Removal and Installation
REMOVAL AND INSTALLATION
- MB991603: Bearing Installer Stopper
- MD998162: Plug Wrench
- MD998285: Crankshaft Front Oil Seal Guide
- MD998371: Silent Shaft Bearing Puller
- MD998372: Silent Shaft Bearing Puller
- MD998375: Crankshaft Front Oil Seal Installer
- MD998705: Silent Shaft Bearing Installer
- MD998727: Oil Pan FIPG Cutter
- MD998783: Plug Wrench Retainer
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. Align the special tool, Plug Wrench (MD998162), with the notch.
2. Set the special tool, Plug Retainer (MD998783), pushing it slight. Place the washer to fit the clearance between Plug Retainer and the housing.
CAUTION:
If loosing the plug cap too much, the oil pump shaft would be affected by excessive force and bent.
3. Loose the plug cap slightly and remove the special tool, Plug Wrench Retainer (MD998162).
4. Remove the plug cap.
[[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
CAUTION:
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.
Using special tool MD998371, remove the counterbalance shaft front bearing from the cylinder block.
[[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[[
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.
]]B[[
RIGHT COUNTERBALANCE SHAFT REAR BEARING INSTALLATION
1. Install the guide pin of special tool MD998705 in the threaded hole of the cylinder block as shown.
2. Align the ratchet ball of special tool MD998705 with the oil hole in the rear bearing to install the bearing of special tool MD998705.
3. Apply engine oil to the bearing outer surface and bearing hole in the cylinder block.
4. Using special tool MD998705, install the rear bearing. Make sure that the oil hole of the bearing is aligned with the oil hole of the cylinder block.
]]C[[
COUNTERBALANCE SHAFT FRONT BEARING INSTALLATION
1. Remove the rear bearing installing portion from special tool MD998705.
2. Install the guide pin of special tool MD998705 in the threaded hole of the cylinder block as shown.
3. Align the ratchet ball of the special tool MD998705 with the oil hole in the rear bearing to install the bearing of the special tool MD998705.
4. Apply engine oil to the front bearing outer surface and bearing hole in the cylinder.
5. Using special tool MD998705, install the rear bearing. Make sure that the oil hole of the bearing is aligned with the oil hole 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 align the alignment marks.
]]H[[
OIL PUMP CASE 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 front case carefully to prevent damaging the oil seal.
4.
CAUTION:
Carefully install the tightening bolts, paying attention to their different lengths, respectively.
Tighten all flange bolts to the specified torque.
Tightening torque: 23± 3Nm (17± 2 ft-lb)
]]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± 3Nm (27± 1 ft-lb)
3. Pull out the screwdriver and screw in the plug.
]]JD[[
PLUG INSTALLATION
1. Install the new o-ring to the oil pump case.
2. Slightly tighten the plug cap by hand.
3. Fit special tool, Plug Retainer (MD998783), into the plug cap notch.
4. Set the special tool, Plug Retainer (MD998783), pushing it slightly. Place the washer to fit the clearance between Plug Retainer and the housing.
CAUTION:
Unless fitting the clearance between Plug Retainer and the housing, the oil pump shaft would be affected by excessive force and bent.
5. Tighten the plug cap to the specified torque of 23 ± 3 Nm.
]]KY[[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 (Three bond 1207F or equivalent) to the flange of the oil pan.
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) bolt in each of the two holes identified by the letter "S" in the illustration, and fit a 10 mm (0.39 inch) bolt in each of the remaining 17 holes. Tighten all bolts to the specified torque.
Tightening torque: 9.0± 3.0Nm (80± 26 in-lb)
NOTE:
After installation, keep the sealed area away from 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. Using general service tool, install the oil filter to the bracket and tighten it to the specified torque.
Tightening torque:
Part number MD356000 filter:
14± 2Nm (124± 17 in-lb)
Other Mitsubishi filter:
17± 3Nm (13± 1 ft-lb)
4. If a torque wrench cannot be used, use the following procedure:
(1) Screw in the oil filter until its o-ring contacts the oil filter bracket.
(2) Tighten the oil filter as follows:
Part number MD356000 filter: one turn
Other Mitsubishi filter: 3/4 turn