[11B] ENGINE OVERHAUL <4G6-SOHC> - - OIL PAN AND OIL PUMP - REMOVAL AND INSTALLATION | PRINT PAGE / INDEX / PRIOR / NEXT

OIL PAN AND OIL PUMP

REMOVAL AND INSTALLATION
|  |  | Removal steps
--- | --- | --- | ---
|  | 1. | Drain plug
| >>O<< | 2. | Drain plug gasket
| >>N<< | 3. | Oil filter
|  | 4. | Transmission stay <4WD>
<<A>> | >>M<< | 5. | Oil pan <2WD>
<<B>> | >>L<< | 6. | Oil pan lower section <4WD>
<<C>> | >>L<< | 7. | Oil pan upper section <4WD>
|  | 8. | Oil screen
|  | 9. | Gasket
|  | 10. | Oil pressure switch
| >>K<< | 11. | Relief plug
|  | 12. | Gasket
|  | 13. | Relief spring
|  | 14. | Relief plunger
|  | 15. | Oil filter bracket
|  | 16. | Gasket
<<D>> | >>J<< | 17. | Plug
|  | 18. | O-ring
<<E>> | >>I<< | 19. | Flange bolt
| >>H<< | 20. | Front case
|  | 21. | Gasket
|  | 22. | Oil pump cover
| >>G<< | 23. | Oil pump driven gear
| >>G<< | 24. | Oil pump drive gear
| >>F<< | 25. | Crankshaft front oil seal
| >>E<< | 26. | Counterbalancer shaft oil seal
| >>D<< | 27. | Oil pump oil seal
|  | 28. | Counterbalancer shaft, right
|  | 29. | Counterbalancer shaft, left
<<F>> | >>C<< | 30. | Counterbalancer shaft front bearing
<<G>> | >>B<< | 31. | Counterbalancer shaft rear bearing, right
<<G>> | >>A<< | 32. | Counterbalancer shaft rear bearing, left
| REMOVAL SERVICE POINTS
| <<A>> OIL PAN REMOVAL <2WD> Remove the oil pan bolts.
| Insert the special tool Oil pen remover (MD998727) into the joint between the cylinder block and oil pan by tapping the tool with a hammer. Remove the oil pan by tapping an edge of the special tool Oil pen remover (MD998727) with a hammer to move it sideways.
| <<B>> OIL PAN LOWER SECTION REMOVAL <4WD> Remove the oil pan by tapping it through a piece of wood applied to a side with a plastic hammer. CAUTION Do not use a scraper or the special tool to remove the oil pan.
| <<C>> OIL PAN UPPER SECTION REMOVAL <4WD>
| Screw bolts into the bolt holes A shown in the drawing (holes at both ends) to remove the oil pan. CAUTION Do not use a scraper or the special tool to remove the oil pan.
| <<D>> PLUG REMOVAL
| Fit the teeth of the special toosl in notches of the plug as shown in the drawing and support the tool with the special tool to loosen the plug. Plug wrench (MD998162) Plug wrench retainer (MD998783)
| <<E>> FLANGE BOLT REMOVAL
| Remove the plug on the left side of the cylinder block. Insert a cross point screwdriver (shank diameter 8 mm) into the plug hole more than 60 mm to prevent the left counterbalancer shaft from rotating.
| Loosen and remove the flange bolt.
| <<F>> COUNTERBALANCER SHAFT FRONT BEARING REMOVAL
| CAUTION Remove the front bearing first. Otherwise, the special tool cannot be used. Use the special tool Silent shaft bearing puller (MD998371) to remove the counterbalancer shaft front bearing from the cylinder block.
| <<G>> COUNTERBALANCER SHAFT REAR BEARING REMOVAL
| Use the special tool Silent shaft bearing puller (MD998372) to remove the counterbalancer shaft rear bearings from the cylinder block.
| When removing the rear bearing of the left counterbalancer shaft, install the special tool Silent shaft bearing installer stopper (MB991603) on the front of the cylinder block and use a special tool Silent shaft bearing puller (MD998372) to pull out the bearing.
| INSTALLATION SERVICE POINTS
| >>A<< LEFT COUNTERBALANCER SHAFT REAR BEARING INSTALLATION
| Install special tool Silent shaft bearing installer stopper (MB991603) to the cylinder block. Apply engine oil to the rear bearing outer surface and bearing hole in the cylinder block. Using special tool Silent shaft bearing installer (MD998705), install the rear bearing. NOTE: The left rear bearing has no oil holes.
| >>B<< RIGHT COUNTERBALANCER SHAFT REAR BEARING INSTALLATION
| Install the guide pin of the Silent shaft bearing installer (MD998705) in the threaded hole of the cylinder block as shown.
| Align the ratchet ball of the special tool with the oil hole in the rear bearing to install the bearing of the special tool. Apply engine oil to the bearing outer surface and bearing hole in the cylinder block.
| Using special tool Silent shaft bearing installer (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
| Remove the rear bearing installing portion from the special tool Silent shaft bearing installer (MD998705).
| Install the guide pin of the Silent shaft bearing installer (MD998705) in the threaded hole of the cylinder block as shown.
| Align the ratchet ball of the special tool with the oil hole in the rear bearing to install the bearing of the special tool. Apply engine oil to the front bearing outer surface and bearing hole in the cylinder.
| Using special tool Silent shaft bearing installer (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<< OIL PUMP OIL SEAL INSTALLATION
| Use an appropriate socket wrench to install the oil pump oil seal.
| >>E<< COUNTERBALANCER SHAFT OIL SEAL INSTALLATION
| Use an appropriate socket wrench to install the counterbalancer shaft oil seal.
| >>F<< CRANKSHAFT OIL SEAL INSTALLATION
| Use the special tool Crankshaft front oil seal installer (MD998375) to install the crankshaft oil seal.
| >>G<< OIL PUMP DRIVEN GEAR/OIL PUMP DRIVE GEAR INSTALLATION
| Apply engine oil generously to the gears and line up the alignment marks.
| >>H<< FRONT CASE INSTALLATION
| Install the special tool Crankshaft front oil seal guide (MD998258) on the front end of crankshaft and apply a thin coat of engine oil to the outer surface of the special tool. Be sure to use the special tool when the front case is fitted with an oil seal. Install the front case on the cylinder block with a new front case gasket in between and temporarily tighten all the flange bolts except those that are used for tightening the filter bracket.
| Install the oil filter bracket on the front case with the oil filter bracket gasket in between and temporarily tighten the washer-assembled bolts. Tighten all the bolts to the specified torques.
| >>I<< FLANGE BOLT INSTALLATION
| Insert a correspond screwdriver (shank diameter 8 mm) into the hole in the left side of the cylinder block to prevent the counterbalancer shaft from rotating.
| Tighten the flange bolts.
| >>J<< PLUG INSTALLATION Install a new O-ring on the front case.
| Use the special tools to tighten the plug to the specified torque. Plug wrench (MD998162) Plug wrench retainer (MD998783)
| >>K<< OIL PRESSURE SWITCH INSTALLATION
| CAUTION Be careful not to block the oil passage with sealant. Apply sealant to the threaded portion. Specified Sealant: 3M ATD Part No.8660 or equivalent
| Tighten the oil pressure switch together with the oil filter bracket by the specified torque using of the special tool MD998054. Tightening torque: 19 ± 3 N·m (14 ± 2 ft-lb)
| >>L<< OIL PAN UPPER SECTION/OIL PAN LOWER SECTION INSTALLATION <4WD> CAUTION Do not apply FIPG over remaining old FIPG. Doing so could result in oil leakage. Clean the gasket surfaces of the cylinder block and oil pan.
| CAUTION Too much FIPG will squeeze out, blocking coolant or oil passages, while too thin a bead could result in leakage. Apply a 4 mm diameter bead of FIPG to the flange surface all around the oil pan. Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent NOTE: In the grooved areas on the oil pan flange, apply FIPG bead along the center of the groove.
| Install the shorter bolts in the locations indicated in the drawing. CAUTION Do not apply FIPG over remaining old FIPG. Doing so could result in oil leakage. Thoroughly remove old FIPG from the gasket surfaces of the oil pan upper and lower sections.
| CAUTION Too much FIPG will squeeze out, blocking coolant or oil passages, while too thin a bead could result in leakage. Apply a 4 mm diameter bead of FIPG to the flange surface all around the oil pan. Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent NOTE: In the grooved areas on the oil pan flange, apply FIPG bead along the center of the groove.
| Install the oil pan lower section by tightening the bolts in the indicated sequence.
| >>M<< OIL PAN INSTALLATION <2WD> CAUTION Do not apply FIPG over remaining old FIPG. Doing so could result in oil leakage. Thoroughly remove old FIPG from the gasket surfaces of the cylinder block and oil pan.
| CAUTION Too much FIPG will squeeze out, blocking coolant or oil passages, while too thin a bead could result in leakage. Apply a 4 mm diameter bead of FIPG to the flange surface all around the oil pan. Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent NOTE: In the grooved areas on the oil pan flange, apply FIPG bead along the center of the groove.
| Install the shorter bolts in the locations indicated in the drawing.
| >>N<< OIL FILTER INSTALLATION
| Clean the installation surface of the filter bracket. Apply engine oil to the o-ring of the oil filter. Install the oil filter to the bracket and tighten it to the specified torque. Tightening torque: 14 ± 2 N·m (124 ± 17 in-lb) If no torque wrench can be used for tightening, use the following procedure: Screw in the oil filter until its o-ring contacts the oil filter bracket. Tighten the oil filter 3/4 turn.
| >>O<< DRAIN PLUG GASKET INSTALLATION
| CAUTION Installing the gasket with the wrong side facing the oil pan will result in oil leakage. Replace the drain plug gasket with a new one. Install it with the side indicated in the drawing toward the oil pan.

[11B] ENGINE OVERHAUL <4G6-SOHC> - - OIL PAN AND OIL PUMP - REMOVAL AND INSTALLATION | PRINT PAGE / INDEX / PRIOR / NEXT

©2004 Mitsubishi Motors Corporation