TSB TSB NUMBER: Removal (2.0L DOHC)

Details

WARNING: This applies to the 2.0L DOHC. The Timing Belt Installation procedures has been revised due to Mitsubishi Bulletin Number TSB NUMBER SC-93-003 TIMING BELT REPLACEMENT, dated December, 1993. The correct installation procedure below is per CHRYSLER Technical Service Bulletin Number 09-15-93. It may be convenient to raise the vehicle on a hoist to a level where work can be performed through the wheel well and over the top of the fender. Remove lower left engine compartment splash shield. Support engine with engine support fixture, tool #C4852 or #7137, and remove the left engine mount and bracket. See Fig 1 . Fig 1: Left Engine Mount Assembly Loosen the water pump pulley bolts. Remove the alternator/water pump drive belts, and the power steering drive belt. NOTE: Loosen water pump pulley bolts before removing belt. Remove water pump pulley. Remove the tensioner pulley bracket and the A/C belt. Remove crankshaft pulley. Remove the upper and lower timing belt covers. Rotate the crankshaft clockwise and align the timing marks so as to bring the No. 1 piston to the Top-Dead-Center (TDC) position of the compression stroke. CAUTION: Rotate the crankshaft in a clockwise direction. The camshaft sprocket dowel Dins must be at the 12 o'clock position and the camshaft sprocket timing marks must be aligned together (left sprocket at the 3 o'clock and right sprocket at the 9 o'clock positions). Both camshaft sprocket timing marks must be in line with the top surface of the cylinder head. See Fig 2 . [A straight edge (ruler) laid across the center of the camshaft attaching bolts will help you to better see and align the timing marks.] The crankshaft and oil pump sprockets must also be aligned with their respective timing marks. See Fig 3 . NOTE: Crankshaft may need to be rotated up to six turns before all sprockets are properly aligned and the rear balance shaft is in phase, due to the oil pump-to balance shaft gear ratio. Fig 2: Camshaft Sprocket Timing Marks Alignment Fig 3: Crankshaft Timing Marks Alignment Remove rubber plug from inner timing belt cover and screw special tool no. MD998738 into the engine left support bracket until it makes contact with the tensioner arm. See Fig 4 & Fig 5 . Loosen the tensioner pulley center bolt. See Fig 5 . Fig 4: Rubber Plug Location Fig 5: Auto Tensioner Assembly Compress the Auto Tensioner push rod by SLOWLY rotating special tool no. MD998738 until hole in Auto Tensioner push rod aligns with the hole in the Auto Tensioner body. See Fig 6 . NOTE: Push rod may need to be rotated if hole in rod is not vertically in line with hole in housing. Insert a 1/16" Allen wrench or similar pin [1.4 mm (.055") in diameter into the aligned holes to hold the push rod in the reset (pinned) position. Back off special tool MD998738 once auto tensioner is in the reset position. See Fig 6 . Fig 6: Compressing Auto Tensioner Push Rod NOTE: Inspect the tensioner and replace it if it shows signs of oil leakage. The auto tensioner should be the latest type, P/N MD164533. It can be identified by measuring the overall body length. The latest type tensioner body length is 100 mm, the old length is 91 mm. Replace the tensioner with the latest type if not so equipped. See Fig 7 . Fig 7: Auto Tensioner Body Length Remove and discard the camshaft timing belt. Loosen timing belt "B" tensioner pulley center bolt. See Fig 8 . Fig 8: Tensioner Pulley and Center Bolt Remove and discard timing belt "B".