Oil Pan

Removal & Installation

2.4L Engine

To Remove:

1. Drain the engine oil.
2. Remove the oil dipstick.
3. Remove the front exhaust pipe and main muffler.
4. Remove the engine oil pan drain plug.
5. Remove the engine oil pan drain plug gasket.
6. Remove the bell housing cover.
7. Remove the oil pan mounting bolts.

   CAUTION
   To keep from deforming the oil pan flange, very carefully remove the oil pan.

8. Remove the oil pan using an oil pan FIPG cutter (special tool #MD998727) and a brass bar.

To Install:

CAUTION
Once you have installed the oil pan, wait at least an hour before starting the engine.

1. To install the oil pan, do the following:
   • Step 1: Remove the old sealant from the oil pan and cylinder block mating surfaces.
   • Step 2: Degrease the sealant-coated surface and the engine mating surface.
   • Step 3: Put sealant around the gasket surface of the oil pan. Use Mitsubishi genuine part #MD970389 or an equivalent.

     NOTE: The sealant should be applied in a continuous bead approximately 0.2 in (4 mm) in diameter.

   • Step 4: Assemble the oil pan onto the cylinder block within 15 minutes of applying the sealant.

   NOTE: During removal, make note of the 2 bolts on the side facing the front of the engine. Their lengths (M6 x 8mm) are different from the other bolts.

2. Install the bell housing cover.
3. When installing the drain plug gasket, install it with the open side facing the oil pan side.
4. Install the drain plug.
5. Install the main muffler and front exhaust pipe.
6. Install the oil dipstick.
7. Refill the engine oil.

3.0L Engine

To Remove:

1. Drain the engine oil.
2. Remove the exhaust pipe.
3. Remove the drain plug and drain plug gasket for the lower oil pan.
4. When removing the lower oil pan, do the following:
   • Step 1: Remove the lower oil pan mounting bolts.

     CAUTION
     Do not use the oil pan FIPG cutter (special tool #MD998727) to remove the lower oil pan because the tool will damage the upper oil pan.

   • Step 2: Put a wooden block against the lower oil pan and remove it by carefully tapping the wood block with a hammer.
5. Remove the upper oil pan drain plug and drain plug gasket.
6. Disconnect the starter connector.
7. Remove the starter.
8. Remove the oil dipstick and dipstick guide.
9. Remove the O-ring.
10. Remove the oil pan bolt hole cover.
11. When removing the upper oil pan, do the following:
    • Step 1: Remove the upper oil pan mounting bolts.
    • Step 2: Screw the M10 bolts that fasten the upper oil pan to the transaxle assembly in the bolt holes, then remove the upper oil pan.

To Install:

1. When installing the upper oil pan, tighten the mounting bolts in the order illustrated.

   CAUTION
   The bolt holes for bolt #13 and bolt #14 in the drawing are cut away on the transaxle side. Make sure not to insert these bolts at an angle.

   Upper oil pan installation (3.0L)

2. Install the oil pan bolt hole cover.
3. When installing the lower oil pan, tighten the lower oil pan mounting bolts as shown.

   Lower oil pan installation (3.0L)

4. Install the O-ring.
5. Install the oil dipstick and dipstick guide.
6. Install the starter.
7. Connect the starter connector.
8. When installing the upper oil pan drain plug gasket, install a new one. Make sure the open side of the gasket is facing the oil pan side.
9. Install the upper oil pan drain plug.
10. Install a new lower oil pan drain plug gasket and drain plug. Make sure the open side of the gasket is facing the oil pan side.