Timing Belt Replacement - 2.0l - DOHC Mitsubishi Lancer Evolution VIII

MANUFACTURER'S SUGGESTED SCHEDULED MAINTENANCE

Manufacturer recommends the belt be replaced every 60,000 miles except in California, Maine, Massachusetts and Vermont. In California, Maine, Massachusetts and Vermont, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 105,000 miles, unless previously changed.

REMOVAL & INSTALLATION

Removal

1. Remove undercover and side cover. Remove accessory drive belt. Remove crankshaft pulley bolts. Remove crankshaft pulley. Remove crossmember bar for access to front exhaust pipe.
2. Remove front exhaust pipe. Remove timing belt upper cover. (Scheme 6)and (Scheme 7). Remove water pump pulley. Remove idler pulley.
3. Remove auto-tensioner. Remove timing belt lower cover. Raise engine and transaxle assembly until its weight is not supported by front engine mount. Remove front engine mount.
4. Rotate crankshaft clockwise to align each timing mark and to set cylinder No. 1 at TDC of compression stroke. (Scheme 8)
5. Remove timing belt under cover rubber plug. (Scheme 9) Screw in Adjusting Bolt (MD998738) until it comes in contact with timing belt tensioner arm. (Scheme 10) CAUTION: Adjusting Bolt will bend if it is screwed in too fast.
6. Gradually screw in adjusting bolt at a rate of 30 degrees per second to align timing belt tensioner adjuster rod set hole "A" with timing belt tensioner adjuster cylinder set hole "B". (Scheme 11)
7. Insert a suitable pin or wire into set hole, and remove adjusting bolt. If timing belt is to be reused, mark rotation direction on belt. Loosen timing belt tensioner pulley mounting bolt, and remove timing belt. (Scheme 12)
8. Disconnect power steering pressure switch connector. Remove power steering pump heat shield. Remove power steering pump with hoses attached, and secure aside. Remove power steering pump bracket. Remove timing belt idler pulley.
9. Remove crankshaft position sensor. Using Special Spanner (MB991367) and Pins (MB991385) to hold crankshaft timing belt sprocket, remove crankshaft center bolt.
10. Using Crankshaft Sprocket Puller (MD998778), remove crankshaft timing belt sprocket. Remove crankshaft angle sensing blade. If balancer belt is to be reused, mark rotation direction on belt.
11. Ensure balancer timing marks are aligned. (Scheme 13) Loosen balancer belt tensioner bolt. Remove balancer belt tensioner. Remove balancer belt.

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

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 black surface. Replace belt if worn, damaged or contaminated. Inspect belt tensioner pulleys for smooth rotation. Replace if defective.
2. Remove timing belt tensioner adjuster. Check timing belt tensioner adjuster for leaks. Hold timing belt tensioner adjuster upright. Measure rod extension length above edge of housing. (Scheme 14) Length should be.5" (12 mm). If length is not as specified, replace timing belt tensioner adjuster.
3. Apply 22-44 lbs. (10-20 kg.) of force to end of rod. (Scheme 15) If rod moves more than 0.39" (1 mm), replace timing belt tensioner adjuster.

Scheme 14

Scheme 15

Installation

1. Ensure balancer timing marks are aligned. (Scheme 13) Install timing belt on crankshaft balancer sprocket and balancer sprocket. Ensure there is no slack on tension side.
2. Temporarily install balancer belt tensioner. With your fingers, lift balancer belt tensioner in direction of arrow. (Scheme 16) CAUTION: When tightening balancer belt tensioner bolt, ensure tensioner does not rotate with the bolt. Allowing it to rotate can cause excessive belt tension.
3. Apply 22-30 INCH lbs. (2.6-4.4 N.m) to balancer belt, then tighten balancer belt tensioner bolt to specification. See «TORQUE SPECIFICATIONS»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/timing-belt/#timing-belt-replacement-20l-dohc__torque-specifications).
4. Turn crankshaft clockwise 2 revolutions. Ensure balancer timing marks are aligned. (Scheme 13)
5. Apply about 22 lbs. (10 kg.) of pressure at center (arrow area) between sprockets as shown. (Scheme 17) Ensure belt deflection is.20-.27" (5.0-7.0 mm).
6. Clean front of crankshaft. Clean and install crankshaft angle sensing blade and crankshaft timing belt sprocket. Apply engine oil to crankshaft center bolt threads and both sides of washer. Install crankshaft center bolt.
7. Using Special Spanner (MB991367) and Pins (MB991385) to hold crankshaft timing belt sprocket, tighten crankshaft center bolt to specification. See «TORQUE SPECIFICATIONS»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/timing-belt/#timing-belt-replacement-20l-dohc__torque-specifications).
8. If timing belt tensioner adjuster was removed and rod is fully extended, slowly compress timing belt tensioner adjuster rod with a vise or press to align timing belt tensioner adjuster rod set hole "A" with timing belt tensioner adjuster cylinder set hole "B".
9. Insert a suitable pin or wire into set hole. Install timing belt tensioner adjuster, and tighten bolts to specification. Install idler pulley, and tighten bolt to specification. See «TORQUE SPECIFICATIONS»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/timing-belt/#timing-belt-replacement-20l-dohc__torque-specifications).
10. Ensure timing marks are aligned. (Scheme 8) To ensure oil pump/balancer shaft is properly aligned, remove cylinder block plug, and insert a phillips screwdriver as shown. (Scheme 18)
11. If screwdriver cannot be inserted 2.36" (60.0 mm) or more, remove screwdriver and rotate oil pump/balancer shaft one revolution. Ensure screwdriver can be inserted 2.36" (60.0 mm) or more. Do not remove screwdriver until timing belt is installed.
12. Install timing belt on crankshaft timing belt sprocket, oil pump/balancer shaft sprocket, and idler pulley in that order. Install timing belt on exhaust camshaft sprocket. Secure timing belt to exhaust camshaft sprocket with paper clamp.
13. Use 2 wrenches on camshaft sprocket bolts to align timing marks on camshaft sprockets with timing marks on valve cover. Install timing belt on intake camshaft sprocket. Secure timing belt to intake camshaft sprocket with paper clamp.
14. Pass timing belt around timing belt tensioner pulley. Apply counterclockwise pressure to intake camshaft. Ensure timing marks are aligned while tension side of belt is tight. Remove paper clamps.
15. Using Tensioner Wrench (MD998767), turn timing belt tensioner in direction shown to apply tension to timing belt. (Scheme 19) Pre-tighten timing belt tensioner pulley bolt.
16. Ensure timing marks are still aligned. Remove Phillips screwdriver installed in step 10). Install cylinder block plug, and tighten to specification. See «TORQUE SPECIFICATIONS»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/timing-belt/#timing-belt-replacement-20l-dohc__torque-specifications). CAUTION: When crankshaft is rotated counterclockwise, crankshaft center bolt may loosen. Retighten if it comes loose.
17. Gradually screw in Adjusting Bolt (MD998738) until wire or pin inserted in timing belt tension adjuster set hole lightly moves. Rotate crankshaft 1/4 turn counterclockwise. Rotate crankshaft clockwise until timing marks are aligned. CAUTION: When tightening timing belt tensioner bolt, ensure timing belt tensioner pulley does not rotate. Allowing it to rotate with bolt can cause insufficient timing belt tension.
18. Loosen timing belt tensioner pulley bolt. Using Tensioner Wrench (MD998767) and torque wrench, apply 31 INCH lbs. (3.5 N.m) tension torque, and tighten timing belt tensioner pulley bolt to specification. See «TORQUE SPECIFICATIONS»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/timing-belt/#timing-belt-replacement-20l-dohc__torque-specifications).
19. Remove wire or pin from timing belt tension adjuster set hole. Remove Adjusting Bolt (MD998738), and install rubber plug into timing belt under cover. Rotate crankshaft clockwise 2 turns, and wait about 15 minutes.
20. Insert wire or pin again, and ensure that it can be pulled out easily. If wire or pin can be easily removed, appropriate tension is applied to timing belt. If wire or pin cannot be easily removed, repeat steps 17 - 19.
21. Measure distance "A" between timing belt tensioner adjuster and timing belt tensioner arm. (Scheme 20) Appropriate timing belt tension is applied when distance is.15-.17" (3.8-4.5 mm).
22. Ensure timing marks are still aligned. To complete installation, reverse removal procedure. Tighten bolts and nuts to specification. When tightening engine mount bolts, ensure weight of engine is on vehicle body. See «TORQUE SPECIFICATIONS»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/timing-belt/#timing-belt-replacement-20l-dohc__torque-specifications).

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TORQUE SPECIFICATIONS