Front Case, Counterbalance Shaft and Oil Pan

REMOVAL AND INSTALLATION

Removal Service Points
[A] Oil Pan Removal
1. Remove all oil pan bolts.





2. Drive in the special tool between the cylinder block and oil pan.

NOTE: Never use a screwdriver or chisel, instead of the service tool, as a deformed oil pan flange will result in oil leakage.

[B] Plug Removal





1. If the plug is too tight, hit the plug head with a hammer two to three times, and the plug will be easily loosened.

[C] Flange Bolt Removal





1. Remove the plug on the side of cylinder block.
2. Insert a Phillips screwdriver [shank diameter 8 mm (0.32 inch)] into the plug hole to lock the counterbalance shaft.





3. Loosen the flange bolt.

[D] Counterbalance Shaft Front Bearing Removal





Using the special tool, remove the counterbalance shaft front bearing from the cylinder block.

NOTE: Be sure to remove the front bearing first. If it has not been removed, the Rear Bearing Puller cannot be used.

[E] Counterbalance Shaft Rear Bearing Removal





Using the special tool, remove the counterbalance shaft rear bearing from the cylinder block.

NOTE: When removing the left counterbalance shaft, install the special tool (MB991603) to the front of the cylinder block.

Installation Service Points
]A[ Right Counterbalance Shaft Rear Bearing Installation
1. Apply engine oil to the outer surface of bearing.





2. Using special tools, install right rear bearing. Make sure that oil hole of bearing is aligned with oil hole of cylinder block.

]B[ Left Counterbalance Shaft Rear Bearing Installation





1. Install the special tool (GUIDE PLATE) to the cylinder block.
2. Apply engine oil to the rear bearing outer inside diameter and bearing hole in cylinder block.





3. Using the special tool, install the rear bearing.

NOTE: The left rear bearing has no oil holes.

]C[ Counterbalance Shaft Front Bearing Installation





1. Using special tools, install front bearing.

]D[ Front Case Installation





1. Place the special tool on the front end of crankshaft and apply a thin coat of engine oil to the outer inside diameter of the special tool to install the front case.





2. Install the front case assembly through a new front case gasket and temporarily tighten the flange bolts (other than those for tightening the filter bracket).





]E[ Counterbalance Shaft Oil Seal Installation





]F[ Oil Pump Oil Seal Installation

]G[ Crankshaft Front Oil Seal Installation





1. Using the special tool, install the crankshaft front oil seal into the front case.

]H[ Oil Pump Driven Gear / Oil Pump Drive Gear Installation





1. Apply engine oil amply to the gears and line up the alignment marks.

]I[ Sealant Application To Oil Pressure Gauge Unit





1. Coat the threads of switch with sealant and install the switch using the special tool.
Specified sealant: 3M ATD Part No. 8660 or equivalent

CAUTION:
1. Keep the end of threaded portion clear of sealant.
2. Avoid an overtightening.

]J[ Sealant Application To Oil Pressure Switch





1. Coat the threads of switch with sealant and install the switch using the special tool.
Specified sealant: 3M ATD Part No.8660 or equivalent

CAUTION:
1. Keep the end of threaded portion clear of sealant.
2. Avoid an overtightening.

]K[ Flange Bolt Installation





1. Insert a Phillips screwdriver into a hole in the left side of the cylinder block to lock the counterbalance shaft.





2. Secure the oil pump driven gear onto the left counterbalance shaft by tightening the flange bolt to specified torque.

]L[ Plug Installation
1. Install a new O-ring to the groove of front case.





2. Using the special tool, install the plug and tighten to specified torque.

]M[ Oil Pan Installation
1. Clean both mating surfaces of oil pan and cylinder block.





2. Apply a 4 mm (0.16 inch) wide bead of sealant to the entire circumference of the oil pan flange.
Specified sealant: MITSUBISHI GENUINE PART No. MD970389 or equivalent

NOTE:
1. Be sure to install the oil pan quickly while the sealant is wet (within 15 minutes).
2. After installation, keep the sealed area away from the oil and coolant for approximately 1 hour.





3. Note the difference in bolt lengths at the location shown.

]N[ Drain Plug Gasket Installation





Install the drain plug gasket in the direction shown in the illustration.

]O[ Oil Cooler Installation





First insert the oil cooler projecting stopper in the oil filter bracket groove and then tighten the oil cooler bolts.

]P[ Oil Filter Installation
1. Clean the installation surface of the filter bracket.





2. Apply engine oil to the O-ring of the oil filter.
3. Screw the oil filter in until the O-ring contacts the bracket. Then tighten 3/4 turn [tightening torque: 17 Nm (12 ft. lbs)].

NOTE: For MD135737, tighten one turn [Tightening torque: 14 Nm (10 ft. lbs.] after the O-ring contacts the bracket.

INSPECTION

Front Case
1. Check oil holes for clogging and clean if necessary.
2. Check left counterbalance shaft front bearing section for wear, damage and seizure. If there is anything wrong with the section, replace the front case.
3. Check the front case for cracks and other damage. Replace cracked or damaged front case.

Oil Seal
1. Check the oil seal lip for wear and damage. Replace oil seal if necessary.
2. Check the oil seal lip for deterioration. Replace oil seal if necessary.

Counterbalance Shaft





1. Check oil holes for clogging.
2. Check journal for seizure, damage and contact with bearing. If there is anything wrong with the journal, replace counterbalance shaft, bearing or front case assembly.

Oil Pump
1. Assemble the oil pump gear to the front case and rotate it to ensure smooth rotation with no looseness.
2. Ensure that there is no ridge wear on the contact surface between the front case and the gear surface of the oil pump cover.





3. Check the side clearance.
Standard value:
Drive gear 0.08 - 0.14 mm (0.0031 - 0.0055 inch)
Driven gear 0.06 - 0.12 mm (0.0024 - 0.0047 inch)