TIMING CHAIN, GUIDES, and BSE KIT

Joined: 09 Jul 2004 Posts: 5758 Location: Albuquerque, NM

If you take apart a REBUILT 2.6 turbo engines frequently (as I have)....it's a DISCOVERY PROCESS to figured out what went WRONG!

Do *I* know-it-all? Rolling Eyes

Hardly......but I DO know a BUNCH! Rolling Eyes

ID where the #1 plug wire is.

Mark things so RE-INDEXING is a CAKE WALK! Wink

Yes....the helicut gears allow indexs to SHIFT upon remove/install.

We want you to be at TDC (top dead center) on the #1 COMPRESSION STROKE.

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Joined: 06 Oct 2004 Posts: 1640 Location: Gilbert, Arizona

As indicated....this is CRANK, TDC. BUT...if the cam gear DOWEL PIN is not very close to 12 o'clock....then it's on the EXHAUST TDC. Wink

Place the engine at TDC (Top Dead Center) on the COMPRESSION stroke. You will know you are on the compression stroke if the cam dowel pin is at the NEARLY 12 o'clock position.

Joined: 06 Oct 2004 Posts: 1640 Location: Gilbert, Arizona

Is your dampner and t-cover off of your engine?
PUT THE KEYWAY AT EXACTLY 3 o'clock to have the CRANK at TDC!

Understand this: you should have exactly, 20 link seperation!
(or use the "marked links")

If the cam dowel pin is not bout 11:59...USE CHANNEL LOCKS to
rotate your cam! Wink

The 2.6 is a "non-interferance engine" (you can't bend your valves
is what that means, duh!)

The KEYWAY in the crank will be EXACTLY 3 o'clock at TDC.

There is a TIMING MARK on the GEAR located just below 3 o'clock. This is where you line up the lower MARKED LINK.

Joined: 06 Oct 2004 Posts: 1640 Location: Gilbert, Arizona

Yes....you CAN make this engine JUMP outta proper cam timing....ACCIDENTLY! Shocked

There is a WARNING placed in the factory manual about this too. Rolling Eyes

EXAMPLE: You park your 5 speed car on a hill, front-end up.....in gear, and the PARKING BRAKE fails to hold your car SOLID, if the car lurks BACKWARDS...you just FORCED the ENGINE in a REVERSE DIRECTION TOO! Shocked

The T-chain tensioner RELAXES......."JUMP" of the T-chain. Rolling Eyes

gears 1 thru 5...but not if it's already in REVERSE. Wink

The upper marked link should be aligned with the timing mark on the cam gear, located just below 3 o'clock. This INDEXES your CAM to be at TDC COMPESSION STROKE! Wink

Note the dowel pin is at 12 o'clock. Once the engine is rotated, these timing marks will not line up again for MANY revolutions, so don't let that throw you.
Rotating the engine in a reverse fashion (using the CRANK to turn the motor) can cause the chain to jump.

HOWEVER, you can rotate the motor in reverse if you turn the CAM BOLT. This will keep tension on the chain so the chain can't jump. Wink

There is a mod to prevent this from ever happening again.

Joined: 06 Oct 2004 Posts: 1640 Location: Gilbert, Arizona

This is an adjustable cam gear. Note the three differant dowel pin holes.
On the left is standard/OEM TDC CAM timing, center hole is 2.5* CAM advanced and the 3rd hole is 3.5* CAM advanced.

Soooo, 2.5* cam = 5* at the crank. 3.5* cam = 7* at the crank.

The edge of the gears are provided with there own TIMING MARKS. Kinda IDIOT PROOF! Wink

We are reffering to CAM TIMING, not ignition timing Exclamation

Joined: 06 Oct 2004 Posts: 1640 Location: Gilbert, Arizona

A DISASTER...in the making! You CAN NOT removes more that .008" from the cylinder head! Not only would that RETARD your cam timing, but the chain would now be too loose! Rolling Eyes

Yes...they did make a SHIM to correct this OVER-MACHINED head. They became OBSOLETE and you should just buy a NEW head in the first place.

VIRGIN HEAD MEASUREMENT ABOVE.

Joined: 06 Oct 2004 Posts: 1640 Location: Gilbert, Arizona

Carquest, Checker, Kragen, Shucks and Napa sell:

"I had a broken T-chain" These are REAL DOUBLE-ROLLER CHAINS!
Odds of a BROKEN LINK suggest that a FOREIGN OBJECT was cycled threw a T-chain and a sprocket.....like using a screwdriver, etc. Rolling Eyes

If you BENT a PIN, sooner or later.....it WILL BREAK!

DOUBLE CAUTION: there IS a lock washer behind the "B" balance shaft guide that fall into harms way! Shocked

See page 3 for more info!

Joined: 06 Oct 2004 Posts: 1640 Location: Gilbert, Arizona

If the SILENT SHAFTS have been removed,
the TOP RIGHT BOLT in this pic will need to be supplied
by yourself.

This is where special bolt "A" was installed from the factory.
See page 3 for more info.

Joined: 06 Oct 2004 Posts: 1640 Location: Gilbert, Arizona

6mm x 18mm cam dowel pin (can be a lil' longer)

No other sizes will work and be RELIABLE! Rolling Eyes

Don't take a chance Exclamation

Use a new one.

Mitsu MD021219 $1 Wink

Joined: 06 Oct 2004 Posts: 1640 Location: Gilbert, Arizona

Place the new cam dowel pin .280".......toward the cam. Wink

Joined: 06 Oct 2004 Posts: 1640 Location: Gilbert, Arizona

Joined: 06 Oct 2004 Posts: 1640 Location: Gilbert, Arizona

Pushing-back the chain tensioner so you
can install the CAM GEAR!

This 'SLEEVE' can travel out of it's bore too far.
This will make the chain too short so you can't start the bolt that holds the cam gear on. Shocked

A long screw driver can be inserted thru the head to push the tensioner back......should it be allowed to travel too far. Wink

Note how much of the tensioner sleeve is exposed. That's because this CYLINDER HEAD WAS MACHINED WAY TOO MUCH! Rolling Eyes

The FSM MAXIMUM IS ONLY .008"!

A new chain and sprockets with TWO RUBBER WASHERS ON IT, will only have about .030 of exposed sleeve. Wink

Restricting this TENSIONER TRAVEL (into the oil pump) will prevent the T-chain from jumping outta CAM time if you REVERSE the engine rotation. Wink

I GATHER......that is why Mitsu UP-GRADED the TENSONER SPRING thru the TSB posted above. Wink

Joined: 06 Oct 2004 Posts: 1640 Location: Gilbert, Arizona

Recommend you mark your index marks so you can SEE
what you are doing! Rolling Eyes

You're killin me! Stuck in the bore.....you bent the "SLEEVE" too...and look at that BENT spring & dampner Exclamation

And that's a O-ring....not a Mitsu "rubber sheet" Laughing

Mitsu MD084945 "DAMPNER" $4 (long skinny part) .....a MUST HAVE.
Appears to have begun use sometime in 85......but was STILL a HEADACHE until the 1990 TSB was issued. Rolling Eyes

This ONLY helps control COIL-BINDING...IT IS NOT A "STOPPER" for the SLEEVE!

DO NOT DOUBLE RUBBER SHEET UNLESS YOUR HEAD IS MACHINED IN EXCESS!!!

Mitsu MD021242 "SHEETS, rubber" $2
Some timing sets come with ONE of these parts and some have NONE! Shocked

But you'll NEED to have at least ONE NEW ONE Exclamation

RED HOT OIL TURBO RETURN IS DUMPED RIGHT ON IT Exclamation

Old ones get hard as a cracker and WILL COMPRESS. Shocked

"My car did not have one." Yes it did, it probably broke and fell into the oil pan. Laughing

Page 9-31 in the 88 Starion service manual.

Once you turn off your engine, the oil pressure bleeds off. The spring on the tensioner/sleeve is not strong enough to keep the tensioner TIGHT while waiting for oil pressure to come back up. Hence.....you hear noises coming from the timing cover as the chain RATTLES when you first start your engine. Shocked

Two rubber sheets/washers keeps the sleeve from RELAXING nearly as far. With new timing components, and two rubber sheets........there is LITTLE ROOM FOR THE TENSIONER TO RELAX. Wink

It will ALSO....prevent the T-chain from JUMPING...causing the cam timing to change Exclamation

"I've never noticed it had one." That's why this manual exsist. Cool

Now...the GERMANS had a lil' better idea.

Yes...it is spring loaded....
Yes...it needs OIL PRESSURE for the tensioner...
But...IT HAS A RATCHET SO IT CAN'T BE FORCED REWARD!

Now...DOUBLE RUBBER SHEETING *IS* THE SOLUTION ON A MITSU
2.6L ENGINE...ESPECIALLY WHEN A YOUTH IS BEHIND DA WHEEL!! Rolling Eyes

True...THE BUILT-IN PLASTIC CHAIN TENSIONER HAS A LIFE...this one broke in-half....and that chain failure locked-up the crankshaft, suggesting that, that engine was BLOWN. Rolling Eyes

*HE*...was WRONG TOOOO! Laughing

Joined: 06 Oct 2004 Posts: 1640 Location: Gilbert, Arizona

Some T-chains..... Rolling Eyes

are NOT RELIABLE and are frequenty NOT INDEXED CORRECTLY! USA, JAPAN...TAKE MY MONEY Exclamation

Read the CHAIN....NOT THE BOX Exclamation

Yep...if you use a bolt that is TOO LONG on the oil pump.... Rolling Eyes

brand new parts turn to HELL-ina-HANDBAG Exclamation

EXAMPLE: Removed the OIL PUMP PHILLIP SCREW...and replaced with a HEX HEAD SCREW, that was ONE THREAD LONGER! Shocked

Normal wear on the left......extreme wear on the right. Shocked

Joined: 06 Oct 2004 Posts: 1640 Location: Gilbert, Arizona

These bolts are SPECIAL! Their HARDNESS & LENGHT come into play. Rolling Eyes

Often found SNAPPED OFF Exclamation

Loctite= DISASTER! Shocked

Joined: 06 Oct 2004 Posts: 1640 Location: Gilbert, Arizona

I know.....you only have TWO HANDS. Laughing

Shelby suggested this is a THIRD HAND. Wink

Mitsu Oil pump gasket MD060521
Mitsu Oil pump O-ring MD068388 yes...it's a special O-ring. Wink

Mitsu Oil pump MD069800 net $150 retail $200
No "HV" pump exsist....Sealed Power are REBOXED pumps $300+ Shocked

Fel-pro supplies gaskets/o-rings it in a "conversion kit"...orange in color. SILICONE!

Joined: 06 Oct 2004 Posts: 1640 Location: Gilbert, Arizona

Because OIL PRESSURE controls the PRESSURE on the TENSIONER.....and the RIGHT OP GASKET has a function......

N/A OP/gasket on the left.......Turbocharged OP/gasket on the right.

......so does OBSTRUCTIONS/CONTAMINATION in your oil supply.....
NOTE: the words "OPEN CENTER" & "RESTRICTED CENTER" when refferd to your OP gasket.

.....and RE-GROUND CAMS are NORTORIOUS for contamination...... Rolling Eyes

(This tiny lil hole squirts oil right on the T-chain & crank sprocket Exclamation

)

.....and so does SHIMING of the OP RELEASE VALVE (to gain too much PSI)

Joined: 06 Oct 2004 Posts: 1640 Location: Gilbert, Arizona

No balance shaft chain damage on this cover........

Note how the timing cover was cast at an angle here for balance shaft chain clearance. If the balance shaft chain ("silent shaft" chain) was never tighten (as the FSM says it should be) the chain will WHIP...and contact the timing cover! Shocked

Joined: 06 Oct 2004 Posts: 1640 Location: Gilbert, Arizona

.....but this one did see some damage! Rolling Eyes

"What's that noise?" Once the chain and guides wear, the chain can make contact with the timing cover. Shocked

Also...FAILURE TO USE RUBBER SHEETS & DAMPNERS ALLOW THE T-CHAIN TO WHIP LIKE A SNAKE Exclamation

YOU DO NOT WANT TINY METALIC FOREIGN OBJECTS PUMPED THRU YOUR ENGINE Exclamation

Joined: 06 Oct 2004 Posts: 1640 Location: Gilbert, Arizona

It's the "boss" for this bolt. Wink

Joined: 06 Oct 2004 Posts: 1640 Location: Gilbert, Arizona

The "B" hole: Laughing

On a HOT/COLD engine...it provides the coolant RE-DIRECTED to cross-over your cylinder head Exclamation

A PRIORITY Exclamation

"Can coolant leak internally into the crankcase?" YOU BET! Shocked

Coolant leaves the water pump, goes thru the timing cover and into the block at this point.

Joined: 06 Oct 2004 Posts: 1640 Location: Gilbert, Arizona

Don't get stupid with the silicone or you'll plug the top hole Shocked

........it's the coolant BY-PASS HIGH PRESSURE HOLE to direct coolant into your HEAD..and thru your intake manifold. Wink

This INCLUDES ANY HOLE that coolant passes thru it. A FINGER SMIR of silicone is all it takes to seal it up. Wink

"A" Hole:

provides a slower velocity......higher volume of coolant directed over your CYLINDERS Exclamation

Joined: 06 Oct 2004 Posts: 1640 Location: Gilbert, Arizona

CORRECTION: LEFT SIDE, SECOND FROM THE BOTTOM.
74mm with a lock washer for the P/S BRACKET.

If you remove your A/C compressor and mount, you'll need to
change the upper three bolts to 70mm long.

They are 8mm x 1.25 pitch. Hit the bone yard and find the 2.6s. Laughing

Removes the 20lbs A/C compressor bracket!

The OBSOLETE MB123891 non A/C duct, replaces the A/C evaporator & the entire housing.

Joined: 06 Oct 2004 Posts: 1640 Location: Gilbert, Arizona

BOLT LENGHTS....with A/C.

CORRECTION: LEFT SIDE, SECOND FROM THE BOTTOM. 74mm with a lock washer for the P/S BRACKET

This is lenght of the bolts with A/C.

Joined: 06 Oct 2004 Posts: 1640 Location: Gilbert, Arizona

WHAT....are you seeing here? Rolling Eyes

DIFFERENT LENGHTS of t-chain guides!
The cure: Buying *PREMIUM* t-chain parts that *I* recommend! Laughing