chalked on the reverse (non-working) surface of the belt.

2. Removing the generator drive belt.

a) Loosen the lock bolt on the generator adjusting bar and the pivot bolt.







b) Turn the adjusting bolt to release the tension of the generator drive belt, then remove the belt.

Caution: If the alternator drive belt is reused, it is necessary to mark an arrow with chalk on the reverse (non-working) surface of the belt indicating the direction of rotation (clockwise).

3. Removing the crankshaft pulley.

Using a special tool, secure the crankshaft pulley from turning and unscrew the crankshaft pulley mounting bolt.

Caution: Secure the special tool securely to prevent it from moving.

4. Removing the timing belt.



a) Turn the crankshaft clockwise until the timing marks on the camshaft pulleys and the crankshaft toothed pulley are aligned with the corresponding timing marks to set the piston of cylinder No.1 to TDC of the compression stroke.

Caution: Always turn the crankshaft clockwise only.

If the timing belt tensioner does not need to be removed or needs to be removed with the rod fixed, then:

Screw the special rod into the hole of the attachment bracket so that it rests against the groove on the tensioner lever.







- Slowly screw in the special rod to align hole "B" on the tensioner body with hole "A" on the tensioner rod.

Note: When the rod rests against the tensioner lever, turn it back 30° for 1 second, then continue turning it again. If the rod is difficult to turn, be careful not to bend the tensioner rod.

- Insert a rigid "L" shaped wire with a diameter of 2 mm into the hole of the tensioner body.



c) If necessary, turn the crankshaft and position the crankshaft timing mark 3 teeth before the corresponding timing mark on the cylinder block.

Caution: If all timing marks are not aligned, the valves may "meet" the piston when the camshaft pulley turns while the piston is at TDC.

d) Loosen the tensioner roller adjusting bolt and remove the timing belt.

Note: If the timing belt is reused, it is necessary to mark with chalk an arrow on the reverse (non-working) surface of the belt indicating the direction of rotation (clockwise).

Examination

Checking the timing belt tensioner

1. Check the tensioner for oil leaks. If there are any leaks, replace the timing belt tensioner.

2. Check the rod for wear and damage, replace the timing belt tensioner if necessary.

3. Measure the amount of rod protrusion. If this value does not correspond to the nominal value, replace the timing belt tensioner.

Nominal value (A) - 11 mm



4. Take the timing belt tensioner in your hands. Press the tensioner rod (for example, by resting it against the cylinder block), applying a force of 98-196 N, and then measure the stroke of the rod "B". If the stroke of the rod is beyond the nominal value, replace the timing belt tensioner.



Nominal value (B) - 1 mm or less

Note: This test can be performed using a vice. When placing the tensioner body in the vice, make sure that the body is not skewed relative to the jaws of the vice. If the rod is easily depressed, replace the tensioner. If the tensioner is in good condition, then recessing the rod requires considerable effort.

Note: When replacing the timing belt, it is recommended to replace all rollers at the same time.

1. Check the ease and smoothness of rotation of the rollers.



2. Check for excessive play in the bearings and extraneous noise when the roller rotates. Replace if necessary.

Installation

Attention:

• Since water or oil can seriously reduce the life of the timing belt, when removing parts, ensure that the timing belt, pulleys and tensioner bracket are clean and dry, never wash them. Contaminated parts must be replaced.
• If any of the parts are oily, check for oil leaks through the seals (including the front camshaft seal).
• Check the condition and smooth rotation of the tensioner roller.
• If you are installing a timing belt that has been in use, check its condition.

Installation is carried out in the reverse order of removal.



When installing parts, please pay attention to the following operations:

1. Installing the timing belt tensioner (if the tensioner rod is in its fully extended position).

a) Place the timing belt tensioner in a vice with soft pads.

b) Gradually tightening the vice, push the timing belt tensioner rod in as slowly as possible until hole "A" in the rod aligns with hole "B" in the tensioner housing.

Attention:

• The tensioner must be installed at a right angle to the surface of the vice jaws, without tilting.
• If you push the plunger in too quickly, it may be damaged or bent, so perform this operation slowly.

b) Insert a 2mm diameter wire into the hole to fix the rod in the tensioner body.

Note: The wire must be fairly stiff (like piano wire, etc.) and must be bent at a right angle (in an "L" shape).

c) Fasten the timing belt tensioner to the engine, tighten the mounting bolts to the specified torque.



Tightening torque 12-14 Nm

2. Installing the timing belt.

Attention:

• Install the timing belt so that the belt tension does not weaken between the pulleys and rollers.
• Install a used belt so that the arrow on the back of the belt matches the direction of rotation of the belt (clockwise).

a) Loosen the tensioner adjusting bolt.

b) Check that the marks on the camshaft pulleys and the toothed pulley of the crankshaft are aligned with the corresponding installation marks (in this case, the piston of cylinder No.1 will be at TDC of the compression stroke). If all the marks are aligned, then proceed to subparagraph "d".

Caution: If the timing marks are not aligned, the valves may "meet" the piston when the camshaft pulley turns when the piston is at TDC.

c) If the installation marks are not aligned, they must be aligned as follows:

- Carefully turn the crankshaft so that the mark on the crankshaft toothed pulley does not reach the mark on the cylinder block by three teeth (i.e. the piston of cylinder No.1 does not reach TDC of the compression stroke by a little).



- Turn the camshafts and align the pulley marks with the timing marks as shown in the figure.

Caution: When turning the camshaft pulley one full turn (to align the marks) while the pulley of the other camshaft remains stationary (marks aligned), collision of the intake and exhaust valves may occur due to a violation of the valve timing phases.

- Align the crankshaft timing mark with the timing mark on the oil pump housing.

d) To simplify the work, it is permissible to leave the pulleys in the position when the marks on the camshaft pulleys are located 2 teeth, and the mark on the toothed pulley of the crankshaft is 3 teeth before the corresponding installation marks on the cylinder block. In this case, the belt is installed starting from the camshaft pulleys. Then, when installing the belt on the toothed pulley of the crankshaft, it must be turned clockwise by 1 tooth.



d) Install the timing belt on the crankshaft toothed pulley, then on the coolant pump pulley and guide roller.



e) Install the timing belt on the exhaust camshaft pulley and secure the belt with a clamp in the position shown in the figure.



g) Make sure that the pulley marks are aligned with the timing marks and, having fixed the relative position of the camshaft pulleys using two keys, install the timing belt on the intake camshaft pulley.



c) Using another clamp, secure the timing belt to the intake camshaft pulley in the position shown in the figure.



i) Install the timing belt onto the belt tensioner roller.

j) Insert the pins of the special tool into the 2 holes of the tensioner roller, lift the tensioner roller in the direction of the arrow, and tighten the tensioner roller lock bolt.



l) Remove the two clamps that secure the belt to the pulleys.

m) Make sure that all timing marks are aligned, then adjust the timing belt tension.

3. Adjusting the timing belt tensioner.

a) First turn the crankshaft 1/4 turn counterclockwise, then turn the crankshaft clockwise to align the timing marks.

b) Loosen the tensioner roller lock bolt and apply torque to the tensioner roller using the special tool and torque wrench (tighten the belt).

The nominal value applied to the tensioner roller is 2.6 N·m

c) Then, holding the tensioner roller from turning with a special device, tighten the lock bolt to the rated tightening torque.

Caution: When tightening the lock bolt, make sure that the tensioner roller shaft does not turn with the bolt.

d) Remove the L-shaped wire that was inserted into the hole in the timing belt tensioner housing (to secure the rod).

Note: Before removing, make sure the wire can be easily removed from the tensioner housing hole.

d) Turn the crankshaft clockwise two revolutions and align the timing marks.

e) Wait for at least five minutes, and then check again that the "L"-shaped wire can be easily inserted into and removed from the timing belt tensioner. If the wire cannot be easily inserted into the timing belt tensioner hole, check that the protrusion amount of the tensioner rod is within the standard value.

Nominal value (A) 3.8 - 4.5 mm



g) If the amount of rod protrusion does not correspond to the range of nominal values, then repeat the operations according to items "a" through "g".

c) Check again that the marks on all pulleys are aligned with the timing marks.

4. Installing the front lower timing belt cover.

a) Install the bolt shown in the figure first.



b) Install the remaining bolts and tighten them to the specified torque.

Tightening torque - 10-12 N·m

5. Installing the guide plate and crankshaft pulley.

(The original material is posted on the website: MitsubishiMan.ru)

a) Clean and then degrease the surface of the crankshaft pulley that contacts the guide plate.

Note: Degreasing is necessary to improve the mating of parts.

b) Clean the threaded hole in the end of the crankshaft, the end of the shaft, the washer of the pulley mounting bolt and the surfaces in contact with it.



c) Install the guide plate on the crankshaft, positioning it as shown in the figure.



d) Lubricate the mating surface (cone) of the crankshaft nose and the thread of the crankshaft bolt with a minimum amount of engine oil.

d) Before installing the crankshaft pulley mounting bolt, it is necessary to install the bolt washer with the chamfered side facing the bolt.

e) Using a special tool, lock the crankshaft pulley from turning or lock the flywheel from turning, and install the crankshaft pulley mounting bolt, tightening it to the rated torque.

Tightening torque: 178-186 Nm

Caution: Secure the special tool securely to prevent it from turning.

After completing the installation of the parts, perform the following operations:

• a) Install the generator adjustment bar.
• b) Install the support bracket and engine mount assembly.
• c) Install the engine crankcase protective cover.
• d) Adjust the tension of the drive belts of the attachments (see the chapter "Maintenance and general check and adjustment procedures").
• d) Install the decorative engine cover.