Mitsubishi Montero, Sport 1998-06

Rocker Arms & Shafts

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Removal & Installation



2.4L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Install the special clips MB 998443-01 to hold the auto-adjusters in place.


    NOTE
    Take care during removal that no oil, grease or dirt comes into contact with the timing belt.



    Breather hose
     
    Positive Crankcase Ventilation (PCV) hose
     
    Valve cover
     



    Rocker arms and rocker arm shafts
     
    Rocker shaft springs

    Click image to see an enlarged view

    Fig. Insert the Lash Adjuster Holder tool MD998443 to prevent the lash adjuster from falling out-2.4L engines

     

  4.  

To install:

  1. Disassemble the rocker assembly, checking each component for wear, scoring, or plugged oil passages. Check the roller for correct and smooth rotation. Inspect the inner diameter of each rocker for any scoring or enlargement. If wear is found inside the rocker, replace it and inspect the shaft for damage.
  2.  
  3. Before reassembly, coat the contact faces liberally with clean motor oil. Observe the numbers on the bearing caps so that they are replaced in the correct location. Reassemble the rocker shafts into the front bearing cap so that the notches face outward. As you continue to assemble the springs, rockers and bearing caps, remember that the arrows on the bearing caps must point in the same direction as the arrow on the head. This is particularly important if the rockers have been removed from both heads.
  4.  
  5. Install or connect the following:

    Rocker arms and rocker arm shafts, Torque the bolts to 23 ft. lbs. (31 Nm).
     
    Valve cover Torque the bolts to 30 inch lbs. (3.4 Nm).
     
    PCV hose
     
    Breather hose

    Click image to see an enlarged view

    Fig. Exploded view of the rocker arms and shafts-3.0L engine

     

  6.  

3.0L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. 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
     



    Valve cover
     
    Auto lash adjuster retainers SST MD998443 on the rocker arms
     
    Rocker arms, rocker shafts and bearing caps, as an assembly

    Click image to see an enlarged view

    Fig. Rocker arms and related components-3.0L engine

     

  4.  

To install:

  1. Inspect the bearing journals on the camshaft and the cylinder head.
  2.  
  3. Lubricate the camshaft journals and camshaft with clean engine oil.
  4.  
  5. Install the rocker arms, rocker arm shaft and the rocker shaft spring as follows:
    1. Temporarily tighten the rocker shaft with the bolts so that the intake valve rocker arms do not push on the valves.
    2.  
    3. Insert the rocker shaft spring from above and mount it at right angles to the plug guide.
    4.  
    5. Before installing the exhaust rocker arms and the rocker arm shaft, mount the rocker shaft spring.
    6.  
    7. Remove tool SST MD998443 used to hold the lash adjuster in position.
    8.  
    9. Check to ensure that the flat side of the rocker shaft is perpendicular to the cylinder head, and facing the valves.
    10.  
    11. Gradually tighten the bearing caps in 2 or 3 steps. In the final step, tighten to 23 ft. lbs. (31 Nm).
    12.  

  6.  
  7. Install or connect the following:

    Valve cover and new gasket. Torque the bolt to 2-3 ft. lbs. (3-4 Nm).
     
    Negative battery cable
     

  8.  
  9. Start the engine and check for leaks and proper operation.
  10.  

12-Valve
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Install the special tools to the rocker arm to hold the lash adjuster. Loosen the camshaft bearing cap bolt. Do not remove the bolts from the cap. Remove the rocker arm, shaft and bearing cap as an assembly.



    Oil filter
     
    Oil filter tube
     
    Rocker cover
     
    Gasket
     
    Circular packing
     
    Camshaft oil seal
     
    Distributor adaptor
     
    O-Ring
     
    Rocker arm, rocker arm shaft
     



    Bearing cap No. 4
     
    Rocker arm

    Click image to see an enlarged view

    Fig. Removing and installing rocker arms/shafts

     

  4.  

To install:

To install, reverse removal procedure noting the following procedures:

  1. When installing the rocker arm and rocker arm shaft insert the lash adjuster to the rocker arm, being careful not to spill the diesel fuel. Then use the special tool to prevent the adjuster from falling while installing it. Apply a minimum amount of 3M Locking No. 4171 or equivalent on the four places of the cylinder head. Install the rocker arms, shafts and bearing caps such that the arrow mark on the bearing cap faces in the same direction as the arrow mark on the cylinder head. Tighten the bearing cap bolts to 14 ft. lbs. (20 Nm). Remove the special tools from all rocker arms.
    NOTE
    Be sure the sealing agent does not swell out onto the cam journal surface of the cylinder head. If it swells out, immediately wipe it off before it can dry.

  2.  
  3. When installing the circular packing, install a .052-.059 inch thick spacer to the special tool and drive the circular packing.
    NOTE
    Use of MD724328 spacer for transmission is recommended.


    CAUTION
    The packing is overdriven if no spacer is fitted to the special tool.

  4.  
  5. When installing the rocker cover, apply 3M ATD part No. 8660 or equivalent on the area specified in the figure below.

    Click image to see an enlarged view

    Fig. Applying sealant on the rocker cover

  6.  

24-Valve
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Install the special tools to the rocker arm to hole the lash adjuster. Loosen the camshaft bearing cap bolt. Do not remove the bolts from the cap. Remove the rocker arm, shaft and bearing cap as an assembly.


    NOTE
    Install the special tools to the rocker arm to hole the lash adjuster. Loosen the camshaft bearing cap bolt. Do not remove the bolts from the cap. Remove the rocker arm, shaft and bearing cap as an assembly.


    NOTE
    If the lash adjuster is re-used, clean the lash adjuster. Set the special tool to prevent the lash adjuster from coming free and falling to the floor.



    Rocker cover
     
    Rocker cover gasket
     
    Oil seal
     
    Camshaft oil seal
     
    Rocker arm, rocker arm shaft
     



    Rocker arm, rocker arm shaft
     



    Rocker shaft spring
     
    Rocker arm -A-
     
    Rocker arm -B-
     
    Rocker arm shaft
     
    Lash adjuster
     



    Rocker arm -C-
     
    Rocker arm shaft
     

  4.  

To install:

To install, reverse the removal procedure. Note the following installation procedures.

  1. When installing the lash adjuster, fit it onto the rocker arm without allowing diesel fuel to spill out. Fit the special tool to prevent the lash adjuster from coming free and falling to the floor.
  2.  
  3. When installing the rocker arm. Rocker arm shaft and rocker shaft spring, temporarily tighten the rocker shaft with bolts at the condition that all the intake valve rocker arms do not push the valves. Insert the rocker shaft spring from above and mount it at right angles to the plug guide. Before installing the exhaust rocker arms and rocker arm shaft, mount the rocker shaft spring. Remove the special tools used to hold the lash adjuster in position. Check to ensure that the flat side of the rocker shaft is directed as shown in the illustration below.

    Click image to see an enlarged view

    Fig. Checking rocker shaft installation 3.0L 24N (1996)

  4.  

3.5L Engines
  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
     
    Valve cover and the semi-circular packing.
     
    Crankshaft Position (CKP) sensor, matchmark for reassembly
     
    Camshaft Position (CMP) sensor, if equipped
     

  6.  


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



Rocker arms and shafts
 
Lash adjusters
 

  1. Check the camshaft journals for wear or damage. Check the cam lobes for damage. Also, check the cylinder head oil holes for clogging.
  2.  

To install:


NOTE
Lubricate the valve train components with clean engine oil.

  1. Bleed and install the lash adjusters to the to the original bores in the cylinder head.
  2.  
  3. Install or connect the following:

    Rocker arms and shafts. Torque the bolts to 23 ft. lbs. (31 Nm).
     
    Camshaft position sensor, if removed. Torque the mounting bolts to 78 inch lbs. (9 Nm).
     
    Camshaft Position (CMP) sensor, if equipped
     
    Valve cover and the semi-circular packing. Torque the bolts to 2.5 ft. lbs. (3.5 Nm).
     
    Negative battery cable
     

  4.  
  5. Run vehicle and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Install auto lash adjuster retainers SST MD998443 on the rocker arms



    Negative battery cable
     
    Valve cover and the semi-circular packing.
     
    Crankshaft Position (CKP) sensor, matchmark for reassembly
     
    Camshaft Position (CMP) sensor, if equipped
     



    Rocker arms and shafts
     
    Lash adjusters
     

  6.  
  7. Check the camshaft journals for wear or damage. Check the cam lobes for damage. Also, check the cylinder head oil holes for clogging.
  8.  

To install:


NOTE
Lubricate the valve train components with clean engine oil.

  1. Bleed and install the lash adjusters to the to the original bores in the cylinder head.
  2.  
  3. Install or connect the following:

    Rocker arms and shafts. Torque the bolts to 23 ft. lbs. (31 Nm).
     
    Camshaft position sensor, if removed. Torque the mounting bolts to 78 inch lbs. (9 Nm).
     
    Camshaft Position (CMP) sensor, if equipped
     
    Valve cover and the semi-circular packing. Torque the bolts to2.5 ft. lbs. (3.5 Nm).
     
    Negative battery cable
     

  4.  
  5. Run vehicle and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Install auto lash adjuster retainers SST MD998443 on the rocker arms



    Negative battery cable
     
    Valve cover and the semi-circular packing.
     
    Crankshaft Position (CKP) sensor, matchmark for reassembly
     
    Camshaft Position (CMP) sensor, if equipped
     



    Rocker arms and shafts
     
    Lash adjusters
     

  6.  
  7. Check the camshaft journals for wear or damage. Check the cam lobes for damage. Also, check the cylinder head oil holes for clogging.
  8.  

To install:


NOTE
Lubricate the valve train components with clean engine oil.

  1. Bleed and install the lash adjusters in their original bores in the cylinder head.
  2.  
  3. Install or connect the following:

    Rocker arms and shafts. Torque the bolts to 23 ft. lbs. (31 Nm).
     
    Camshaft position sensor, if removed. Torque the mounting bolts to 78 inch lbs. (9 Nm).
     
    Camshaft Position (CMP) sensor, if equipped
     
    Valve cover and the semi-circular packing. Torque the bolts to 2.5 ft. lbs. (3.5 Nm).
     
    Negative battery cable
     

  4.  
  5. Run vehicle and check for leaks.
  6.  

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



    Negative battery cable
     
    Oil filler cap
     
    Positive Crankcase Ventilation (PCV) valve and gasket
     
    Valve cover, gasket and oil seal(s)
     



    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



    Rocker arms and shafts
     

  6.  

To install:


NOTE
Lubricate the valve train components with clean engine oil.

  1. Bleed and install the lash adjusters to in their original bores in the cylinder head.
  2.  
  3. Install or connect the following:

    Rocker arms and shafts. Torque the bolts to 21-25 ft. lbs. (28-34 Nm).

    Click image to see an enlarged view

    Fig. Rocker arm installation identification points

     



    Valve cover oil seals and gasket
     
    Valve cover. Torque the bolts to 27-35 inch lbs.
     
    Positive Crankcase Ventilation (PCV) valve and gasket
     
    Oil filler cap
     
    Negative battery cable
     

  4.  
  5. Start the engine and check for leaks. Correct as required.
  6.  

 
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