2004 MITSUBISHI ENDEAVOR crankshaft timing marks

Fig. 29: Checking Timing Marks Of All The Sprockets Are In Alignment

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
9. Rotate the crankshaft a quarter turn counterclockwise. Then rotate it back
clockwise to verify that all the timing marks are aligned.
10. Loosen the flange bolt securing the tensioner pulley, and then mount special
tool MD998767 and a torque wrench on the tensioner pulley.
11. Torque it to 4.4 N.m (39 in-lb) with the torque wrench.
12. While holding the tensioner pulley in position, tighten the flange bolt to the
specified torque.
Ti
ghtenin
g tor
que: 48+
/-6 N.m (35+
/-4 f
t-lb)

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

4. Install the auto-tensioner to the engine.
>>B<< TIMING BELT INSTALLATION 1. Align the timing marks on the camshaft sprockets with those on the rocker
cover and the timing mark on the crankshaft sprocket with that on the engine
block as shown in the illustration.
CAUTION: Do not remove the setting pin from the auto-
tensioner.
CAUTION: The camshaft sprocket (right bank) can turn
easily due to the spring force applied, so be
careful not to get your fingers caught.

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

2. Install the timing belt by the following procedure so that there is no deflection
in the timing belt between each sprocket and pulley.
1. Crankshaft sprocket
2. Idler pulley
3. Camshaft sprocket (Left bank)
4. Water pump pulley
5. Camshaft sprocket (Right bank)
6. Tensioner pulley
3. Turn the camshaft sprocket (Right bank) counterclockwise until the tension
side of the timing belt is firmly stretched. Check all the timing marks again.
4. Use special tool MD998767 to push the tensioner pulley into the timing belt,
then temporarily tighten the center bolt.
Fi
g. 92: Pushin
g Tensioner Pulle
y Into Timin
g Bel
t

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA
.
5. Use special tool MD998769 to turn the crankshaft 1/4 turn counterclockwise,
then turn it again clockwise until the timing marks are aligned.
Fig. 93: Aligning Timing Marks

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
6. Loosen the center bolt of the tensioner pulley. Use special tool MD998767 and
a torque wrench to apply the tension torque to the timing belt as shown in the
illustration. Then tighten the center bolt to the specified torque.
Standard value: 4.4 N.m (39 in-lb) < Timing belt tension torque >
CAUTION: When tightening the center bolt, be careful that
the tensioner pulley does not turn with the bolt.

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

Fig. 95: Removing Setting Pin That Has Been Inserted Into Auto
-
Tensioner

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
8. Turn the crankshaft clockwise twice to align the timing marks.
9. Wait for at least five minutes, then check that the auto-tensioner pushrod
extends within the standard value range.
Standard value (A): 4.8 - 6.0 mm (0.19 - 0.24 inch)

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

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 105,000 miles, unless previously changed. REMOVAL & INSTALLATION 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. 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
pulle
y center bolt. Remove timin
g belt. Remove timin
g CAUTION: This application is an interference engine. Do not
rotate camshaft or crankshaft when timing belt is
removed, or engine damage may occur.
CAUTION: Always turn crankshaft in clockwise direction (as
viewed from front of engine).

2004 Mitsubishi Endeavor Limited MITSUBISHI 3.8L V6 - SOHC - Endeavor & Galant


2004 Mitsubishi Endeavor Limited MITSUBISHI 3.8L V6 - SOHC - Endeavor & Galant

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. 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 o
f
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. CAUTION: Never compress the auto-tensioner too fast, or
the push rod will be damaged.

2004 Mitsubishi Endeavor Limited MITSUBISHI 3.8L V6 - SOHC - Endeavor & Galant