Vise Jaws

2006 galant timing belt replacement procedures?

MITSUBISHI
3.8L V6 - SOHC - Endeavor & Galant
MANUFACTURER'S SUGGESTED SCHEDULED MAINTENANCE

Manufacturer recommends the belt be replaced every 60,000 miles except in California, Massachusetts and Vermont. In California, Massachusetts and Vermont, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles, unless previously changed.
REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur.
TIMING BELT
Removal

1. On Galant, remove engine cover. On all models, remove skid plate and under cover. Remove accessory drive belts. Using Pulley Holder (MB991800) and Pins "B" (MB001802), remove crankshaft pulley.
2. Disconnect harness connectors on connector bracket. See Fig. 1 or Fig. 2 . Remove connector bracket. Remove engine mount support bracket. Remove both upper timing belt covers.
3. Remove tensioner pulley and tensioner bracket. Remove crankshaft position sensor harness clamp. Remove lower timing belt cover. Remove front engine mount and front engine mount bracket.
4.

CAUTION: Always turn crankshaft in clockwise direction (as viewed from front of engine).
Turn crankshaft clockwise to align camshaft and crankshaft timing marks. See Fig. 3 . If timing belt is to be reused, place arrow on belt to indicate direction of belt rotation.
5. Loosen belt tensioner pulley center bolt. Remove timing belt. Remove timing belt auto-tensioner.

Fig. 1: Exploded View Of Timing Belt Components (Endeavor)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig. 2: Exploded View Of Timing Belt Components (Galant)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig. 3: Aligning Timing Marks
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Inspection

1. Inspect timing belt for wear on edges of drive teeth. Inspect belt for signs of oil contamination, cracks, separation, worn or missing teeth, or hardened back surface. Replace belt if worn, damaged or contaminated. Inspect belt tensioner pulley for smooth rotation. Replace if defective.
2. Check timing belt auto-tensioner for leaks. Check for wear or damage at end of rod. Hold timing belt auto-tensioner upright. Measure rod protrusion above edge of housing. See Fig. 4. Apply 22-44 lbs. (98-196 N) of force to end of rod. If auto tensioner rod moves more than 0.39" (1 mm), replace the auto-tensioner.

Fig. 4: Checking Timing Belt Auto-Tensioner Movement
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Installation

1. Place auto-tensioner in soft-jawed vise to SLOWLY compress the push rod. If there is a plug at the base of the auto-tensioner body, place flat washer around plug so it will not contact vise jaw.
2.

CAUTION: Never compress the auto-tensioner too fast, or the push rod will be damaged.
Slowly compress auto-tensioner push rod until holes in push rod and auto-tensioner housing are aligned. Insert a locking pin into the alignment holes. Install auto-tensioner on engine.
3. Ensure all timing marks are still aligned. See Fig. 3. Install timing belt on crankshaft sprocket, idler pulley, left bank camshaft sprocket, water pump pulley, right bank camshaft sprocket, and tensioner pulley. Take all slack out of timing belt.
4. Loosen the tensioner pulley center bolt. Rotate tensioner pulley against timing belt. Temporarily tighten tensioner pulley center bolt. Turn crankshaft 1/4 turn counterclockwise. Turn crankshaft 1/4 turn clockwise. Ensure all timing belt marks are still aligned.
5. Loosen tensioner pulley center bolt. Position tensioner pin holes at bottom of tensioner. Install Adapter (MD998767) on tensioner pulley. See Fig. 5. Using torque wrench, apply 39 INCH lbs. (4.4 N.m) of torque (counterclockwise direction) to tensioner pulley. Tighten tensioner center bolt to specification while holding tensioner pulley stationary. See TORQUE SPECIFICATIONS .
6. Remove locking pin from auto-tensioner. Turn crankshaft 2 revolutions clockwise and align all timing marks. DO NOT rotate counterclockwise.
7. Wait for at least 5 minutes, then check auto-tensioner push rod protrusion. To check push rod protrusion, measure clearance between body of auto-tensioner and bottom of tensioner pulley bracket arm. Clearance should be 0.19-0.24" (4.8-6.0 mm). If protrusion is not correct, repeat timing belt tensioning procedure.
8. Install timing belt covers. Install crankshaft pulley. Using Pulley Holder (MB991800) and Pins "B" (MB001802), tighten crankshaft pulley bolt to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

Fig. 5: Adjusting Timing Belt Tension
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Auto-Tensioner Bolt 15-19 (20-26)
Camshaft Sprocket Bolt 58-72 (78-98)
Crankshaft Pulley Bolt (1) 134-140 (180-190)
Engine Mount Bracket-To-Engine Bolt 31-37 (42-48)
Timing Belt Idler Pulley Bolt 30-36 (39-49)
Timing Belt Tensioner Arm Pivot Bolt 26-40 (34-54)
Timing Belt Tensioner Center Bolt 32-40 (42-54)
INCH Lbs. (N.m)
Timing Belt Cover Bolt 97 (11)
(1) Apply engine oil to bolt threads before installation.

FIG 2
http://www.napaprolink.com/NapaDataSets/TBR/TIF/5/0/00293405.TIF
FIG 3
http://www.napaprolink.com/NapaDataSets/TBR/TIF/6/0/00293406.TIF

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