Rocker Arms and Camshaft
ROCKER ARMS AND CAMSHAFTREMOVAL AND INSTALLATION
Removal Steps 1-32:
Required Special Tools:
REMOVAL SERVICE POINT
[[A]] LASH ADJUSTER REMOVAL
CAUTION: When reusing a lash adjuster, it must be washed and inspected before installation.
INSTALLATION SERVICE POINTS
]]A[[ OIL FEEDER CONTROL VALVE FILTER INSTALLATION
CAUTION: Install the oil feeder control valve filter on which no foreign materials, no defects and no deformation are confirmed.
]]B[[ EYE BOLT INSTALLATION
Holding the oil pipe joint with a spanner, tighten the eye bolt to the specified torque.
Tightening torque: 42 ± 2 Nm (31 ± 2 ft. lbs.)
NOTE: When the oil pipe joint is rotated together with the eye bolt at the installation, the oil pump would be possibly damaged.
]]C[[ LASH ADJUSTER INSTALLATION
CAUTION: When reusing a lash adjuster, it must be washed and inspected before installation.
Install the lash adjuster into the rocker arm, being careful not to spill the diesel fuel it contains.
]]D[[ CAMSHAFT INSTALLATION
CAUTION:
^ Do not confuse the intake camshaft with the exhaust camshaft.
^ As shown in the illustration, the shapes of the intake camshaft and the exhaust camshaft are different.
]]E[[ BEARING CAP INSTALLATION
1. Set each camshaft with its dowel pin at the top.
2. The bearing caps Nos. 2 - 5 are identical in shape for both intake and exhaust camshafts. Check the identification mark on each cap before installation.
Identification mark (stamped on front and Nos. 2 - 5 bearing caps)
I: intake side
E: exhaust side
3. Remove completely any sealant remaining on the bearing caps and cylinder head.
4. Apply sealant (MITSUBISHI Genuine Part number MD970389 or equivalent) to the surfaces indicated in the illustration.
5. Install each bearing cap and tighten its bolts in two or three passes.
6. Finally, tighten the bolts to the specified torque.
Tightening torque: 20 ± 1 Nm (15 ± 1 ft. lbs.)
7. Check that the rocker arms are correctly installed.
NOTE: Wipe off any squeezed out sealant completely.
]]F[[ CAMSHAFT OIL SEAL INSTALLATION
Use the special tool MD998713 to drive each oil seal into position in the cylinder head.
]]G[[ CAMSHAFT POSITION SENSOR SUPPORT INSTALLATION
1. Remove completely the FIPG remaining on the camshaft position sensor support and cylinder head.
2. Apply a 3 ± 1 mm diameter bead of FIPG to the indicated surface of the camshaft position sensor support.
Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent
]]H[[ CAMSHAFT POSITION SENSING CYLINDER INSTALLATION
1. Turn the exhaust camshaft to the No. 1 cylinder top dead centre position.
NOTE: The camshaft will slightly turn counterclockwise by the force of the exhaust valve spring.
2. Install the camshaft position sensing cylinder with the vanes and paint located as shown in the drawing.
]]I[[ COVER / GASKET INSTALLATION
1. Before the cover and the gasket installations, confirm the vanes and paint of the every sensing cylinder are in position indicated in the illustration with the camshaft on No. 1 top dead center of compression stroke.
2. At the intake side, install the cover notch and the gasket projection in position indicated in the illustration, and then tighten them to the specified torque.
At the exhaust side, the cover and the gasket do not have the specified direction or angle of the installation.
Tightening torque: 14 ± 1 Nm (124 ± 9 inch lbs.)
NOTE: The cover and the gasket have no difference between the front and the reverse sides.
]]J[[ CAMSHAFT POSITION SENSOR INSTALLATION
Install the camshaft position sensor with paying attention to the installation direction because an identification paint is not applied to the camshaft position sensor at the intake side.
INSPECTION
CAMSHAFT
Measure the cam height and replace the camshaft if any height exceeds the specified limit.
Standard value:
Intake: 35.96 mm (1.42 inches)
Exhaust: 35.49 mm (1.40 inches)
Limit:
Intake: 35.46 mm (1.40 inches)
Exhaust: 34.99 mm (1.38 inches)
LASH ADJUSTERS
CAUTION:
^ The lash adjuster is a precision-engineered component. Do not allow dust or other foreign matter to enter it.
^ Do not disassemble lash adjusters.
^ Use only non-contaminated diesel fuel to clean the lash adjuster.
1. Prepare three containers and approximately five liters of diesel fuel. Pour into each container the diesel fuel in an amount enough for a lash adjuster placed in the container in its upright position to completely submerge.
2. Place the lash adjuster in container A and wash its outside surface.
NOTE: Use a nylon brush if there are hard-to-remove deposits.
CAUTION: The steel ball spring of the lash adjuster is extremely weak. The lash adjuster's functionality may be badly affected if the special tool is inserted too strongly.
3. While gently pushing the internal steel ball using the special tool MD998442, move the plunger in and out 5 - 10 times to eliminate stiffness in the plunger and expel contaminated oil.
NOTE: The plunger must be free from jamming and any other abnormalities. If a defect is found in plunger operation, replace the lash adjuster.
CAUTION: The hole in the side of the lash adjuster must be directed toward the inside of container A. Never direct it toward any person.
4. Take the lash adjuster out of the container, then move the plunger by pushing the steel ball gently to discharge the diesel fuel from the pressure chamber.
CAUTION: The steel ball spring of the lash adjuster is extremely weak. The lash adjuster's functionality may be badly affected if the special tool is inserted too strongly.
5. Soak the lash adjuster in the diesel fuel in container B. Move the plunger in and out 5 - 10 times by gently pushing the internal steel ball using the special tool MD998442 until the plunger moves smoothly to wash the lash adjuster's pressure chamber.
CAUTION: The hole in the side of the lash adjuster must be directed toward the inside of container B. Never direct it toward any person.
6. Take the lash adjuster out of the container, then move the plunger by pushing the steel ball gently to discharge the diesel fuel from the pressure chamber.
CAUTION: Do not use container C for cleaning. If cleaning is performed in container C, foreign matter could enter the pressure chamber when the chamber is filled with diesel fuel.
7. Soak the lash adjuster in the diesel fuel in container C. Gently push the internal steel ball using the special tool MD998442.
8. Place the lash adjuster upright with the plunger at the top. Push the plunger firmly until it makes a full stroke, then return the plunger slowly and release the hold of the steel ball to allow the pressure chamber to be filled with diesel fuel.
9. Take the lash adjuster out of the container, place it upright with the plunger at the top, and push the plunger firmly. The plunger must not move at all.
NOTE: If the lash adjuster contracts, perform the operations 7 through 9 again. Replace the lash adjuster if it still contracts even after the pressure chamber has completely been filled with diesel fuel (air has been bled).
10. Keep the serviced lash adjusters in their upright positions to prevent diesel fuel from spilling out. Protect them from dust or other foreign matter. Install the lash adjusters onto the engine as soon as possible.