Mitsubishi Montero, Sport 1998-06

Camshaft, Bearings & Lifters

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Inspection



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the camshaft from the engine.
  4.  
  5. Check the camshaft bearing journals for damage and binding.
  6.  
  7. If the journals are binding, check the cylinder head for damage.
  8.  
  9. Check the cylinder head for clogged oil holes.
  10.  
  11. As required, check the tooth surface of the distributor drive gear teeth of the camshaft. Replace the camshaft if wear is evident.
  12.  
  13. Check the camshaft surface for abnormal wear and damage. Replace the camshaft, as required.
  14.  
  15. Measure the cam height and replace the camshaft if not within specification.
  16.  
  17. If equipped with a 3.0L engine, the intake camshaft standard specification is 1.485 inches. Minimum limit is 1.465 inches. The exhaust camshaft standard specification is 1.462 inches. Minimum limit is 1.443.
  18.  
  19. If equipped with a 3.5L engine, the intake camshaft standard specification is 1.472 inches. Minimum limit is 1.452 inches. The exhaust camshaft standard specification is 1.452 inches. Minimum limit is 1.443inches.
  20.  
  21. If equipped with a 3.8L engine, the intake camshaft standard specification is 1.485 inches. Minimum limit is 1.462 inches. The exhaust camshaft standard specification is 1.465 inches. Minimum limit is 1.443inches.
  22.  

Removal & Installation



2.4L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain and recycle the engine coolant.
  4.  
  5. Drain and recycle the engine crankcase.
  6.  
  7. Remove or disconnect the following:
    CAUTION
    Wait at least 90 seconds after the negative battery cable is disconnected to prevent possible deployment of the air bag.



    Negative battery cable
     



    Positive Crankcase Valve (PCV) hose
     
    Valve cover and the upper timing belt cover
     

  8.  
  9. Rotate the crankshaft clockwise and align the camshaft sprocket timing mark with the timing mark on the cylinder head.
  10.  
  11. Remove or disconnect the following:

    Distributor, matchmark for reassembly
     

  12.  
  13. Install auto lash adjuster retainer MD998443 to each rocker arm to hold the auto lash adjusters in place
  14.  
  15. Remove or disconnect the following:
    WARNING
    Do not rotate the crankshaft after the sprocket is removed from the camshaft. Be sure there is no slack in the timing belt. Be sure the timing belt does not disengage from the sprocket. If the crankshaft is rotated or the timing belt position is disturbed, timing belt and sprocket alignment will have to be set.



    Rocker arm and shafts
     



    Thrust cage and o-ring
     
    Camshaft and the front seal from the engine
     

  16.  

To install:

  1. Install or connect the following:

    Front seal
     
    Camshaft, lubricate with engine oil
     
    Thrust cage and o-ring. Torque the bolts to 13 ft. lbs. (18 Nm).
     
    Rocker arm and shafts. Torque the bolts to 23 ft. lbs. (31 Nm).
     

  2.  
  3. Remove the auto lash adjuster retainer MD998443 from each rocker arm.
  4.  
  5. Install or connect the following:

    Valve cover and upper timing belt cover
     
    Positive Crankcase Valve (PCV) hose
     
    Distributor, aligning the mark made during removal
     
    Negative battery cable
     

  6.  
  7. Start the engine and check for leaks.
  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain and recycle the engine coolant.
  4.  
  5. Drain and recycle the engine crankcase.
  6.  
  7. Remove or disconnect the following:
    CAUTION
    Wait at least 90 seconds after the negative battery cable is disconnected to prevent possible deployment of the air bag.



    Negative battery cable
     



    Positive Crankcase Valve (PCV) hose
     
    Valve cover and the upper timing belt cover
     

  8.  
  9. Rotate the crankshaft clockwise and align the camshaft sprocket timing mark with the timing mark on the cylinder head.
  10.  
  11. Remove or disconnect the following:

    Distributor, matchmark for reassembly
     

  12.  
  13. Install auto lash adjuster retainer MD998443 to each rocker arm to hold the auto lash adjusters in place
  14.  
  15. Remove or disconnect the following:
    WARNING
    Do not rotate the crankshaft after the sprocket is removed from the camshaft. Be sure there is no slack in the timing belt. Be sure the timing belt does not disengage from the sprocket. If the crankshaft is rotated or the timing belt position is disturbed, timing belt and sprocket alignment will have to be set.



    Rocker arm and shafts
     



    Thrust cage and o-ring
     
    Camshaft and the front seal from the engine
     

  16.  

To install:

  1. Install or connect the following:

    Front seal
     
    Camshaft, lubricate with engine oil
     
    Thrust cage and o-ring. Torque the bolts to 13 ft. lbs. (18 Nm).
     
    Rocker arm and shafts. Torque the bolts to 23 ft. lbs. (31 Nm).
     

  2.  
  3. Remove the auto lash adjuster retainer MD998443 from each rocker arm.
  4.  
  5. Install or connect the following:

    Valve cover and upper timing belt cover
     
    Positive Crankcase Valve (PCV) hose
     
    Distributor, aligning the mark made during removal
     
    Negative battery cable
     

  6.  
  7. Start the engine and check for leaks.
  8.  

3.0L & 3.5L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil and coolant.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     

  8.  


CAUTION
Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative battery cable is disconnected.



Intake manifold plenum
 
Valve cover
 
Timing belt
 
Sprocket from the camshaft
 

  1. Install auto lash adjuster retainers SST MD998443 on the rocker arms.
  2.  
  3. Remove or disconnect the following:

    Distributor and the distributor extension, if equipped
     
    Rocker arms, rocker shafts and bearing caps, as an assembly
     
    Thrust cage and O-ring
     
    Camshaft from the cylinder head
     

  4.  
  5. Inspect the bearing journals on the camshaft and the cylinder head.
  6.  

To install:

  1. Lubricate the camshaft journals and camshaft with clean engine oil
  2.  
  3. Install or connect the following:

    Camshaft in the cylinder head.
     
    Thrust cage and O-ring. Torque the bolts to 109 inch lbs. (12 Nm).
     
    Rocker arms, rocker arm shaft and the rocker shaft spring.
     

  4.  
  5. Temporarily tighten the rocker shaft with the bolts positioned so that the intake valve rocker arms do not push the valves.
  6.  
  7. Install or connect the following:

    Rocker shaft spring from above and mount it at right angles to the plug guide.
     

  8.  
  9. Before installing the exhaust rocker arms and the rocker arm shaft, mount the rocker shaft spring.
  10.  
  11. Remove the SST used to hold the lash adjuster in position.
  12.  
  13. Check to ensure that the flat side of the rocker shaft is perpendicular to the cylinder head, and facing the valves.
  14.  
  15. Gradually tighten the bearing caps in 2 or 3 steps. In the final step tighten to 23 ft. lbs. (31 Nm).
  16.  
  17. Install or connect the following:

    Distributor, if removed
     
    Sprockets. Torque the bolts to 65 ft. lbs. (88 Nm).
     
    Timing belt and timing belt cover
     
    Valve cover. Torque the bolts to 26 inch lbs. (3.4 Nm).
     
    Intake manifold plenum
     
    Negative battery cable
     

  18.  
  19. Start the engine and check for leaks and proper operation.
  20.  
  21. Refill the coolant and crankcase.
  22.  


    Click image to see an enlarged view

    Fig. The camshaft bearing caps have identification marks on them-3.5L engine


  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain and recycle the engine coolant.
  6.  
  7. Drain and recycle the engine crankcase.
  8.  
  9. Remove or disconnect the following:
    CAUTION
    Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative battery cable is disconnected.



    Negative battery cable
     



    Intake manifold plenum
     
    Valve cover
     
    Timing belt
     
    Sprocket from the camshaft
     

  10.  
  11. Install auto lash adjuster retainers SST MD998443 on the rocker arms.
  12.  
  13. Remove or disconnect the following:

    Distributor and the distributor extension, if equipped
     
    Rocker arms, rocker shafts and bearing caps, as an assembly
     
    Thrust cage and o-ring
     
    Camshaft from the cylinder head
     

  14.  
  15. Inspect the bearing journals on the camshaft and the cylinder head.
  16.  

To install:

  1. Lubricate the camshaft journals and camshaft with clean engine oil
  2.  
  3. Install or connect the following:

    Camshaft in the cylinder head.
     
    Thrust cage and o-ring. Torque the bolts to 109 inch lbs. (12 Nm).
     
    Rocker arms, rocker arm shaft and the rocker shaft spring.
     

  4.  
  5. Temporarily tighten the rocker shaft with the bolts positioned so that the intake valve rocker arms do not push the valves.
  6.  
  7. Install or connect the following:

    Rocker shaft spring from above and mount it at right angles to the plug guide.
     

  8.  
  9. Before installing the exhaust rocker arms and the rocker arm shaft, mount the rocker shaft spring.
  10.  
  11. Remove the SST used to hold the lash adjuster in position.
  12.  
  13. Check to ensure that the flat side of the rocker shaft is perpendicular to the cylinder head, and facing the valves.
  14.  
  15. Gradually tighten the bearing caps in 2 or 3 steps. In the final step tighten to 23 ft. lbs. (31 Nm).
  16.  
  17. Install or connect the following:

    Distributor, if removed
     
    Sprockets. Torque the bolts to 65 ft. lbs. (88 Nm).
     
    Timing belt and timing belt cover
     
    Valve cover. Torque the bolts to 26 inch lbs. (3.4 Nm).
     
    Intake manifold plenum
     
    Negative battery cable
     

  18.  
  19. Start the engine and check for leaks and proper operation.
  20.  
  21. Refill the coolant and crankcase.

    Click image to see an enlarged view

    Fig. The camshaft bearing caps have identification marks on them-3.5L engine

  22.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil and coolant.
  6.  
  7. Remove or disconnect the following:
    CAUTION
    Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative battery cable is disconnected.



    Negative battery cable
     



    Intake manifold plenum
     
    Valve cover
     
    Timing belt
     
    Sprocket from the camshaft
     

  8.  
  9. Install auto lash adjuster retainers SST MD998443 on the rocker arms.
  10.  
  11. Remove or disconnect the following:

    Distributor and the distributor extension, if equipped
     
    Rocker arms, rocker shafts and bearing caps, as an assembly
     
    Thrust cage and O-ring
     
    Camshaft from the cylinder head
     

  12.  
  13. Inspect the bearing journals on the camshaft and the cylinder head.
  14.  

To install:

  1. Lubricate the camshaft journals and camshaft with clean engine oil
  2.  
  3. Install or connect the following:

    Camshaft in the cylinder head.
     
    Thrust cage and O-ring. Torque the bolts to 109 inch lbs. (12 Nm).
     
    Rocker arms, rocker arm shaft and the rocker shaft spring.
     

  4.  
  5. Temporarily tighten the rocker shaft with the bolts positioned so that the intake valve rocker arms do not push the valves.
  6.  
  7. Install or connect the following:

    Rocker shaft spring from above and mount it at right angles to the plug guide.
     

  8.  
  9. Before installing the exhaust rocker arms and the rocker arm shaft, mount the rocker shaft spring.
  10.  
  11. Remove the SST used to hold the lash adjuster in position.
  12.  
  13. Check to ensure that the flat side of the rocker shaft is perpendicular to the cylinder head, and facing the valves.
  14.  
  15. Gradually tighten the bearing caps in 2 or 3 steps. In the final step tighten to 23 ft. lbs. (31 Nm).
  16.  
  17. Install or connect the following:

    Distributor, if removed
     
    Sprockets. Torque the bolts to 65 ft. lbs. (88 Nm).
     
    Timing belt and timing belt cover
     
    Valve cover. Torque the bolts to 26 inch lbs. (3.4 Nm).
     
    Intake manifold plenum
     
    Negative battery cable
     

  18.  
  19. Start the engine and check for leaks and proper operation.
  20.  
  21. Refill the coolant and crankcase.

    Click image to see an enlarged view

    Fig. Camshaft bearing cap identification marks-3.5L engine

  22.  

3.8L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Cylinder head assembly
     
    Camshaft sprocket, using special tools M998715 and MB990767
     

  6.  


NOTE
Install auto lash adjuster retainers SST MD998443 on the rocker arms



Intake rocker arm, shaft and lash adjuster assembly. Loosen the rocker arm assembly mounting bolt and remove the assembly with the bolt still attached.
 
Exhaust rocker arm, shaft and lash adjuster assembly. Loosen the rocker arm assembly mounting bolt and remove the assembly with the bolt still attached.
 


Click image to see an enlarged view

Fig. Install the special tool to prevent the lash adjusters from falling to the floor during rocker arm removal-3.8L engine

Camshaft Position (CMP) sensor support and O-ring
 
Sensing CMP cylinder
 
Camshaft
 



Click image to see an enlarged view

Fig. Exploded view of the camshaft and related components-3.8L engine

To install:



Camshaft
 
Sensing CMP cylinder
 
CMP sensor support and O-ring
 
Exhaust rocker arm, shaft and lash adjuster assembly
 
Intake rocker arm, shaft and lash adjuster assembly
 
Camshaft sprocket
 
Cylinder head assembly
 
Negative battery cable
 

  1. Run vehicle and check for leaks.
  2.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:
    CAUTION
    Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative battery cable is disconnected.


    NOTE
    Install auto lash adjuster retainers SST MD998443 on the rocker arms



    Negative battery cable
     



    Cylinder head assembly
     
    Camshaft sprocket, using special tools M998715 and MB990767
     



    Intake rocker arm, shaft and lash adjuster assembly. Loosen the rocker arm assembly mounting bolt and remove the assembly with the bolt still attached.
     
    Exhaust rocker arm, shaft and lash adjuster assembly. Loosen the rocker arm assembly mounting bolt and remove the assembly with the bolt still attached.

    Click image to see an enlarged view

    Fig. Install the special tool to prevent the lash adjusters from falling to the floor during rocker arm removal-3.8L engine

     
    Camshaft Position (CMP) sensor support and O-ring
     
    Sensing CMP cylinder
     
    Camshaft

    Click image to see an enlarged view

    Fig. Camshaft and related components-3.8L engine

     

  6.  

To install:



Camshaft
 
Sensing CMP cylinder
 
CMP sensor support and O-ring
 
Exhaust rocker arm, shaft and lash adjuster assembly
 
Intake rocker arm, shaft and lash adjuster assembly
 
Camshaft sprocket
 
Cylinder head assembly
 
Negative battery cable
 

  1. Run vehicle and check for leaks.
  2.  

 
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