Front Case and Oil Pump
FRONT CASE AND OIL PUMP
REMOVAL AND INSTALLATION
REMOVAL SERVICE POINTS
[[A]] OIL PAN REMOVAL
1. Remove all oil pan bolts.
2. Drive in special tool MD998727 between the cylinder block and oil pan.
NOTE: Never use a screwdriver or chisel to remove the oil pan. It will deform the oil pan flange and result in oil leakage.
3. Gently hit the special tool on its corner (shoulder), then slide it along the oil pan to remove it.
[[B]] PLUG REMOVAL
1. Fit special tool MD998162 on the plug, and then hold it in position with special tool MD998783.
2. Loosen the plug.
3. Remove special tools MD998783 and MD998162 and then the plug.
[[C]] FLANGE BOLT REMOVAL
1. Remove the plug on the side of the cylinder block.
2. Insert a Phillips screwdriver [shank diameter 8 mm (0.3 inch)] into the plug hole to lock the counterbalance shaft.
3. Loosen the flange bolt.
[[D]] COUNTERBALANCE SHAFT FRONT BEARING REMOVAL
Using special tool MD998371, 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, special tool MD998372 cannot be used for rear balance shaft bearing removal.
[[E]] COUNTERBALANCE SHAFT REAR BEARING REMOVAL
1. Install special tools MB991603 and MD998372 in front of the cylinder block when removing the left counterbalance shaft rear bearing.
2. Using special tool MD998372, remove the right counterbalance shaft rear bearing from the cylinder block.
INSTALLATION SERVICE POINTS
]]A[[ RIGHT COUNTERBALANCE SHAFT REAR BEARING INSTALLATION
1. Apply engine oil to the bearing outer surface and bearing hole in the cylinder block.
2. Using special tool MD998705, install the rear bearing. Make sure that the oil hole of the bearing is aligned with that of the cylinder block.
]]B[[ LEFT COUNTERBALANCE SHAFT REAR BEARING INSTALLATION
1. Install special tool MB991603 to the cylinder block.
2. Apply engine oil to the rear bearing outer surface and bearing hole in the cylinder block.
3. Using special tool MD998705, install the rear bearing.
NOTE: The left rear bearing has no oil holes.
]]C[[ COUNTERBALANCE SHAFT FRONT BEARING INSTALLATION
1. Apply engine oil to the front bearing outer surface and bearing hole in the cylinder.
2. Using special tool MD998705, install the front bearing. Make sure that the oil hole of the bearing is aligned with that of the cylinder block.
]]D[[ COUNTERBALANCE SHAFT OIL SEAL INSTALLATION
Using a suitable socket wrench, install the counterbalance shaft oil seal into the front case.
]]E[[ OIL PUMP OIL SEAL INSTALLATION
Using a suitable socket wrench, install the oil pump oil seal into the front case.
]]F[[ CRANKSHAFT FRONT OIL SEAL INSTALLATION
Using special tool MD998375, install the crankshaft front oil seal into the front case.
]]G[[ OIL PUMP DRIVEN GEAR/OIL PUMP DRIVE GEAR INSTALLATION
Install the oil pump gears into the front case and line up the alignment marks.
]]H[[ OIL PUMP CASE ASSEMBLY/OIL FILTER BRACKET INSTALLATION
1. Set special tool MD998285 on the front end of crankshaft and apply a thin coat of engine oil to the outer surface of special tool MD998285.
2. Apply engine oil to the lip of the crankshaft front oil seal.
3. Install the oil pump case assembly together with the new front case gasket.
4. Install the oil filter bracket together with the new gasket.
5. Tighten the all flange bolts to the specified torque.
Tightening torque: 23 ± 3 Nm (17 ± 2 ft. lbs.)
]]I[[ FLANGE BOLT INSTALLATION
1. Insert a Phillips head screwdriver [shank diameter 8 mm (0.3 inch)] into the 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 the specified torque.
Tightening torque: 36 ± 3 Nm (27 ± 2 ft. lbs.)
3. Pull out the screwdriver and screw in the plug.
]]J[[ PLUG INSTALLATION
1. Install a new O-ring to the groove of the front case.
2. Install the plug to the front case.
3. Fit special tool MD998162 on the plug, and then hold it in position with special tool MD998783.
4. Tighten the plug to the specified torque.
Tightening torque: 23 ± 3 Nm (17 ± 2 ft. lbs.)
5. Remove special tools MD998783 and MD998162.
]]K[[ OIL PAN INSTALLATION
1. Clean both gasket surfaces of oil pan and cylinder block.
2. Apply a 4 mm (0.15 inch) diameter bead of sealant (MITSUBISHI Genuine Part number MD970389 or equivalent) to the flange of the oil pan.
Apply sealant as indicated by the broken line in the illustration; the grooves must be traced and the bolt holes must be surrounded with a bead of sealant.
3. Install the oil pump case assembly to the front side of the cylinder block.
NOTE: Be sure to install the oil pan quickly while the sealant is wet (within 15 minutes).
4. Fit an 8 mm (0.30 inch) long bolt in each of the two holes identified by the letter "S" in the illustration and a 10 mm (0.39 inch) long bolt in each of the remaining 17 holes. Tighten all bolts to the specified torque.
Tightening torque: 9.0 ± 3.0 Nm (80 ± 26 inch lbs.)
NOTE: After installation, keep the sealed area away from the oil for approximately one hour
]]L[[ DRAIN PLUG GASKET INSTALLATION
CAUTION: If the gasket is installed in the wrong direction, oil leaks will occur. Install the drain plug gasket in the direction shown.
]]M[[ 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. Install the oil filter to the bracket and tighten it to the specified torque.
Tightening torque:
Part number MD360935 filter: 14 ± 2 Nm (122 ± 17 inch lbs.)
Other MITSUBISHI Genuine filter: 17 ± 3 Nm (12 ± 2 ft. lbs.)
4. If no torque wrench can be used for tightening, use the following procedure.
1. Screw in the oil filter until its O-ring contacts the oil filter bracket.
2. Tighten the oil filter by giving the specified amount of turn.
Part number MD360935 filter: one turn
Other MITSUBISHI Genuine filter: 3/4 turn
]]N[[ SEALANT APPLICATION TO ENGINE OIL
CAUTION: Be careful not to block the oil passage with sealant.
1. Apply the sealant (3M AAD Part number 8672 or equivalent) to the threads of the engine oil pressure switch.
2. Tighten the switch to the specified torque.
Tightening torque: 19 ± 3 Nm (14 ± 2 ft. lbs.)
INSPECTION
FRONT CASE
1. Check the oil passage for clogging and clean if necessary.
2. Check the left counterbalance shaft front bearing for wear, damage and seizure. If the bearing is damaged, 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 the oil seal if necessary.
2. Check the oil seal lip for deterioration. Replace the oil seal if necessary.
COUNTERBALANCE SHAFT
1. Check the oil holes for clogging and clean if necessary.
2. Check the journal for seizure, damage and contact with bearing. If there is anything wrong with the journal, replace the counterbalance shaft, bearing or front case assembly if required.
OIL PUMP
1. Assemble the oil pump gears 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 (0.004 - 0.006 inch)
Driven gear 0.06 - 0.12 mm (0.003 - 0.004 inch)