DOHC DSM camshaft, cam gear, and 3G lifter install

Click the image to see 1G to 3G lifter comparisons

Installing the camshafts

Tools/Parts needed:

I used Clevite Cam Gard Assembly Lube, Redline Synthetic High Speed Grease, Mopar ATF-RTV (very good sealing transmission RTV - the black stuff), a socket wrench, torque wrench, and a 12mm socket.

Installing 3rd Generation Mitsubishi lifters

First, soak the new lifters in motor oil for an hour or so. This helps fill them with oil/gets the air out. Another helpful hint for those of you installing new cam seals and/or cam gears. Break the cam gear bolts loose first with an air gun. Follow the instructions in your shop manual and the pictures below to disassemble the head enough to install the new lifters.

Reassembly

First apply engine oil or cylinder head assembly lube to the lifters, roller rockers, journals, and cams of the camshafts. Install the camshafts on the cylinder head. Use care not to confuse the intake camshaft with the exhaust camshaft. The intake camshaft has a slit on its rear end for driving the crankshaft position sensor.

Align the both cams with dowel pins up

Try to keep the bearing caps in order. If you get them confused, there are identification marks stamped on top of them.

I: for Intake camshaft side

E: for Exhaust camshaft side

Install the caps on the cylinder head in the proper order and orientation (they should fit only one way.) Only "L" or "R" is stamped on No. 1 bearing caps. The Cap No. is stamped on No. 2 to No. 5 bearing caps. No. 6 bearing cap has no stamping. The cam gear (sprocket)/dowel pin side of the camshafts start with bearing cap No. 1 with the No. 6 bearing caps on the rear of the cylinder head.

Tighten the Cam Bearing Caps in the following order. Torque progressively in two to three steps. Tighten to 20Nm or 14ft/lbs in the final sequence. Check to ensure that the rocker arm is held in position on the lash adjuster and valve stem end.

Grease and install the new camshaft seal. Then install the Timing Belt Gears.

Here are some pictures of the process:

Pull the cam bearing caps off of the first cam you are going to work on

Keep them in order and clean to make this process easier.

Remove the camshaft and place it in a safe place

Remove the first roller rocker for the lifter you are going to replace

Remove the old lifter

Apply assembly lube and install the new lifter (3rd generation lifter shown)

Apply more assembly Lube.

More will be applied right before the Valve Cover is installed

Apply assembly lube to the journals/camshaft bearing caps

Install cam and cam bearing caps per the instructions above. Make sure to align the cam dowel pins pointing straight up before tightening the cam bearing caps

Remove the old cam gear and apply grease to the new cam seal. Fill the inner seal

Apply assembly lube to the cam journal portion and RTV to the edges to help it seal. Be careful to a thin layer of RTV so that it will not squeeze out when installed

Push on the new cam seal

Install the bearing caps and finger tighten the bolts in the diagram above

Finish tightening the cam bearing caps according to the torque diagram above

Remove old cam gear, install and torque the new cam gear

This is usually a job for an air gun and hopefully you read my warning to pre-loosen the bolts. The cam gears are stuck on there very tight.

If necessary, clean out the threads for the cam gear bolt. Hand torque the new gear to 86ft/lbs.

DONE!

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