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NS 2007 3.8l SOHC MIVEC Timing Belt - Done!

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  • dunk_c
    Member
    • Nov 2007
    • 100
    • Ipswich, Qld

    NS 2007 3.8l SOHC MIVEC Timing Belt - Done!

    Just wanted to post a brief description of the work just completed- might help someone else. I have done the DOHC 2L belts on my Alfa a few times so had some experience of this type of work but never done this engine.

    Job: basically a 200k Service, quoted price from dealer about 3k. I did the following for the cost of parts and about three days of my holiday: timing belt, pulleys and tensioner; spark plugs; water pump, hoses and thermostat; cam seals, tappet clearances, valve cover gaskets; auxiliary belt and tensioner; intake manifold gaskets; new crank bolt and washer; checked injector resistances; replaced all bonnet rubber seals; new air filter.
    I bought the wrong crank and cam angle sensors, and spark plug leads which I will put up for sale (shopped using someone else’s parts list - costly mistake). See Market Place if interested.

    Lessons learnt: take photos as you go, make sure you have a magnetic retriever and broken bolt extractor kit, don’t throw your tools in a big pile and expect to find “that” socket quickly, check bolt thread pitch as some look the same but could be course or fine pitch - too late when the nut gets damaged.

    Problems encountered: wasted an hour searching for a dropped bolt from the power steering pump and never found it. Several plastic wiring loom clips perished, replaced with cable ties. Last bolt to tighten snapped and lost plastic seal (used some thread seal) barely snugged it up (air bleed bolt). Refitting the power steering pump was a bugger getting the top bolts to line up and forgot to reattach the sensor wire until car back together. The fan clutch would not reseat onto shaft so had to dress both surfaces to get it on (not sure how both sides got damaged). During first drive there was some surging, at idle there was erratic rpms when a/c was turned on or off - this fixed itself after I sprayed some contact cleaner on a few wiring connectors including the throttle control plug. Also, when cleaning the throttle body I opened the throttle plate a tad so pressed this closed and few times (may have reset something).

    I used the online faq.out-club.ru/download/pajero_iv manual, Haynes Manual, and some other online sources (including this forum) for removal and replacement sequences and torque settings.

    I built a tool for torquing the timing belt tensioner, as I could not get the correct pin stick out with other methods described (picture below). Welded a couple of 3mm roll pins to a 1/4” 8mm socket with a chamfered edge. Just left enough space to fit a spanner to tighten the bolt.

    As mentioned by others the job is not technically difficult just long and stressful because if there is an issue, such as a leak, there is a lot of work to get back in. Certainly not a weekend job for the novice if this is your only car. Timing belt fitment was straightforward, just use the timing marks on the three pulleys and make a simple tool to set the tension in the belt tensioner if you have a torque wrench that does 4.4NM!

    Old spark plugs showed a range of conditions, a couple dark and one quite white. Some variability in electrode length as well.

    Used Nulon 50:50 green coolant and the two bleed bolts provided to purge the system. Had bought a vacuum tool for this but it had an odd air connector so could not use it. Car only took 8L of coolant so there must have been some water that did not drain.

    Conclusion: no leaks of coolant, fuel or oil. No left over bolts left in tray - always a good sign. Running well: temp at 94, idle at 700, no fault codes. Tappets still seam a bit noisy but I don’t know what they should sound like. Better a bit loose than not closing fully. Took me a few days to do the work but apart from torquing every bolt and cleaning everything (including fan blade) I lost time: drinking - bloody hot here in Ipswich, getting a replacement cam seal that I drove in too far, chasing the dropped bolt, trying to remember where everything went, drilling out the snapped bolt, struggling to remove parts around the PS pump, stuffing around trying to find the PS pump sensor, wasted hours trying to figure out how the crank sensor wire went back, and this was my first time.

    Wish I had replaced the cam and crank sensors and the two auxiliary belt idler pulleys. Could have used a set of stubby ratchet spanners as well.
    Attached Files
    Last edited by dunk_c; 14-01-18, 11:16 AM. Reason: Spelling corrections
    2006 Gen 4.1 LWB NS Pajero, manual. Bilstein Lovel 1” suspension, Dueller 697 17” tyres, Boos bash plates (3), Icom UHF with foldable roof rail mounted aerials, MM nudge bar with Stedi light bar, Rhino Rack Xtray, Kings awning, Kluger cargo barrier, custom iPad bracket, Alpine amplifier, Fosgate speakers, Titan drawers, battery system in the rear footwell, Matson BT battery monitor on starter battery, TP-13 TPMS. Mostly a commuter but ready to go for most adventures
  • benckj
    Valued Member
    • Oct 2017
    • 516
    • Alexandra , New Zealand

    #2
    Just completed my NS cam belt but only st 100 km. My biggest problem was determining which was to tighten the tensioner bearing as there is misleading info with some procedures. Had to tear it back down to re-correct.

    Jim

    Comment

    • dunk_c
      Member
      • Nov 2007
      • 100
      • Ipswich, Qld

      #3
      I found that online advice, drawings etc usually did not clearly specify the engine type and errors could easily be made. Pulling it back apart - scary thought. Hope it ended up well? Can you still hear your tappets after adjustment?
      2006 Gen 4.1 LWB NS Pajero, manual. Bilstein Lovel 1” suspension, Dueller 697 17” tyres, Boos bash plates (3), Icom UHF with foldable roof rail mounted aerials, MM nudge bar with Stedi light bar, Rhino Rack Xtray, Kings awning, Kluger cargo barrier, custom iPad bracket, Alpine amplifier, Fosgate speakers, Titan drawers, battery system in the rear footwell, Matson BT battery monitor on starter battery, TP-13 TPMS. Mostly a commuter but ready to go for most adventures

      Comment

      • benckj
        Valued Member
        • Oct 2017
        • 516
        • Alexandra , New Zealand

        #4
        Yes all fixed now and no strange noise. Still need to take for decent test drive but I’m satisfied all is well.

        Jim

        Comment

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