Mitsubishi Car 1999-05

Rocker Arms & Shafts

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Removal & Installation



  1. Disconnect the negative battery cable.
  2.  
  3. Remove the rocker arm cover.
  4.  
  5. Install the lash adjuster clips on the rocker arms, then loosen the bearing cap bolts. Do not remove the bolts from the bearing caps.
  6.  
  7. Remove the rocker arms, shafts and bearing caps as an assembly.
  8.  

To install:

  1. Install the bearing caps/rocker arm assemblies. Tighten the bolts to 23 ft. lbs. (31 Nm).
  2.  
  3. Remove the lash adjuster clips.
  4.  
  5. Install the rocker arm cover using a new gasket.
  6.  
  7. Connect the negative battery cable.
  8.  



Click image to see an enlarged view

Fig. Camshaft, rocker arm and shaft assemblies-1.5L engine



Click image to see an enlarged view

Fig. Camshaft, rocker arm and shaft assemblies-1.8L engine

  1. Remove or disconnect the following:

    Negative battery cable
     
    Spark plug cables-for 1.8L engine
     
    Accelerator cable, breather hose and Positive Crankcase Ventilation (PCV) hose connections
     
    Rocker cover
     

  2.  
  3. Loosen both rocker arm shaft assemblies gradually and evenly and remove the rocket shafts from the vehicle.
  4.  
  5. If disassembly is required, keep all parts in the exact order of removal.
  6.  

To install:

  1. Lubricate the rocker shaft with clean engine oil and install the rockers and springs.
  2.  
  3. Install the rocker arm and shaft assemblies. Tighten the rocker arm shaft retainer bolts to 23 ft. lbs. (32 Nm).
  4.  
  5. Check valve adjustment and install the valve cover. Tighten the valve cover bolts to 16 inch lbs. (1.8 Nm) for the 1.5L engine or to 29 inch lbs. (3.3 Nm) for the 1.8L engine.
  6.  
  7. Install or connect the following:

    Spark plug cables, if detached
     

  8.  
  9. Connect the accelerator cable, breather hose and PCV hose.
  10.  
  11. Connect the negative battery cable.
  12.  

1.5L And 1.8L Engines


Click image to see an enlarged view

Fig. Camshaft, rocker arm and shaft assemblies-1.5L engine



Click image to see an enlarged view

Fig. Camshaft, rocker arm and shaft assemblies-1.8L engine

  1. Disconnect the negative battery cable.
  2.  
  3. For 1.8L engines, label and disconnect the spark plug cables.
  4.  
  5. Disconnect the accelerator cable, breather hose and PCV hose connections.
  6.  
  7. Remove the rocker cover.
  8.  
  9. Loosen both rocker arm shaft assemblies gradually and evenly and remove the rocket shafts from the vehicle.
  10.  
  11. If disassembly is required, keep all parts in the exact order of removal.
  12.  

To install:

  1. Lubricate the rocker shaft with clean engine oil and install the rockers and springs.
  2.  
  3. Install the rocker arm and shaft assemblies. Tighten the rocker arm shaft retainer bolts to 23 ft. lbs. (32 Nm).
  4.  
  5. Check valve adjustment and install the valve cover. Tighten the valve cover bolts to 16 inch lbs. (1.8 Nm) for the 1.5L engine or to 29 inch lbs. (3.3 Nm) for the 1.8L engine.
  6.  
  7. If detached, connect the spark plug cables.
  8.  
  9. Connect the accelerator cable, breather hose and PCV hose.
  10.  
  11. Connect the negative battery cable.
  12.  

2.0L Engine
  1. Disconnect the negative battery cable. Remove the air cleaner assembly. Remove the ignition coil.
  2.  
  3. Disconnect the breather hose connection, PCV valve connection and accelerator cable clamp.
  4.  
  5. Remove the rocker arm cover retaining bolts. Remove the rocker arm cover. Discard the gasket.
  6.  
  7. Loosen the rocker arm and shaft assembly mounting bolts. Remove the rocker arm and shaft assembly with the bolts still attached.
    NOTE
    Never disassemble the rocker arm and shaft assembly.

  8.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  

2.4L Engine


Click image to see an enlarged view

Fig. Rocker arm shafts and related components-2000-2005 Eclipse 2.4L engine

  1. Remove or disconnect the following:

    Negative battery cable
     
    Accelerator cable, remove the cable clamp mounting screws and position the accelerator cable out of the way.
     
    Air intake hose
     
    Breather hose and the Positive Crankcase Ventilation (PCV) hose
     
    Spark plug cables from the spark plugs
     
    Rocker cover and gasket
     

  2.  
  3. Install the lash adjuster retainer tools to the rocker arm.
  4.  
  5. Remove the rocker shaft hold-down bolts gradually and evenly and remove the rocker shaft/arm assemblies.
  6.  
  7. Disassemble the rockers and the rocker shaft springs from the rocker shafts. If they are to be reused, note the location and positioning of all rocker arm shaft components. It is recommended that all lash adjusters and rockers be replaced as a complete set.
  8.  

To install:

Click image to see an enlarged view

Fig. Installing the rocker shaft springs-2000-2005 Eclipse 2.4L engine

  1. Immerse the lash adjusters in clean diesel fuel, and using a small wire, move the plunger up and down 4 or 5 times. While pushing down lightly on the check ball in order to bleed the air from the adjuster.
  2.  
  3. Install the lash adjusters to the rocker arms and attach the special holding tool.
  4.  
  5. Lubricate the rocker shaft with clean engine oil and install the rocker arms.
  6.  
  7. Temporarily tighten the rocker shaft assembly with the mounting bolts so that all rocker arms on the inlet valve side do not push on the valves.
  8.  
  9. Fit the rocker shaft springs from above and position them so that they are at right angles to the plug side. Install the rocker springs before installing the exhaust side rocker shaft and rocker arm assembly.
  10.  
  11. Install the exhaust side rocker shaft assembly in the engine. Tighten the rocker shaft mounting bolts gradually and evenly to 23 ft. lbs. (32 Nm).
  12.  
  13. Remove the lash adjuster retaining tools.
  14.  
  15. Install or connect the following:

    Rocker cover and tighten the mounting bolts to 29 inch lbs. (3.3 Nm)
     
    Spark plug wires to the spark plugs
     
    PCV and breather hoses
     
    Air intake hose
     
    Accelerator cable brackets and reconnect the accelerator cable
     
    Negative battery cable
     

  16.  

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the accelerator cable, remove the cable clamp mounting screws and position the accelerator cable out of the way.
  4.  
  5. Remove the air intake hose.
  6.  
  7. Disconnect the breather hose and the Positive Crankcase Ventilation (PCV) hose.
  8.  
  9. Disconnect the spark plug cables from the spark plugs.
  10.  
  11. Remove the rocker cover and gasket.
  12.  
  13. Install lash adjuster retainer tools to the rocker arm.
  14.  
  15. Remove the rocker shaft hold-down bolts gradually and evenly and remove the rocker shaft/arm assemblies.
  16.  
  17. Disassemble the rockers and the rocker shaft springs from the rocker shafts. If they are to be reused, note the location and positioning of all rocker shaft components. It is recommended that all lash adjusters and rockers be replaced as a complete set.
  18.  

To install:

  1. Immerse the lash adjusters in clean diesel fuel, and using a small wire, move the plunger up and down 4 or 5 times. While pushing down lightly on the check ball in order to bleed the air from the adjuster.
  2.  
  3. Install the lash adjusters to the rocker arms and attach the special holding tool.
  4.  
  5. Lubricate the rocker shaft with clean engine oil and install the rocker arms.
  6.  
  7. Temporarily tighten the rocker shaft assembly with the mounting bolts so that all rocker arms on the inlet valve side do not push on the valves.
  8.  
  9. Fit the rocker shaft springs from above and position them so that they are at right angles to the plug side. Install the rocker springs before installing the exhaust side rocker shaft and rocker arm assembly.
  10.  
  11. Install the exhaust side rocker shaft assembly in the engine. Tighten the rocker shaft mounting bolts gradually and evenly to 23 ft. lbs. (32 Nm).
  12.  
  13. Remove the lash adjuster retaining tools.
  14.  
  15. Install the rocker cover and tighten the mounting bolts to 29 inch lbs. (3.3 Nm).
  16.  
  17. Connect the spark plug wires to the spark plugs.
  18.  
  19. Connect the PCV and breather hoses.
  20.  
  21. Install the air intake hose.
  22.  
  23. Install the accelerator cable brackets and reconnect the accelerator cable.
  24.  
  25. Connect the negative battery cable.
  26.  

  1. Disconnect the negative battery cable.
  2.  
  3. If equipped with manual transaxle, remove the EMC. If equipped with automatic transaxle remove the PCM.
  4.  
  5. Remove the air cleaner assembly. Remove the battery. Remove the ignition coils.
  6.  
  7. Remove the timing belt upper cover.
  8.  
  9. Disconnect the control wiring harness connection. Remove the rocker cover PCV connection.
  10.  
  11. Remove the rocker cover breather hose connection. Remove the engine oil control valve and O-ring. Remove the oil pressure switch.
  12.  
  13. Remove the rocker cover retaining bolts. Remove the rocker cover. Discard the gasket.
  14.  
  15. Remove the spark plug guide oil seals. Remove the accumulator assembly.
  16.  
  17. Remove the exhaust rocker arm shaft caps. Remove the exhaust rocker arm shaft assembly.
  18.  
  19. Remove the intake rocker arm shaft caps. Remove the intake rocker arm shaft assembly.
    NOTE
    Never disassemble the exhaust or intake rocker arm assembly.



    Click image to see an enlarged view

    Fig. Intake rocker arm shaft installation locating point-2004-2005 Galant 2.4L engine



    Click image to see an enlarged view

    Fig. Exhaust rocker arm shaft installation locating point-2004-2005 Galant 2.4L engine

  20.  

To install:

  1. Position the intake rocker arm assembly so that its 0.22 inch hole faces toward the cylinder head. Install the rocker shaft mounting bolts. Torque to 21-25 ft. lbs. 29-34 Nm).
  2.  
  3. Position the exhaust rocker arm assembly so that its notch is positioned as shown in the illustration. Install the rocker shaft mounting bolts. Torque to 106-124 inch lbs. 12-14 Nm).
  4.  
  5. Continue the installation in the reverse order of the removal procedure.
  6.  
  7. Adjust the valves.
  8.  
  9. To initialize the ECM, manual transaxle equipped vehicles, or the PCM, automatic transaxle equipped vehicles, turn the ignition switch ON then OFF and keep it in the OFF position for at least ten seconds.
  10.  

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly. Remove the battery. Remove the ignition coils.
  4.  
  5. Remove the timing belt upper cover.
  6.  
  7. Disconnect the control wiring harness connection. Remove the rocker cover PCV connection.
  8.  
  9. Remove the rocker cover breather hose connection. Remove the engine oil control valve and O-ring. Remove the oil pressure switch.
  10.  
  11. Remove the rocker cover retaining bolts. Remove the rocker cover. Discard the gasket.
  12.  
  13. Remove the spark plug guide oil seals. Remove the accumulator assembly.
  14.  
  15. Remove the exhaust rocker arm shaft caps. Remove the exhaust rocker arm shaft assembly.
  16.  
  17. Remove the intake rocker arm shaft caps. Remove the intake rocker arm shaft assembly.
    NOTE
    Never disassemble the exhaust or intake rocker arm assembly.

  18.  

To install:

  1. Position the intake rocker arm assembly so that its 0.22 inch hole faces toward the cylinder head. Install the rocker shaft mounting bolts. Torque to 21-25 ft. lbs. 29-34 Nm).
  2.  
  3. Position the exhaust rocker arm assembly so that its notch is positioned as shown in the illustration. Install the rocker shaft mounting bolts. Torque to 106-124 inch lbs. 12-14 Nm).
  4.  
  5. Continue the installation in the reverse order of the removal procedure.
  6.  
  7. Adjust the valves.
  8.  

3.0L Engines

The hydraulic lash adjusters are built into the rocker arms.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the valve cover. Install lash adjuster retainer tools to prevent the auto-lash adjuster from falling out of the rocker arm.
  4.  
  5. Loosen rocker arm and shaft assembly evenly in several steps. Remove the rocker arm and shaft assembly as a complete unit.
  6.  
  7. Remove the rear camshaft bearing cap and slide the rocker arms, springs and washers from the shaft. If they are to be reused, note the location and positioning of all rocker shaft components. It is recommended that all lash adjusters and rockers be replaced as a complete set.
  8.  

To install:

  1. Immerse the lash adjusters in clean diesel fuel. Using a small wire, move the plunger of the lash adjuster up and down 4 or 5 times while pushing down lightly on the check ball in order to bleed out the air. Install the lash adjusters in the rocker arms.
  2.  
  3. Using a light coat of engine oil, assemble the rocker arms to the shaft. Install the rear camshaft bearing cap.
  4.  
  5. Lubricate the camshaft and rocker shaft with clean engine oil and position on the cylinder head.
  6.  
  7. Apply a drop of sealant to the rear edges of the end caps.
  8.  
  9. Install or connect the following:

    Assembly making sure the notches in the rocker shafts are facing up
     
    Cap bolts and tighten evenly and gradually to 14 ft. lbs. (20 Nm). Remove the lash adjuster retainers.
     
    Valve cover
     
    Negative battery cable
     

  10.  

  1. Disconnect the negative battery cable.
  2.  
  3. On the left side, remove the thermostat housing assembly. Remove the PCV valve hose connection, spark plug cable and battery cable connection.
  4.  
  5. On the right side, remove the intake manifold plenum, breather hose connection and spark plug cable.
  6.  
  7. Remove the rocker arm cover retaining bolts. Remove the rocker arm cover. Discard the gasket.
  8.  
  9. Install tool MD998443 on the rocker arms, so that the lash adjusters will not fall out.
  10.  
  11. Loosen the rocker arm and shaft assembly mounting bolts. Remove the rocker arm and shaft assembly with the bolts still attached.
    NOTE
    Never disassemble the rocker arm and shaft assembly.

  12.  

To install:

  1. Rotate the camshaft until the dowel pin on its front end is located as shown in the illustration.
    NOTE
    Placing the camshaft in the illustrated position minimizes the amount of cam lift, making it easier to install the rocker arm shaft assembly.



    Click image to see an enlarged view

    Fig. Rocker arm and shaft positioning-2004-2005 Eclipse 3.0L engine



    Click image to see an enlarged view

    Fig. Rocker shaft spring alignment-2004-2005 Eclipse 3.0L engine

  2.  
  3. Temporarily tighten the rocker shaft with the bolts so that all rocker arms on the inlet valve side do not push the valves.
  4.  
  5. Push the rocker shaft spring so that it takes a right angle against the plug guide.
    NOTE
    Set the rocker shaft spring before installing the rocker arm and shaft assembly on the exhaust side.

  6.  
  7. Tighten the rocker arm and shaft assembly mounting bolts to 21-25 ft. lbs. 28-34 Nm). Remove tool MD998443.
  8.  
  9. Continue the installation in the reverse order of the removal procedure. Be sure to use new valve cover gaskets.
  10.  

The hydraulic lash adjusters are built into the rocker arms.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the valve cover. Install lash adjuster retainer tools to prevent the auto-lash adjuster from falling out of the rocker arm.
  4.  
  5. Loosen rocker arm and shaft assembly evenly in several steps. Remove the rocker arm and shaft assembly as a complete unit.
  6.  
  7. Remove the rear camshaft bearing cap and slide the rocker arms, springs and washers from the shaft. If they are to be reused, note the location and positioning of all rocker shaft components. It is recommended that all lash adjusters and rockers be replaced as a complete set.
  8.  

To install:

  1. Immerse the lash adjusters in clean diesel fuel. Using a small wire, move the plunger of the lash adjuster up and down 4 or 5 times while pushing down lightly on the check ball in order to bleed out the air. Install the lash adjusters in the rocker arms.
  2.  
  3. Using a light coat of engine oil, assemble the rocker arms to the shaft. Install the rear camshaft bearing cap.
  4.  
  5. Lubricate the camshaft and rocker shaft with clean engine oil and position on the cylinder head.
  6.  
  7. Apply a drop of sealant to the rear edges of the end caps.
  8.  
  9. Install the assembly making sure the notches in the rocker shafts are facing up.
  10.  
  11. Install the cap bolts and tighten evenly and gradually to 14 ft. lbs. (20 Nm). Remove the lash adjuster retainers.
  12.  
  13. Install the valve cover.
  14.  
  15. Connect the negative battery cable.
  16.  

DOHC Engine


Click image to see an enlarged view

Fig. The rocker arms sit beneath the camshaft and are supported on one end by the valve stem and on the other end by the hydraulic lash adjuster-Diamante with 3.0L DOHC engine

  1. Relieve the fuel system pressure.
  2.  


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Disconnect battery negative cable.
  2.  
  3. Remove the timing belt cover and timing belt. Refer to the timing belt procedure in this section.
  4.  
  5. Remove the center cover, breather and PCV hoses, and spark plug cables.
  6.  
  7. Remove the rocker cover.
  8.  
  9. Remove the throttle body stay, both camshaft sprockets, and oil seals.
  10.  
  11. Remove the Camshaft Position (CMP) sensor and adapter from the rear of the camshaft.
  12.  
  13. Remove the intake and exhaust camshafts.
  14.  
  15. Remove rocker arms and lash adjusters from the head. It is recommended that all lash adjusters and rockers be replaced as a complete set.
  16.  

To install:

  1. Immerse the lash adjusters in clean diesel fuel. Using a small wire, move the plunger of the lash adjuster up and down four or five times while pushing down lightly on the check ball in order to bleed out the air. Lubricate and install the lash adjusters in the cylinder head.
  2.  
  3. Lubricate the camshafts with clean engine oil and position the camshafts on the cylinder head.
  4.  
  5. Install the bearing caps. Tighten the caps in sequence, in 2 or 3 steps. Caps 2, 3 and 4 have a front mark. Install with the mark aligned with the front mark on the cylinder head. Intake caps have I stamped on the cap and exhaust caps have E . Also, be sure the rocker arm is correctly mounted on the lash adjuster and the valve stem end. Torque the front and rear retaining cap bolts to 14 ft. lbs. (20 Nm) and tighten the center 3 retaining cap bolts to 8 ft. lbs. (11 Nm).
  6.  
  7. Apply a coating of engine oil to the oil seals and install.
  8.  
  9. Install the timing belt, valve cover and all related parts. Refer to the timing belt procedure in this section.
  10.  
  11. Connect the negative battery cable and check for leaks.
  12.  



Click image to see an enlarged view

Fig. The rocker arms sit beneath the camshaft and are supported on one end by the valve stem and on the other end by the hydraulic lash adjuster-3.0L DOHC engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect battery negative cable.
  6.  
  7. Remove the timing belt cover and timing belt. Refer to the timing belt unit repair section.
  8.  
  9. Remove the center cover, breather and PCV hoses, and spark plug cables.
  10.  
  11. Remove the rocker cover.
  12.  
  13. Remove the throttle body stay, both camshaft sprockets, and oil seals.
  14.  
  15. Remove the Camshaft Position (CMP) sensor and adapter from the rear of the camshaft.
  16.  
  17. Remove the intake and exhaust camshafts.
  18.  
  19. Remove rocker arms and lash adjusters from the head. It is recommended that all lash adjusters and rockers be replaced as a complete set.
  20.  

To install:

  1. Immerse the lash adjusters in clean diesel fuel. Using a small wire, move the plunger of the lash adjuster up and down four or five times while pushing down lightly on the check ball in order to bleed out the air. Lubricate and install the lash adjusters in the cylinder head.
  2.  
  3. Lubricate the camshafts with clean engine oil and position the camshafts on the cylinder head.
  4.  
  5. Install the bearing caps. Tighten the caps in sequence and in 2 or 3 steps. Caps 2, 3 and 4 have a front mark. Install with the mark aligned with the front mark on the cylinder head. Intake caps have I stamped on the cap and exhaust caps have E . Also, be sure the rocker arm is correctly mounted on the lash adjuster and the valve stem end. Torque the front and rear retaining cap bolts to 14 ft. lbs. (20 Nm) and tighten the center 3 retaining cap bolts to 8 ft. lbs. (11 Nm).
  6.  
  7. Apply a coating of engine oil to the oil seals and install.
  8.  
  9. Install the timing belt, valve cover and all related parts. Refer to the timing belt unit repair section.
  10.  
  11. Connect the negative battery cable and check for leaks.
  12.  

SOHC Engine

On this engine, the hydraulic lash adjusters are built into the rocker arms.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the valve cover. Install lash adjuster retainer tools MD998443 or equivalent, to prevent the auto-lash adjuster from falling out of the rocker arm.
  4.  
  5. Loosen rocker arm and shaft assembly evenly in several steps. Remove the rocker arm and shaft assembly as a complete unit.
  6.  
  7. Remove the rear camshaft bearing cap and slide the rocker arms, springs and washers from the shaft. If they are to be reused, note the location and positioning of all rocker shaft components. It is recommended that all lash adjusters and rockers be replaced as a complete set.
  8.  

To install:

  1. Immerse the lash adjusters in clean diesel fuel. Using a small wire, move the plunger of the lash adjuster up and down 4 or 5 times while pushing down lightly on the check ball in order to bleed out the air. Install the lash adjusters in the rocker arms.
  2.  
  3. Using a light coat of engine oil, assemble the rocker arms to the shaft. Install the rear camshaft bearing cap.
  4.  
  5. Lubricate the camshaft and rocker shaft with clean engine oil and position on the cylinder head.
  6.  
  7. Apply a drop of sealant to the rear edges of the end caps.
  8.  
  9. Install the assembly making sure the notches in the rocker shafts are facing up.
  10.  
  11. Install the cap bolts and tighten evenly and gradually to 14 ft. lbs. (20 Nm). Remove the lash adjuster retainers.
  12.  
  13. Install the valve cover.
  14.  
  15. Connect the negative battery cable.
  16.  



Click image to see an enlarged view

Fig. Rocker arm assembly-3.0L SOHC engine



Click image to see an enlarged view

Fig. When installing the rocker arm/shaft assemblies, ensure that the arrow marks point in the same direction as the arrow stamped into the cylinder head-3.0L SOHC engine

On this engine, the hydraulic lash adjusters are built into the rocker arms.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the valve cover. Install lash adjuster retainer tools MD998443 or equivalent, to prevent the auto-lash adjuster from falling out of the rocker arm.
  6.  
  7. Loosen rocker arm and shaft assembly evenly in several steps. Remove the rocker arm and shaft assembly as a complete unit.
  8.  
  9. Remove the rear camshaft bearing cap and slide the rocker arms, springs and washers from the shaft. If they are to be reused, note the location and positioning of all rocker shaft components. It is recommended that all lash adjusters and rockers be replaced as a complete set.
  10.  

To install:

  1. Immerse the lash adjusters in clean diesel fuel. Using a small wire, move the plunger of the lash adjuster up and down 4 or 5 times while pushing down lightly on the check ball in order to bleed out the air. Install the lash adjusters in the rocker arms.
  2.  
  3. Using a light coat of engine oil, assemble the rocker arms to the shaft. Install the rear camshaft bearing cap.
  4.  
  5. Lubricate the camshaft and rocker shaft with clean engine oil and position on the cylinder head.
  6.  
  7. Apply a drop of sealant to the rear edges of the end caps.
  8.  
  9. Install the assembly making sure the notches in the rocker shafts are facing up.
  10.  
  11. Install the cap bolts and tighten evenly and gradually to 14 ft. lbs. (20 Nm). Remove the lash adjuster retainers.
  12.  
  13. Install the valve cover.
  14.  
  15. Connect the negative battery cable.

    Click image to see an enlarged view

    Fig. Rocker arm assembly-3.0L SOHC engine



    Click image to see an enlarged view

    Fig. When installing the rocker arm/shaft assemblies, ensure that the arrow marks point in the same direction as the arrow stamped into the cylinder head-3.0L SOHC engine

  16.  

3.5L Engines


Click image to see an enlarged view

Fig. Camshaft, rocker arm and shaft assemblies-3.5L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the rocker arm cover.
  4.  
  5. Install the lash adjuster clips on the rocker arms, then loosen the bearing cap bolts. Do not remove the bolts from the bearing caps.
  6.  
  7. Remove the rocker arms, shafts and bearing caps as an assembly.
  8.  

To install:

  1. Install the bearing caps/rocker arm assemblies. Tighten the bolts to 23 ft. lbs. (31 Nm).
  2.  
  3. Remove the lash adjuster clips.
  4.  
  5. Install the rocker arm cover using a new gasket.
  6.  
  7. Connect the negative battery cable.
  8.  

3.8L Engine
  1. Disconnect the negative battery cable. Drain the cooling system.
  2.  
  3. On the left side, remove the thermostat housing assembly. Remove the PCV valve hose connection, ignition coil connector and ignition coil. Disconnect the engine control wiring harness clamp and harness bracket.
  4.  
  5. On the right side, remove the intake manifold plenum, breather hose connection, heater hose and water hose connection. Remove the ignition coil connector and coil.
  6.  
  7. Remove the rocker arm cover retaining bolts. Remove the rocker arm cover. Discard the gasket.
  8.  
  9. Install tool MD998443 on the rocker arms, so that the lash adjusters will not fall out.
  10.  
  11. Loosen the rocker arm and shaft assembly mounting bolts. Remove the rocker arm and shaft assembly with the bolts still attached.
    NOTE
    Never disassemble the rocker arm and shaft assembly.

  12.  

To install:

Click image to see an enlarged view

Fig. Rocker arm and shaft positioning-2004-2005 Galant 3.8L engine

  1. Install the rocker arm, shaft and lash adjuster assembly.
  2.  
  3. Check that the notches in the rocker shaft are facing the direction, shown in the illustration. Install the rocker shaft cap with its identification mark as shown in the illustration.
  4.  
  5. Tighten the intake side rocker arm and shaft assembly mounting bolts to 21-25 ft. lbs. 28-34 Nm). Tighten the exhaust side rocker arm and shaft assembly mounting bolts to 106-124 inch. lbs. 12-14 Nm). Remove tool MD998443.
  6.  
  7. Continue the installation in the reverse order of the removal procedure. Be sure to use new valve cover gaskets.
  8.  

Lancer Evolution


Click image to see an enlarged view

Fig. Rocker arm assemblies and related components-Evolution

  1. Remove the engine under cover. Remove the side cover.
  2.  
  3. Disconnect the battery cable. Drain the engine coolant.
  4.  
  5. Remove the air duct assembly. Remove the air pipe -C- assembly.
  6.  
  7. Remove the accelerator cable. Remove the timing belt.
  8.  
  9. Disconnect the oil feed control valve connector and remove the oil feed control valve and O-ring.
  10.  
  11. Remove the rocker cover center cover. Remove the spark plug cables and ignition coils.
  12.  
  13. Disconnect the front heated oxygen sensor connector, crankshaft position sensor connector, control wiring harness connection and rocker cover PCV hose.
  14.  
  15. Remove the rocker cover breather hose, upper radiator hose and camshaft position sensor connector (exhaust and inlet side).
  16.  
  17. Disconnect the ground terminal, the control wiring harness connection and vacuum hose and pipe assembly.
  18.  
  19. Remove the valve cover retaining bolts. Remove the valve cover. Remove the spark plug hole gaskets. Remove and discard the valve cover gasket.
  20.  
  21. Remove the camshaft position sensor support cover, and gasket. Remove the camshaft position sensing cylinder (exhaust side).
  22.  
  23. Remove the camshaft position sensor support, cover and gasket.
  24.  
  25. Remove the camshaft sensing cylinder (intake side). Remove the camshaft position sensor support. Remove the exhaust camshaft sprocket and oil seal. Remove the intake camshaft sprocket and oil seal.
  26.  
  27. Remove the front camshaft bearing cap. Remove the rear camshaft bearing cap.
  28.  
  29. Remove bearing cap number 2, 5, 3 and 4. Remove the exhaust camshaft sprocket and washer
  30.  
  31. Remove the intake camshaft sprocket and oil seal. Remove the camshaft bearing front cap. Remove bearing cap number 2, 5, 3 and 4. Remove the intake camshaft.
  32.  
  33. Remove the rocker arms.
  34.  

To install:

  1. Clean the lash adjusters if they are being reused.
  2.  
  3. Install the oil delivery body and tighten the bolt to 90-106 inch lbs. (10-12 Nm).
  4.  
  5. Install the lash adjusters into the rocker arms.
  6.  
  7. Install the rocker arms.
  8.  
  9. Install the camshaft(s). The exhaust camshaft has a 0.16 inch (4mm) wide slit at the rear end, so not to confuse it with the intake camshaft. Make sure that the dowel pin on the end of each camshaft is in the top position.
  10.  
  11. Install the camshaft bearing caps. Intake and exhaust bearing caps for intake Nos. 2 through 5 are identical, except for an identification mark on each of them. (Example: E2=exhaust side No. 2; I3=Intake side No. 3.) Be sure to install the correct cap in the correct location.
  12.  
  13. Install the front and rear camshaft bearing caps. Apply fresh sealant to the mating surfaces between the caps and cylinder head.
  14.  
  15. Once the camshaft bearing caps are installed, tighten each bolt in 2 or 3 passes. Finally tighten the bolts to 15 ft. lbs. (20 Nm). Completely wipe off any squeezed out sealant.
  16.  
  17. Install the camshaft oil seals.
  18.  
  19. Apply a 0.12 inch (3mm) bead of sealant around the circumference of the sensor support that mates to the bearing cap/cylinder head side. Install the CMP sensor support.
  20.  
  21. Install the CMP sensing cylinder and tighten the bolt to 90-106 ft. lbs. (18-26 Nm).
  22.  
  23. Install the CMP sensor support cover and gasket.
  24.  
  25. Install CMP sensor.
  26.  
  27. Install the rocker arm cover gasket and cover. Tighten the bolts to 27-35 inch lbs. (3.0-4.0 Nm).

    Click image to see an enlarged view

    Fig. Rocker arm cover sealant application-Evolution

  28.  
  29. Install or connect the oil filler cap.
  30.  
  31. Install or connect the PCV hose.
  32.  
  33. Install or connect the breather hose.
  34.  
  35. Fill the crankcase with oil and connect the negative battery cable.
  36.  

 
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