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#616102 - 06/18/05 05:11 PM 95 SR DOHC Timing Belt Change (pics) *  
justice  Offline
Roll Me Over
Joined: Feb 2000
Posts: 3,269
So Cal, USA *****
The Mods might want to move this to the Tech Section if they see fit, or make a write up after I'm done but anyways here goes....


Monday I was driving home from work and started to hear a weird sound like a Power Steering belt was slipping or something. The Temp guage started to rapidly climb so I pulled over and let it cool. started it back up and temp guage went back to normal but I could hear a faint "rumbling sound". I thought in could be a bad water pump bearing that was temporarily frozen. I cautiously drove the rest of the way home with the heater on with no problems. I pulled the drivers side timing belt cover off and found the smooth side of the belt showing signs of slippage. I ordered the Timing belt, Idler pully, and tensioner pully, off ebay on Tues morning. I had a lifetime warrantee on the Water pump so I called the Auto parts store and made sure they had one in stock for exchange when I got the old one pulled off. The Belt (napa Brand) and Pully/Bearing were all on my doorstep by thursday morning. My plan was to do this on the weekend, but I was lucky enough to get off early Friday so I began the tear down process..Here's the Photo's, please excuse the red Moab mud all over the engine:

First oreder was to remove the Plastic plenum cover, battery with tray, Air box, fan and accessorie belts. The Power Steering pump was dissconnected from the acc. bracket but the Hydraulic lines were left connnected and pump moved out of the way. The hardest part of this is removing the AC pump from drivers side of the engine its connected by (4) 10mm bolts that arent the easiest to get to. Strong hands/forarms and a 1/4" drive ratchet come in handy for this one. Leave the soft lines connected to the pump and move out of the way, bungee cords or twine can come in handy for keeping stuff out of the way. Remove ac pump mounting bracket after pump is out of the way.

[Linked Image]

Next I removed the big aluminum Accesory bracket, leave the alternator connected, and dont forget to onplug it from the wiring harness and disconnect positive lead.

[Linked Image]

Here's a shot of the engine with the bracket off:

[Linked Image]

The next step was to remove the crankshaft pully. There is a special tool available to assist in this and I would highly reccommend you use it if available. It holds the pully stationary while you remove the crankshft bolt. I dont have the tool so I used the Imfamous "electric impact" better known as the starter trick, which involves one person putting a 1/2" breaker bar with socket on the crank bolt, bracing it against the steering box and another person cranking the engine momentarily. This method has broken crank bolts in the past so if you decide to use this technique proceed with caution. It worked for me and the next step was to remove the plastic timing belt cover.

When I removed the cover this fell out:

[Linked Image]

The Idler pully bearings had exploded. Luckily the timming belt didnt slip any cogs.

[Linked Image]

That was enough work for a friday afternoon, I'll pull the water pump and replace it. Hopefully I'll have the rest of the truck together and documented before the end of today(Sat)

on an unrelated note, sasquatch was spotted in So Cal next to my Montero yesterday..... <img src="/forums/images/graemlins/lol.gif" alt="" />

[Linked Image]


99 Gen 2.5, fixing blown head gasket
89 SWB- 33's, ARB Front locker, SR rear locker/axle, SR F brakes, winch, WST Offroad Armor all Around, 2.85 Aussie T-case Gears (SOLD)
Sold: (2) 95 SR's, 86 SWB, 90LWB, 91 LWB
-Can Change a timing belt in my sleep..


#616103 - 06/18/05 05:26 PM Re: 95 SR DOHC Timing Belt Change (pics) [Re: justice]  
off-roader  Offline

Web Wheeler
Joined: Jan 2000
Posts: 16,224
Bay Area, CA *****
That's cool it didn't cause any real damage and you're now able to document the repair Justice!

Wow, didn't know sasquatch has tat's!

I'll move this over to the tech section though where more folks who may be looking for it will find it. <img src="/forums/images/graemlins/kewl.gif" alt="" />


Off Roader
96SR (3.15:1 xcase, 35's)
96SR Build Up Thread
Old web page
Old web page

#616104 - 06/20/05 02:05 PM Re: 95 SR DOHC Timing Belt Change (pics) [Re: justice]  
scaesare  Offline
Wheeler
Joined: Feb 2005
Posts: 115
Ashburn, VA
Oooh... and not just the idler pully, but the TENSIONER pulley!!

You are one fortunate man. <img src="/forums/images/graemlins/smile.gif" alt="" />

I can personally attest that the 3.5DOHC is an interference engine.

Have you done a timing belt on these righs before? I ask because there's an error in the FSM for them...


-Steve
-1995 Montero SR 3.5L V6 DOHC

#616105 - 06/20/05 05:20 PM Re: 95 SR DOHC Timing Belt Change (pics) [Re: justice]  
Winston  Offline
Rock Warrior
Joined: Feb 2005
Posts: 509
SF Bay Area
Thanks for posting about your incedent. It is always informative to hear about failures. The obvious question; How long since last timing belt change? How many miles on truck?


'90 Montero XLS (Sold, sadly)
'95 Montero LS 160k
'03 Montero Limited 30k

#616106 - 06/20/05 06:10 PM Re: 95 SR DOHC Timing Belt Change (pics) [Re: Winston]  
justice  Offline
Roll Me Over
Joined: Feb 2000
Posts: 3,269
So Cal, USA *****
This is my 2nd time doing the Job on this truck..did it a few years ago when I first bought the truck with 65K on it. Replaced the T belt and water pump at that time, and should have done Idler pully and tensioner pully at that time but didnt, but it lasted till 150K which is on the truck now. The Idler pully is on the drivers side and the Tensioner pully is the one down low closest to the Crank Sprocket. Replaced both of those along with the water pump and thermostat and Timing belt. The truck started on first crank..I'll post pics of the rest of the job when I get home from work. I probably should of changed out the hydraulic tensioner too but it showed no signs of wear and at 120 bucks it can wait a few months when I pull this thing apart again and do the Valve Guide seals.. <img src="/forums/images/graemlins/barf.gif" alt="" />


99 Gen 2.5, fixing blown head gasket
89 SWB- 33's, ARB Front locker, SR rear locker/axle, SR F brakes, winch, WST Offroad Armor all Around, 2.85 Aussie T-case Gears (SOLD)
Sold: (2) 95 SR's, 86 SWB, 90LWB, 91 LWB
-Can Change a timing belt in my sleep..

#616107 - 06/20/05 06:21 PM Re: 95 SR DOHC Timing Belt Change (pics) [Re: justice]  
Winston  Offline
Rock Warrior
Joined: Feb 2005
Posts: 509
SF Bay Area
85k on a timing belt? You should be hung by your toenails. Just kidding. Have you pulled out the butterfly valve on your truck?

I might get banned because I keep recommending this, but try www.auto-rx.com for your oil burning problem.


'90 Montero XLS (Sold, sadly)
'95 Montero LS 160k
'03 Montero Limited 30k

#616108 - 06/20/05 06:34 PM Re: 95 SR DOHC Timing Belt Change (pics) [Re: Winston]  
justice  Offline
Roll Me Over
Joined: Feb 2000
Posts: 3,269
So Cal, USA *****
slow day at work lets see how much I can get posted..

Here's a shot of the water pump, It was an aftermarket unit made by Airtex with lifetime warrantee, the shaft had lots of slop and the weep hole on the back was starting to seep water..Picked up a new one for free. Good thing I saved the receipt and original box. <img src="/forums/images/graemlins/kewl.gif" alt="" />

[Linked Image]

In the pic below of the back of the water pump housing, you can see the leakage.

[Linked Image]


99 Gen 2.5, fixing blown head gasket
89 SWB- 33's, ARB Front locker, SR rear locker/axle, SR F brakes, winch, WST Offroad Armor all Around, 2.85 Aussie T-case Gears (SOLD)
Sold: (2) 95 SR's, 86 SWB, 90LWB, 91 LWB
-Can Change a timing belt in my sleep..

#616109 - 06/20/05 06:44 PM Re: 95 SR DOHC Timing Belt Change (pics) [Re: justice]  
justice  Offline
Roll Me Over
Joined: Feb 2000
Posts: 3,269
So Cal, USA *****
Next I separated the pump from the housing and cleaned the gasket surface. If you plan to keep your truck for any length of time, do yourself a favor and use the Mits OEM metal gaskets, makes the job alot easier the next go around. In my experience both OEM and aftermarket water pumps have trouble at around 70 to 90K and should be replaced whenever the T-belt is changed.

[Linked Image]

Dont forget to replace the Oring that goes on the heater core pipe that goes into this hole in the back of the Water pump housing.

[Linked Image]


99 Gen 2.5, fixing blown head gasket
89 SWB- 33's, ARB Front locker, SR rear locker/axle, SR F brakes, winch, WST Offroad Armor all Around, 2.85 Aussie T-case Gears (SOLD)
Sold: (2) 95 SR's, 86 SWB, 90LWB, 91 LWB
-Can Change a timing belt in my sleep..

#616110 - 06/20/05 06:56 PM Re: 95 SR DOHC Timing Belt Change (pics) [Re: justice]  
justice  Offline
Roll Me Over
Joined: Feb 2000
Posts: 3,269
So Cal, USA *****
here's the block with the water pump off and gasket surface prepped. Sorry abput the crappy pic but you can see the heater core pipe in the center. Be sure to plug the water passage holes with rags while prepping gasket suface to keep debris out.

[Linked Image]

here's a shot with the new water pump and T-belt bearings/pully's insalled.

[Linked Image]


99 Gen 2.5, fixing blown head gasket
89 SWB- 33's, ARB Front locker, SR rear locker/axle, SR F brakes, winch, WST Offroad Armor all Around, 2.85 Aussie T-case Gears (SOLD)
Sold: (2) 95 SR's, 86 SWB, 90LWB, 91 LWB
-Can Change a timing belt in my sleep..

#616111 - 06/20/05 07:03 PM Re: 95 SR DOHC Timing Belt Change (pics) [Re: justice]  
justice  Offline
Roll Me Over
Joined: Feb 2000
Posts: 3,269
So Cal, USA *****
Here's the Thermostat Housing. I decided to splurge and put in OEM mitsu T-stat. Note how wimpy the afterrmarket unit looks next to the Mitsu T-stat on the left. <img src="/forums/images/graemlins/lol.gif" alt="" />

[Linked Image]

ok, thats all for now, tonight when I get home I can upload pics of the Timing belt installation..

Enjoy.


99 Gen 2.5, fixing blown head gasket
89 SWB- 33's, ARB Front locker, SR rear locker/axle, SR F brakes, winch, WST Offroad Armor all Around, 2.85 Aussie T-case Gears (SOLD)
Sold: (2) 95 SR's, 86 SWB, 90LWB, 91 LWB
-Can Change a timing belt in my sleep..

#616112 - 06/20/05 07:36 PM Re: 95 SR DOHC Timing Belt Change (pics) [Re: justice]  
FrankR  Offline
Web Wheeler
Joined: Feb 2004
Posts: 10,238
Columbia, SC ****
Nice prep job! <img src="/forums/images/graemlins/kewl.gif" alt="" />

Frank


'89 [color:"white"]G-Raider[color:"white"] [color:"black"]Supercharged 3.0L, MegaSquirt 2, lockup A/T, 2.5" exhaust, 172k, Cibie H4s/Oscar SCs, Hella Micro DE fogs, Cobra CB, Superwinch hubs, LSD rear/Aussie Locker front, Bilsteins, Lifeline AGM, Rust-Oleum

#616113 - 06/20/05 09:40 PM Re: 95 SR DOHC Timing Belt Change (pics) [Re: FrankR]  
bretwalda  Offline
Roll Me Over
Joined: Sep 2002
Posts: 3,634
Milwaukee WI
Good stuff. Thanks for posting. I learn by pictures. <img src="/forums/images/graemlins/smile.gif" alt="" />


concreteprinter.com

#616114 - 09/02/05 12:32 AM Re: 95 SR DOHC Timing Belt Change (pics) [Re: justice]  
hotrod4x5  Offline
Rock Warrior
Joined: May 2001
Posts: 849
Riverside, CA, USA
You kinda left us hanging. Do you have pics of the rest of the job? If you have time, it would be great if you could to complete this thread.


Rodney,95 SR 3.5 L, Rancho RS 9000's, 31x10.5-15 Bridgestone Dueler A/T's, OEM Rear locker My Monty in action!

#616115 - 09/02/05 04:29 AM Re: 95 SR DOHC Timing Belt Change (pics) [Re: hotrod4x5]  
justice  Offline
Roll Me Over
Joined: Feb 2000
Posts: 3,269
So Cal, USA *****
Here's the parts used in the job...note the two small holes in the front of the tensioner pully. These are used to set the tension on the belt prior to pulling the "pin" out of the hydraulic tensioner.

[Linked Image]


99 Gen 2.5, fixing blown head gasket
89 SWB- 33's, ARB Front locker, SR rear locker/axle, SR F brakes, winch, WST Offroad Armor all Around, 2.85 Aussie T-case Gears (SOLD)
Sold: (2) 95 SR's, 86 SWB, 90LWB, 91 LWB
-Can Change a timing belt in my sleep..

#616116 - 09/02/05 04:33 AM Re: 95 SR DOHC Timing Belt Change (pics) [Re: justice]  
justice  Offline
Roll Me Over
Joined: Feb 2000
Posts: 3,269
So Cal, USA *****
The Hydraulic tensioner must be removed and the unit is squeezed in a vice until the "pin" can be inserted into the unit to hold it in place. Mitsu has a special tool for this but I found a small allen wrench to work just fine.

[Linked Image]


99 Gen 2.5, fixing blown head gasket
89 SWB- 33's, ARB Front locker, SR rear locker/axle, SR F brakes, winch, WST Offroad Armor all Around, 2.85 Aussie T-case Gears (SOLD)
Sold: (2) 95 SR's, 86 SWB, 90LWB, 91 LWB
-Can Change a timing belt in my sleep..

#616117 - 09/02/05 04:37 AM Re: 95 SR DOHC Timing Belt Change (pics) [Re: justice]  
justice  Offline
Roll Me Over
Joined: Feb 2000
Posts: 3,269
So Cal, USA *****
Use paper clips to hold the belt in place while installing. Always double and tripple check all the marks. These photos are not at the best angle and you will need to use a manual to get it right.

[Linked Image]


99 Gen 2.5, fixing blown head gasket
89 SWB- 33's, ARB Front locker, SR rear locker/axle, SR F brakes, winch, WST Offroad Armor all Around, 2.85 Aussie T-case Gears (SOLD)
Sold: (2) 95 SR's, 86 SWB, 90LWB, 91 LWB
-Can Change a timing belt in my sleep..

#616118 - 09/02/05 04:48 AM Re: 95 SR DOHC Timing Belt Change (pics) [Re: justice]  
justice  Offline
Roll Me Over
Joined: Feb 2000
Posts: 3,269
So Cal, USA *****
Here's how I set the tension. Mitsu has a "special tool" for this as well that fits on a 1/4" ratchet and has two pins that insert into the tensioner bearing. I found a pair of needle nose pliers work fine for the job and I was able to get more than enough torque on the bearing to set the tension. Once tension is set the Pin can be removed and engine rotated two full rotations re-check all 5 timing marks for alighnment (4 cams and crankshaft) and also check the tensioner. you should still be able to freely insert the pin or (allen wrench) into the tensioner. If you cant insert the pin refer to your manual for min/max clearance between tensioner and pivoting tensioner bracket if its within spec your good to go, if not re-set tension and try again.


[Linked Image]


99 Gen 2.5, fixing blown head gasket
89 SWB- 33's, ARB Front locker, SR rear locker/axle, SR F brakes, winch, WST Offroad Armor all Around, 2.85 Aussie T-case Gears (SOLD)
Sold: (2) 95 SR's, 86 SWB, 90LWB, 91 LWB
-Can Change a timing belt in my sleep..

#616119 - 09/02/05 04:51 AM Re: 95 SR DOHC Timing Belt Change (pics) [Re: justice]  
justice  Offline
Roll Me Over
Joined: Feb 2000
Posts: 3,269
So Cal, USA *****
When the belt is on and pin removed your engine should look something like this but hopefully without all the red dirt and mud <img src="/forums/images/graemlins/lol.gif" alt="" />

[Linked Image]

now the fun part...reassemble in reverse order <img src="/forums/images/graemlins/nana.gif" alt="" />


99 Gen 2.5, fixing blown head gasket
89 SWB- 33's, ARB Front locker, SR rear locker/axle, SR F brakes, winch, WST Offroad Armor all Around, 2.85 Aussie T-case Gears (SOLD)
Sold: (2) 95 SR's, 86 SWB, 90LWB, 91 LWB
-Can Change a timing belt in my sleep..

#616120 - 09/02/05 06:28 AM Re: 95 SR DOHC Timing Belt Change (pics) [Re: justice]  
Winston  Offline
Rock Warrior
Joined: Feb 2005
Posts: 509
SF Bay Area
Great photos. I love the "high tech" tools, especially the "paper clips" and the needle nose pliers. A few questions.

1. When you applied the "torque" to the needle nose pliers, did you do that with just the pliers? Or did you grab them with another wrench? And could you describe in words how hard you "wrenched" on the pliers?

2. I see that you replaced a lot of items with pretty new parts, but you chose to use the old tensioner. What was your reasoning for reusing that part?

3. Did you really turn the engine through two revs? If so, how did you rotate it? With the crank bolt?


'90 Montero XLS (Sold, sadly)
'95 Montero LS 160k
'03 Montero Limited 30k

#616121 - 09/02/05 06:50 AM Re: 95 SR DOHC Timing Belt Change (pics) [Re: Winston]  
justice  Offline
Roll Me Over
Joined: Feb 2000
Posts: 3,269
So Cal, USA *****
Quote
Great photos. I love the "high tech" tools, especially the "paper clips" and the needle nose pliers. A few questions.

I ACTUALLY LEARNED THE NEEDDLE NOSE AND PAPER CLIP TRICKS FROM A MITSUBISHI MASTER TECH BELIEVE IT OR NOT. I ASKED TO BORROW HIS SPECIAL TOOL AND HE TOLD ME TO JUST USE NEEDLE NOSE.

1. When you applied the "torque" to the needle nose pliers, did you do that with just the pliers? Or did you grab them with another wrench? And could you describe in words how hard you "wrenched" on the pliers?

JUST THE PLIERS, HOW HARD??? HARD TO TELL BUT IT WAS HARD ENOUGH TO KEEP IT IN SPEC ONCE THE "PIN" WAS REMOVED FROM THE TENSIONER. THE TENSIONER IS WHAT REALLY KEEPS THE BELT TIGHT. "SETTING THE TENSION" IN REALITY IS JUST GIVING THE TENSIONER ENOUGH TRAVEL TO DO ITS JOB (ONCE YOU TAKE OUT THE PIN) IF THE BELT STRETCHES OR BEARINGS WEAR.

2. I see that you replaced a lot of items with pretty new parts, but you chose to use the old tensioner. What was your reasoning for reusing that part?

I ALREADY REPLACED IT ONCE AT 70 K AND AT $130.00 I'LL TAKE MY CHANCES. THE WATER PUMP WAS FREE (WARRANTEE) AND THE OTHER PARTS WERE RELATIVELY CHEAP. IF YOU HAVE THE MONEY AND WANT PEACE OF MIND IT WOULD BE A GOOD IDEA TO REPLACE THIS ITEM AS WELL.

3. Did you really turn the engine through two revs? If so, how did you rotate it? With the crank bolt?

YES, VERY SLOWLY AND CAREFULLY WITH THE CRANK BOLT. ONCE DONE A QUICK COUNTERCLOCKWISE JERK LOOSENS IT BACK UP.



Last edited by justice; 09/02/05 06:55 AM.

99 Gen 2.5, fixing blown head gasket
89 SWB- 33's, ARB Front locker, SR rear locker/axle, SR F brakes, winch, WST Offroad Armor all Around, 2.85 Aussie T-case Gears (SOLD)
Sold: (2) 95 SR's, 86 SWB, 90LWB, 91 LWB
-Can Change a timing belt in my sleep..

#616122 - 09/02/05 03:05 PM Re: 95 SR DOHC Timing Belt Change (pics) [Re: justice]  
MontyMcV  Offline
Trail Leader
Joined: Jun 2003
Posts: 7,340
Cleve-burg OH USA
I recently did my 95 3.0L 24V. It is more similar to the 3.5L than to the older 3.0L I think. A couple of comments from my first crack at this not-too-small job:

1) When rotating the engine, do it from the crank. I first did it from a cam sprocket. Turns out it cannot turn then engine easily and I jumped a tooth on the belt. Which of course meant I had to do it all over again. <img src="/forums/images/graemlins/angry.gif" alt="" />

2) A tip from my B-I-L to help with the align the new was to mark the old belt and each of the sprockets with a white paint pen. Then transfer those marks to the new belt. Install the new so it aligns with the ones on the sprockets. I think this helped me in that you have to thread the whole belt in one direction to get to all the teeth right. I wasn't sure if I was dong it properly, but when the marks all lined up... Note that this does not replace the need to check the engine's markings as well.

3) Yes, those A/C bolts are a pain. There is one way back that I didn't know was there at first and was getting real PO's trying to find it.

4) For those unsure of doing, but equally sure of not wanting to shell out the $$$ to have it done, just take your time. Make sure you understand all that comes off as you do it and it will make more sense then going back together. FSM is helpful.


Big Truck: 00, 3.5, Endeavor, 5-Spd drive line in hand!
Little Truck: 87, 2.6T I/C, MT, LSDs, Tonneau Top
Her Truck: 03, 3.8, 20th Anniv, 65k
Daughter's: 06 Eclipse, Keeping it Mitsu!
FSMs: MitsubishiLinks.com

#616123 - 09/05/05 06:42 PM Re: 95 SR DOHC Timing Belt Change (pics) [Re: MontyMcV]  
Anonymous
Unregistered

Great job Justice thanks for the pics. I am glad to learn something new on this lazy holiday. Thanks for documenting everything for us.


#616124 - 09/07/05 12:59 AM Re: 95 SR DOHC Timing Belt Change (pics)  
sparkem  Offline
Trail Leader
Joined: Dec 2000
Posts: 6,892
Ponchatoula, LA ***
Great post. Archive if not already. Nice tan too. Ha, I look like that too.


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