Oil Pump

Removal & Installation

2.4L Engine

To Remove:

1. Remove the drain plug and gasket.
2. Remove the oil filter.
3. Remove the engine oil pressure switch.

   Oil pan remover

4. To remove the Oil Pan, do the following:
   • Step 1: Remove all of the oil pan bolts.
   • Step 2: Place the oil pan remover (special tool #MD998727) between the cylinder block and oil pan.

     NOTE: Do not use a screwdriver or chisel when removing the oil pan. This will cause the oil pan flange to deform causing oil leakage.

   • Step 3: Carefully and lightly hit the special tool on its corner (shoulder), and then slide it along the oil pan to remove it.
5. Remove the oil screen and oil screen gasket.

   Plug wrench & plug wrench retainer

6. When removing the plug, do the following:
   • Step 1: Place a plug wrench (special tool #MD998162) onto the plug then hold it in position with the plug wrench retainer (special tool #MD998783).
   • Step 2: Carefully loosen the plug.
   • Step 3: Remove the plug wrench retainer (special tool #MD998783) and the plug wrench (special tool #MD998162) then the plug.
7. Remove the O-ring.
8. To remove the flange bolt, do the following:
   • Step 1: Remove the plug on the side of the cylinder block.
   • Step 2: Place a Phillips head screwdriver into the plug hole to lock the counterbalance shaft. The screwdriver must have a shank diameter of 0.3 in (8 mm).
   • Step 3: Loosen the flange bolt.
9. Remove the relief plug.
10. Remove the gasket.
11. Remove the relief spring.
12. Remove the relief plunger.
13. Remove the oil filter bracket.
14. Remove the oil filter bracket gasket.
15. Remove the oil pump case assembly.
16. Remove the front case and front case gasket.
17. Remove the oil pump cover.
18. Remove the oil pump driven gear.
19. Remove the oil pump drive gear.
20. Remove the crankshaft front oil seal.
21. Remove the oil pump oil seal.
22. Remove the counterbalance shaft oil seal.
23. Remove the front case.
24. Remove the counterbalance shafts (left) and (right).
25. To remove the counterbalance shaft (front bearing), use the silent shaft bearing puller (special tool #MD998371) to remove the counterbalance shaft front bearing from the cylinder block.

    CAUTION
    Remove the front bearing first. If it has not been removed, use a silent shaft bearing puller (special tool #MD998372) cannot be used for rear balance shaft bearing removal.

26. To remove the counterbalance shaft (rear bearing) (right) and the counterbalance shaft (rear bearing) (left), install a bearing installer stopper (special tool #MB991603) and silent shaft bearing puller (special tool #MD998372) in front of the cylinder block when removing the left counterbalance shaft rear bearing. Next use the silent shaft bearing puller to remove the right counterbalance shaft rear bearing from the cylinder block.

To Install:

1. To install the counterbalance shaft (rear bearing) (left), do the following:
   • Step 1: Install the bearing installer stopper (special tool #MB991603) to the cylinder block.
   • Step 2: Apply the engine oil to the rear bearing outer surface and bearing hole the cylinder block.
   • Step 3: Use a silent shaft bearing installer (special tool #MD998705) to install the rear bearing.

   NOTE: The left rear bearing has no oil holes.

2. To install the counterbalance shaft (rear bearing) (right), do the following:
   • Step 1: Put clean engine oil to the bearing outer surface and bearing hole in the cylinder block.
   • Step 2: Use a silent shaft bearing installer (special tool #MD998705) install the rear bearing. Be sure the oil hole of the bearing is lined up with the oil hole on the cylinder block.
3. To install the counterbalance shaft (front bearing), do the following:
   • Step 1: Apply clean engine oil to the front bearing outer surface and bearing hole in the cylinder.
   • Step 2: Use the silent shaft bearing installer (special tools #MD998705) to install the front bearing. Be certain that the oil hole of the bearing is lined up with the oil hole on the cylinder block.
4. Install the counterbalance shafts (right) and (left).
5. Install the front case.
6. Use an appropriate socket wrench and install the counterbalance shaft oil seal onto the front case.
7. Use an appropriate socket wrench to install the oil pump oil seal into the front case.
8. Use the crankshaft front oil seal installer (special tool #MD998375) to install the crankcase front oil seal onto the front case.
9. When installing the oil pump drive gear and the oil pump driven gear, install them onto the front case and line up the alignment marks.
10. Install the oil pump cover.
11. Install the front case gasket and the front case.
12. When installing the oil pump case assembly:
    • Step 1: Place a crankshaft front oil seal guide (special tool #MD998285) onto the front end of the crankshaft and put a small amount of clean engine oil onto the outer surface of the crankshaft front oil seal guide (special tool #MD998285).
    • Step 2: Put a small amount of clean engine oil onto the lip of the crankshaft front oil seal.
    • Step 3: Install the oil pump case assembly along with a new front case gasket.
    • Step 4: Install the oil filter bracket along with a new gasket.
    • Step 5: Tighten the flange bolts to 17 ft-lbs (23 Nm).
13. Install the oil filter bracket gasket.
14. When installing the oil filter bracket, do the following:
    • Step 1: Place a crankshaft front oil seal guide (special tool #MD998285) onto the front end of the crankshaft and put a small amount of clean engine oil onto the outer surface of the crankshaft front oil seal guide (special tool #MD998285).
    • Step 2: Put a small amount of clean engine oil onto the lip of the crankshaft front oil seal.
    • Step 3: Install the oil pump case assembly along with a new front case gasket.
    • Step 4: Install the oil filter bracket along with a new gasket.
    • Step 5: Tighten the flange bolts to 17 ft-lbs (23 Nm).
15. Install the relief plunger.
16. Install the relief spring.
17. Install the gasket.
18. Install the relief plug.
19. To install the flange bolt, do the following:
    • Step 1: Place a Phillips head screwdriver into the hole in the left side of the cylinder block to lock the counterbalance shaft. The screwdriver must have a shank diameter of 0.3 in (8 mm).
    • Step 2: Fasten the oil pump driven gear onto the left counterbalance shaft by tightening the flange bolt to 27 ft-lbs (36 Nm).
    • Step 3: Pull out the screwdriver then screw in the plug.
20. Install the O-ring.

    Plug wrench & plug wrench retainer

21. To install the plug, do the following:
    • Step 1: Install a new O-ring onto the groove of the front case.
    • Step 2: Install the plug onto the front case.
    • Step 3: Place the plug wrench (special tool #MD998162) onto the plug then hold it in position with a plug wrench retainer (special tool #MD998783).
    • Step 4: Tighten the plug to 17 ft-lbs (23 Nm).
    • Step 5: Remove the plug wrench retainer (special tool #MD998783) and the plug wrench (special tool #MD998162).
22. Install oil screen gasket and oil screen.
23. To install the oil pan, do the following:
    • Step 1: Clean both of the gasket surfaces of the oil pan and cylinder block.
    • Step 2: Put a 0.15 in (4 mm) diameter bead of sealant onto the flange of the oil pan. The manufacturer recommends Mitsubishi genuine part #MD970389 or a suitable equivalent. Apply the sealant by tracing the grooves and going around the bolt holes.
    • Step 3: Install the oil pump case assembly onto the front side of the cylinder block.

      NOTE: Install the oil pan within 15 minutes while the sealant is still wet.

      Oil pan installation

    • Step 4: Fit a 0.30 in (8 mm) long bolt into each of the two holes labeled with "Y" in the drawing and a 0.39 in (10mm) long bolt in each of the remaining 17 holes. Tighten all of the bolts to 80 in-lbs (9.0 Nm).

    NOTE: After installing, do not get oil on the sealed area for at least an hour.

    CAUTION
    Installing the gasket incorrectly will cause oil leaks.

24. When installing the drain plug gasket, install the gasket with the open side facing the oil pan side.
25. Install the drain plug.

    CAUTION
    Make sure not to block the oil passage with sealant.

26. When installing the engine oil pressure switch, put sealant on the threads of the engine oil pressure switch, then tighten to 14 ft-lbs (19 Nm). The manufacturer recommends using 3M™ AAD part #8672 or an equivalent.
27. To install the oil filter, do the following:
    • Step 1: Clean the installation surface of the filter bracket.
    • Step 2: Put a small amount of clean engine oil onto the oil filter O-ring.
    • Step 3: Install the oil filter onto the bracket then tighten it to the correct torque spec:
28. Part #MD360935 filter: 122 in-lbs (14 Nm)
29. Other Mitsubishi Genuine filter: 12 ft-lbs (17 Nm)
30. If a torque wrench cannot be used for tightening, use the following procedure:
31. Screw in the oil filter until its O-ring contacts the oil filter bracket.
32. Tighten the oil filter by turning it as follows:
33. Part #MD360935 filter: one turn
34. Other Mitsubishi Genuine filter: ¾ turn

3.0L Engine

To Remove:

1. Remove the engine oil pressure switch.
2. Remove the oil filter.
3. Remove the oil filter bracket and gasket.
4. Remove the drain plug and gasket.
5. When removing the lower oil pan, do the following:
   • Step 1: Remove the lower oil pan mounting bolts.

     CAUTION
     Do not use a scraper or other tool to remove the oil pan.

   • Step 2: Hold a wooden plank against the lower oil pan and remove that pan by tapping on the side wall with a plastic mallet through the wooden plank.
6. Remove the cover.

7. To remove the upper oil pan, do the following:
   • Step 1: Remove the long bolts labeled "Z" in the illustration.
   • Step 2: Remove all of the other bolts.

     CAUTION
     Do not use a scraper or other tool to remove the oil pan.

   • Step 3: Remove the oil pan.
   • Step 4: Screw the M10 bolts into the two bolt holes in the oil pan to break the joint and remove the oil pan.
8. Remove the baffle plate.
9. Remove the oil screen and gasket.
10. Remove the baffle plate.
11. Remove the plug.
12. Remove the relief spring.
13. Remove the relief plunger.
14. Remove the crankshaft front oil seal.
15. Remove the oil pump case assembly.
16. Remove the O-ring.
17. Remove the oil pump cover.
18. When removing the oil pump inner and outer rotors, make alignment dots on both rotors for correct assembly later.
19. Remove the oil pump case.

To Install:

1. Install the oil pump case.
2. When installing the oil pump inner and outer rotors, apply a small amount of clean engine oil to the rotors. Next, install the rotors and line up the alignment dots made during removal.
3. Install the oil pump cover.
4. Install the O-ring.
5. When installing the oil pump case assembly, do the following:
   • Step 1: Clean the gasket mating surfaces of the oil pump case and cylinder block.
   • Step 2: Put a 0.1 in (3 mm) diameter bead of sealant onto the oil pump case. Use Mitsubishi Genuine part #MD970389 or an equivalent. Apply the sealant by tracing the grooves and surrounding the bolt holes.
   • Step 3: Install the oil pump case assembly onto the front of the cylinder.

     NOTE: Install the oil pump case within 15 minutes while the sealant is still wet.

   • Step 4: Tighten the oil pump case mounting bolts to the following torque specs:
6. M8 bolt: 122 in-lbs (14 Nm)
7. M10 bolt: 30 ft-lbs (41 Nm)

   NOTE: After installing, keep oil and coolant away from the sealed area for an hour.

8. When installing the crankshaft front oil seal, do the following:
   • Step 1: Install the guide of the crankshaft front oil seal installer (special tool #MD998717) onto the front end of the crankshaft.
   • Step 2: Put a small amount of clean engine oil onto the lip area of a new oil seal and push it in until it contacts with the oil pump case.
   • Step 3: Use the crankshaft front oil seal installer (special tool #MD998717) to press-fit the oil seal into the oil pump case.
9. Install the relief plunger.
10. Install the relief spring.
11. Install the plug.
12. Install the baffle plate.
13. Install the oil screen gasket and the oil screen.
14. Install the baffle plate.
15. To install the upper oil pan, do the following:
    • Step 1: Clean both of the gasket surfaces of the upper oil pan and cylinder block.
    • Step 2: Put a 0.2 in (4 mm) diameter bead of sealant onto the upper oil pan. Use Mitsubishi Genuine part #MD970389 or an equivalent. Apply the sealant by tracing the grooves and surrounding the bolt holes with a bead of sealant.

      CAUTION
      When you install the upper oil pan, make sure not to force out sealant from the oil pan flange on the corners.

    • Step 3: Install the oil pan to the bottom of the cylinder block.

      NOTE: Make sure you install the oil pan within 15 minutes while the sealant is still wet.

      Upper oil pan installation (3.0L)

    • Step 4: Tighten the upper oil pan bolts in the sequence in the illustration. Tighten to 80 in-lbs (9.0 Nm).

    NOTE: After installing, keep oil and coolant away from the sealed area for an hour.

16. Install the cover.
17. To install the lower oil pan, do the following:
    • Step 1: Clean both gasket surfaces of the upper and lower oil pans.
    • Step 2: Put a 0.2 in (4 mm) diameter bead of sealant onto the lower oil pan. Use Mitsubishi Genuine part #MD970389 or an equivalent. Apply the sealant by tracing the grooves and surrounding the bolt holes.

      NOTE: Make sure to install the oil pan within 15 minutes while the sealant is still wet.

    • Step 3: Install the lower oil pan onto the upper oil pan.

    • Step 4: Tighten the lower oil pan bolts in the sequence shown. Tighten the bolts to 95 in-lbs (11 Nm).

    NOTE: After installing, keep oil away from the sealed area for about an hour.

    CAUTION
    Make sure to install the gasket in the correct direction or oil leaks will result.

18. When installing the drain plug gasket, install it with the open side facing the oil pan side.
19. Install the drain plug.
20. Install the oil filter bracket gasket and bracket.
21. When installing the oil filter, do the following:
    • Step 1: Clean the installation surface of the filter bracket.
    • Step 2: Put clean engine oil onto the oil filter O-ring.
    • Step 3: Install the oil filter
22. When installing the engine oil pressure switch, do the following:

    CAUTION
    Make sure you do not block the oil passage with sealant.

    • Step 1: Put sealant onto the threads of the engine oil pressure switch. Use 3M™ AAD part #8672 or an equivalent.
    • Step 2: Tighten the switch to 87 in-lbs (10 Nm).