Mitsubishi Car 1999-05

Oil Pan 1

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the oil pan drain plug and drain the engine oil.
  6.  
  7. On vehicles equipped with AWD, remove the transfer case assembly.
  8.  
  9. Disconnect and lower the exhaust pipe and on turbocharged engines, disconnect the return pipe for the turbocharger from the side of the oil pan.
  10.  
  11. Remove the oil pan mounting bolts.
  12.  
  13. Using the special tool MD998727 or equivalent, separate and remove the engine oil pan.
  14.  

To install:

  1. Thoroughly clean the oil pan, cylinder block bolts and bolt holes.
  2.  
  3. Apply a thin bead of sealer around the surface of the oil pan.
  4.  
  5. Assemble the oil pan to the cylinder block within 15 minutes after applying the sealant.
  6.  
  7. Install the oil pan mounting bolts and tighten to 4-6 ft. lbs. (6-8 Nm).
  8.  
  9. Fill the engine with the proper amount of oil.
  10.  
  11. Connect the negative battery cable and check for leaks.

    Click image to see an enlarged view

    Fig. Oil pan bolt tightening sequence and application of sealant to the pan

  12.  

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove the mounting bolts from the lower oil pan.
  6.  
  7. Place a block of wood against the side of the pan and tap the block with a hammer to break the seal and remove the lower pan.
  8.  
  9. Remove or disconnect the following:
    WARNING
    Do not pry or use seal breaker tool to remove the oil pan. Damage to the aluminum surface can result.



    Starter
     
    Dipstick tube
     
    Upper oil pan
     

  10.  
  11. Screw a bolt into the threaded hole to force the oil pan from the engine block and remove the pan.
  12.  
  13. Remove the bolt used to remove the pan.

    Click image to see an enlarged view

    Fig. Install a bolt in the threaded hole to force the oil pan from the engine block-3.5L engine

  14.  

To install:

  1. Clean and degrease the sealing surfaces of the upper oil pan and engine block.
  2.  
  3. Apply a bead of silicone sealant along the mounting surface of the upper oil pan.

    Click image to see an enlarged view

    Fig. Apply sealant and tighten the bolts in the order shown-3.5L engine, upper oil pan

  4.  
  5. Install or connect the following:

    Upper oil pan. Tighten the bolts in sequence to 48 inch lbs. (6 Nm).
     
    Dipstick tube using a new O-ring
     
    Starter assembly
     

  6.  
  7. Clean and degrease the sealing surface of the lower oil pan.
  8.  
  9. Place a bead of sealant on the mounting surface of the lower oil pan. Install the lower pan. Tighten the bolts in sequence to 84-108 inch lbs. (10-12 Nm).

    Click image to see an enlarged view

    Fig. Apply sealant and tighten the bolts in the order shown-3.5L engine, lower oil pan

  10.  
  11. Install the drain plug using a new washer. Tighten the drain plug to 29 ft. lbs. (39 Nm).
  12.  
  13. Lower the vehicle and fill the crankcase to the correct level.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Start the engine and check for leaks.
  18.  

1.5L Engine


Click image to see an enlarged view

Fig. Oil pan and related components-Mirage 1.5L (4G15) engine

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine oil.
  4.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Remove the bell housing lower cover.
  2.  
  3. Remove the oil pan retainer bolts. Tap the oil pan with a rubber mallet to break seal.
  4.  


NOTE
Do not use a prytool when removing the oil pan. If available, oil pan remover tool MD998727 or equivalent may be used to break the seal.

To install:

  1. Clean all gasket surfaces of the cylinder block and the oil pan.
  2.  
  3. Apply sealant to the gasket surfaces of the oil pan.
  4.  
  5. Install the oil pan onto the cylinder block within 15 minutes after applying sealant. Install the fasteners and tighten to 60 inch lbs. (7 Nm).
  6.  
  7. Install the bell housing cover.
  8.  
  9. Install the oil drain plug with a new seal and tighten to 29 ft. lbs. (40 Nm).
  10.  
  11. Lower the vehicle and fill the crankcase to the proper level with clean engine oil.
  12.  


WARNING
Operating the engine without the proper amount and type of engine oil will result in severe engine damage.

  1. Connect the negative battery cable. Start the engine and check for leaks.
  2.  



Click image to see an enlarged view

Fig. Oil pan and related components-1.5L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Do not use a pry tool when removing the oil pan.



    Bell housing lower cover
     
    Oil pan retainer bolts
     

  6.  

To install:

  1. Clean all gasket surfaces of the cylinder block and the oil pan.
  2.  
  3. Apply sealant to the gasket surfaces of the oil pan.
  4.  
  5. Install or connect the following:

    Oil pan onto the cylinder block within 15 minutes after applying sealant. Tighten to 60 inch lbs. (7 Nm).
     
    Bell housing cover
     
    Oil drain plug with a new seal and tighten to 29 ft. lbs. (40 Nm)
     

  6.  
  7. Lower the vehicle and fill the crankcase to the proper level with clean engine oil.
  8.  
  9. Connect the negative battery cable. Start the engine and check for leaks.
  10.  

1.8L Engine


Click image to see an enlarged view

Fig. Oil pan and related components-1.8L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Raise the vehicle and support safely.
  4.  
  5. Remove the oil pan drain plug and drain the engine oil.
  6.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Disconnect and lower the exhaust pipe from the engine manifold.
  2.  
  3. Remove the bell housing lower cover.
  4.  
  5. Remove the oil pan retainer bolts and remove the oil pan.
  6.  


NOTE
Do not use a prytool when removing the oil pan. If available, oil pan remover tool MD998727 or equivalent may be used break the seal.

To install:

  1. Clean all gasket surfaces of the cylinder block and the oil pan.
  2.  
  3. Apply sealant around the gasket surfaces of the oil pan.
  4.  
  5. Install the oil pan onto the cylinder block within 15 minutes after applying sealant. Install the fasteners and tighten to 60 inch lbs. (5 Nm).
  6.  
  7. Install the bell housing cover.
  8.  
  9. Connect the exhaust pipe to the engine manifold with new gasket in place. Tighten the exhaust pipe to manifold flange nuts to 33 ft. lbs. (45 Nm). Install and tighten the support bolt to 18 ft. lbs. (25 Nm).
  10.  
  11. Install the oil drain plug and tighten to 29 ft. lbs. (40 Nm).
  12.  
  13. Fill the crankcase to the proper level.
  14.  


WARNING
Operating the engine without the proper amount and type of engine oil will result in severe engine damage.

  1. Connect the negative battery cable. Start the engine and check for leaks.
  2.  

  1. Disconnect the negative battery cable.
  2.  
  3. Raise the vehicle and support safely.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Do not use a pry tool when removing the oil pan.



    Oil pan drain plug and drain the engine oil
     
    Exhaust pipe from the engine manifold
     
    Bell housing lower cover
     
    Oil pan retainer bolts and remove the oil pan
     



    Click image to see an enlarged view

    Fig. Oil pan and related components-1.8L engine

  6.  

To install:

  1. Clean all gasket surfaces of the cylinder block and the oil pan.
  2.  
  3. Apply sealant around the gasket surfaces of the oil pan.
  4.  
  5. Install or connect the following:

    Oil pan onto the cylinder block within 15 minutes after applying sealant. Tighten to 60 inch lbs. (5 Nm).
     
    Bell housing cover
     
    Exhaust pipe to the engine manifold with new gasket in place. Tighten the exhaust pipe to manifold flange nuts to 33 ft. lbs. (45 Nm). Install and tighten the support bolt to 18 ft. lbs. (25 Nm).
     
    Oil drain plug and tighten to 29 ft. lbs. (40 Nm)
     

  6.  
  7. Fill the crankcase to the proper level.
  8.  
  9. Connect the negative battery cable. Start the engine and check for leaks.
  10.  

2.0L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Engine undercover
     
    Front exhaust pipe
     
    Lower oil pan bolts and lower pan
     
    Cover
     
    Upper oil pan bolt and upper pan
     
    Baffle plate

    Click image to see an enlarged view

    Fig. Oil pan and related components-2.0L engine

     

  6.  

To install:

  1. Clean all gasket surfaces of the cylinder block and the upper and lower oil pan.
  2.  
  3. Install or connect the following:

    Baffle plate
     

  4.  
  5. Apply a 0.16 in. (4mm) bead of sealant to the gasket surfaces of the upper oil pan.

    Upper oil pan onto the cylinder block within 15 minutes after applying sealant. Tighten the bolts as shown in the accompanying figure.

    Click image to see an enlarged view

    Fig. Upper oil pan bolt location and torque sequence-2.0L engine

     

  6.  
  7. Apply 0.16 in. (4mm) bead of sealant to the gasket surfaces of the lower oil pan.

    Lower oil pan and tighten the bolts, in the sequence shown, to 88-106 inch lbs. (10-12 Nm)

    Click image to see an enlarged view

    Fig. Lower oil pan bolt tightening sequence-2.0L engine

     
    Front exhaust pipe
     
    Engine undercover
     
    Oil drain plug with a new gasket and tighten to 29 ft. lbs. (40 Nm)

    Click image to see an enlarged view

    Fig. Make sure to the install the new drain plug gasket as shown, or leaks will occur

     

  8.  
  9. Lower the vehicle and fill the crankcase to the proper level with clean engine oil.
  10.  
  11. Connect the negative battery cable. Start the engine and check for leaks.
  12.  

Non-Turbo Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Drain the engine oil into a suitable container.
  6.  
  7. Once the oil has completely drained, install the plug and tighten to 25 ft. lbs. (34 Nm).
  8.  
  9. Remove the front exhaust pipe.
  10.  
  11. Remove the engine oil dipstick and tube assembly.
  12.  
  13. Remove the front plate.
  14.  
  15. Unfasten the oil pan mounting bolts, then remove the oil pan and gasket.

    Click image to see an enlarged view

    Fig. Exploded view of the oil pan and related components-1999 2.0L non-turbo engine

  16.  

To install:

  1. Apply sealant at the point where the engine block meets the oil pump.
  2.  
  3. Use a new gasket and install the oil pan. Tighten the mounting bolts to 8.9 ft. lbs. (12 Nm).
  4.  
  5. Install the front plate.
  6.  
  7. Install the front exhaust pipe.
  8.  
  9. Install the dipstick and tube assembly.
  10.  
  11. Safely lower the vehicle to the floor.
  12.  
  13. Refill the crankcase with oil to the proper level.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Start the engine and check for leaks.
  18.  

Turbo Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Safely raise and support the vehicle.
  4.  
  5. Remove the front exhaust pipe.
  6.  
  7. Remove the exhaust pipe and muffler assembly.
  8.  
  9. Drain the engine oil into a suitable container. Once the oil has drained completely, tighten the plug to 29 ft. lbs. (39 Nm).
  10.  
  11. Remove the dipstick and tube.
  12.  
  13. For AWD vehicles, remove the transfer case assembly as follows:
    1. With the propeller shaft still installed, remove the transfer mounting bolt.
    2.  
    3. Insert a suitable prytool in between the transfer case and transaxle, then remove the transfer case from the center shaft.
    4.  
    5. Remove the transfer case from the center shaft. Do NOT tilt the transfer assembly to the rear or oil will leak out.
    6.  
    7. After removing the transfer assembly, insert tool MB991193 or equivalent, to prevent the oil from leaking out. Use a piece of wire to suspend the transfer case from the body.

      Click image to see an enlarged view

      Fig. View of the transfer case with the tool installed to prevent oil from leaking out-1999 2.0L turbo engines

    8.  

  14.  
  15. Remove the bell housing cover.
  16.  
  17. Disconnect the oil return pipe from the oil pan.
  18.  
  19. Remove the oil pan mounting bolts. Tap the oil pan seal breaker MB998727 or equivalent between the oil pan and the engine block to break the seal and remove the oil pan.

    Click image to see an enlarged view

    Fig. Exploded view of the oil pan and sealant application-1999 2.0L Turbo engine

  20.  

To install:

  1. Clean the sealing surface on the oil pan and engine block. Apply a continuous bead of sealant MD970389 or equivalent to the oil pan.
  2.  
  3. Clean the oil pan mounting bolt holes in the oil seal case.
  4.  
  5. Install the oil pan to the engine block. Tighten the mounting bolts to 5.1 ft. lbs. (6.9 Nm).
  6.  
  7. Use a new gasket and connect the oil return pipe to the oil pan.
  8.  
  9. Install the bell housing cover.
  10.  
  11. If equipped with AWD, install the transfer case assembly.
  12.  
  13. Install the dipstick and tube assembly.
  14.  
  15. Install the front exhaust pipe.
  16.  
  17. Install the exhaust pipe and muffler.
  18.  
  19. Install a new oil filter.
  20.  
  21. Safely lower the vehicle to the floor and add five quarts of oil to the crankcase.
  22.  
  23. Connect the negative battery cable.
  24.  
  25. Start the engine and check for leaks.
  26.  

2.4L Engine


Click image to see an enlarged view

Fig. Oil pan and related components-2.4L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the oil pan drain plug and drain the engine oil.
  4.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Remove the oil dipstick and tube assembly.
  2.  
  3. Detach the Heated Oxygen (HO 2 S) sensor connector.
  4.  
  5. Remove the front exhaust pipe from the vehicle.
  6.  
  7. Remove the bell housing cover.
  8.  
  9. Remove the oil pan retainer bolts. Using special tool MD998727 or equivalent, tap in between the engine block and the oil pan.
  10.  


NOTE
Do not use a prytool when removing the oil pan. Damage to engine components may occur.

To install:

  1. Apply sealant around the gasket surfaces of the oil pan.
  2.  
  3. Install the oil pan onto the cylinder block within 15 minutes after applying sealant. Install the fasteners and tighten to 6 ft. lbs. (8 Nm).
  4.  
  5. Install the oil drain plug and tighten to 29 ft. lbs. (39 Nm).
  6.  
  7. Install the bell housing cover, and tighten the mounting bolts to 7 ft. lbs. (9 Nm).
  8.  
  9. Install the front exhaust pipe and tighten the bolts at the catalytic converter to 36 ft. lbs. (49 Nm). Tighten the nuts at the exhaust manifold to 32 ft. lbs. (44 Nm).
  10.  
  11. Reconnect the HO 2 S sensor connector.
  12.  
  13. Fill the crankcase to the proper level.
  14.  


WARNING
Operating the engine without the proper amount and type of engine oil will result in severe engine damage.

  1. Connect the negative battery cable. Start the engine and check for leaks.
  2.  

  1. Remove the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Drain the engine oil into a suitable container. When the oil has completely drained, install the plug and tighten to 29 ft. lbs. (39 Nm).
  6.  
  7. Remove the engine dipstick and tube assembly.
  8.  
  9. Remove the front exhaust pipe.
  10.  
  11. Remove the bell housing inspection cover.
  12.  
  13. Unfasten the bolts attaching the oil pan to the cylinder block, then using special tool, remove the oil pan assembly from the vehicle.

    Click image to see an enlarged view

    Fig. Oil pan sealer application points

  14.  

To install:

  1. Make sure that the oil pan and cylinder block mating surfaces are free of any old sealing material. Apply the specified sealant or the equivalent.
  2.  
  3. Install the oil pan to the cylinder block and tighten the bolts to 5 ft. lbs. (7 Nm).
  4.  
  5. Reinstall the bell housing inspection cover. Tighten the bolts to 7 ft. lbs. (9 Nm).
  6.  
  7. Install the front exhaust pipe.
  8.  
  9. Reinstall the engine dipstick and tube assembly using a new O-ring.
  10.  
  11. Carefully lower the vehicle.
  12.  
  13. Refill the engine with oil. Reconnect the negative battery cable. Start the engine and check for leaks.
  14.  

  1. Remove the negative battery cable.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Engine dipstick and tube assembly
     
    Front exhaust pipe
     
    Bell housing inspection cover
     
    Bolts attaching the oil pan to the cylinder block
     

  6.  
  7. Remove the oil pan assembly.

    Click image to see an enlarged view

    Fig. Oil pan and related components-2002-2005 Eclipse 2.4L Engine

  8.  

To install:

  1. Clean the sealing surface on the oil pan and engine block. Apply a continuous bead of sealant to the oil pan.
  2.  
  3. Install or connect the following:

    Oil pan to the cylinder block and tighten the bolts to 60 inch lbs. (7 Nm)
     
    Bell housing inspection cover. Torque the bolts to 84 inch lbs. (9 Nm).
     
    Front exhaust pipe
     
    Engine dipstick and tube assembly using a new O-ring
     

  4.  
  5. Refill the engine with oil. Connect the negative battery cable. Start the engine and check for leaks.
  6.  

  1. Remove or disconnect the following:

    Negative battery cable
     
    Oil pan drain plug and drain the engine oil
     
    Oil dipstick and tube assembly
     
    Heated Oxygen (HO 2 S) sensor connector
     
    Front exhaust pipe from the vehicle
     
    Bell housing cover
     
    Oil pan retainer bolts
     

  2.  
  3. Tap in between the engine block and the oil pan.
    NOTE
    Do not use a pry tool when removing the oil pan. Damage to engine components may occur.

  4.  

To install:

  1. Apply sealant around the gasket surfaces of the oil pan.
  2.  
  3. Install or connect the following:

    Oil pan onto the cylinder block within 15 minutes after applying sealant. Tighten to 72 inch lbs. (8 Nm).
     
    Oil drain plug and tighten to 29 ft. lbs. (39 Nm)
     
    Bell housing cover. Tighten the mounting bolts to 84 inch lbs. (9 Nm).
     
    Front exhaust pipe and tighten the bolts at the catalytic converter to 36 ft. lbs. (49 Nm). Tighten the nuts at the exhaust manifold to 32 ft. lbs. (44 Nm).
     
    HO 2 S sensor connector
     

  4.  
  5. Fill the crankcase to the proper level.
  6.  
  7. Connect the negative battery cable. Start the engine and check for leaks.
  8.  

  1. Remove the negative battery cable.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove the engine under cover. Remove the front exhaust pipe.
  6.  
  7. Remove the torque converter housing front lower cover.
  8.  
  9. Remove the oil pan retaining bolts. Remove the oil pan. Discard the gasket.
    NOTE
    Use tool MD998727 to remove the oil pan. Tap the tool into the range (B) between the cylinder block and the engine oil pan, and then slide the tool sideways. Do not position the tool in area (A) of the engine oil pan as this may cause deformation of the front case because the front case is made of aluminum.



    Click image to see an enlarged view

    Fig. Tool installation and positioning-2004-2005 Galant and 2004-2005 Lancer 2.4L Engine



    Click image to see an enlarged view

    Fig. Oil pan and related components-2004-2005 Galant and 2004-2005 Lancer 2.4L Engine

  10.  

To install:

  1. Clean the sealing surface on the oil pan and engine block. Apply a continuous bead of sealant to the oil pan.
  2.  
  3. Install the oil pan. Torque the bolts to specification.
  4.  
  5. Continue the installation in the reverse order of the removal procedure.
  6.  

  1. Remove the negative battery cable.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove the engine under cover. Remove the front exhaust pipe.
  6.  
  7. Remove the torque converter housing front lower cover.
  8.  
  9. Remove the oil pan retaining bolts. Remove the oil pan. Discard the gasket.
    NOTE
    Use tool MD998727 to remove the oil pan. Tap the tool into the range (B) between the cylinder block and the engine oil pan, and then slide the tool sideways. Do not position the tool in area (A) of the engine oil pan as this may cause deformation of the front case because the front case is made of aluminum.

  10.  

To install:

  1. Clean the sealing surface on the oil pan and engine block. Apply a continuous bead of sealant to the oil pan.
  2.  
  3. Install the oil pan. Torque the bolts to specification.
  4.  
  5. Continue the installation in the reverse order of the removal procedure.
  6.  

3.0L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the oil pan drain plug and drain the engine oil.
  4.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Remove the left side crossmember. If equipped with 4WS, it will also be necessary to remove the right side crossmember.
  2.  
  3. Remove the starter motor.
  4.  
  5. Disconnect the roll stopper stay bracket, from the rear transaxle stay bracket. Remove the both transaxle stay brackets.
  6.  
  7. Remove the bell housing lower cover.
  8.  
  9. Remove the oil pan mounting bolts. Using special tool MD998727 or equivalent, separate and remove the engine oil pan.
  10.  

To install:

  1. Apply a 0.16 in. (4mm) continuous bead of sealer around the surface of the oil pan.
  2.  


NOTE
Assemble the oil pan to the cylinder block within 15 minutes after applying the sealant.

  1. Install the oil pan mounting bolts. Following proper sequence, tighten mounting bolts to 48 inch lbs. (6 Nm).
  2.  



Click image to see an enlarged view

Fig. Oil pan bolt tightening sequence and application of sealant to the pan-Diamante 3.0L engines

  1. Install lower bell housing cover and the starter motor.
  2.  
  3. Install the transaxle stay brackets and connect the roll stopper bracket.
  4.  
  5. Install the crossmember(s) and tighten the mounting bolts to 43-51 ft. lbs. (60-70 Nm).
  6.  
  7. Fill the engine with the proper amount of oil.
  8.  


WARNING
Operating the engine without the proper amount and type of engine oil will result in severe engine damage.

  1. Connect the negative battery cable and check for leaks.
  2.  

  1. Remove or disconnect the following:

    Negative battery cable
     
    Oil pan drain plug and drain the engine oil
     
    Left side crossmember.
     
    Starter motor
     
    Roll stopper stay bracket, from the rear transaxle stay bracket
     
    Transaxle stay brackets
     
    Bell housing lower cover
     
    Oil pan mounting bolts
     
    The engine oil pan
     

  2.  

To install:

  1. Apply a 0.16 in. (4mm) continuous bead of sealer around the surface of the oil pan.
    NOTE
    Assemble the oil pan to the cylinder block within 15 minutes after applying the sealant.

  2.  
  3. Install the oil pan mounting bolts. Following proper sequence, tighten mounting bolts to 48 inch lbs. (6 Nm).

    Click image to see an enlarged view

    Fig. Oil pan bolt tightening sequence and application of sealant to the pan-2002-2003 Eclipse and Galant 3.0L engine

  4.  
  5. Install or connect the following:

    Lower bell housing cover and the starter motor
     
    Transaxle stay brackets and connect the roll stopper bracket
     
    Crossmember(s) and tighten the mounting bolts to 43-51 ft. lbs. (60-70 Nm)
     

  6.  
  7. Fill the engine with the proper amount of oil.
  8.  
  9. Connect the negative battery cable and check for leaks.
  10.  

  1. Remove the negative battery cable.
  2.  
  3. Drain the engine oil. Remove the front exhaust pipe.
  4.  
  5. To remove the lower oil pan, remove the lower oil pan retaining bolts. Remove the lower oil pan. Discard the gasket.
  6.  
  7. To remove the upper oil pan, remove the engine oil dipstick and guide assembly. Remove the starter.
  8.  
  9. Remove the upper oil pan retaining bolts. Remove the upper oil pan from the engine. Discard the gasket.
    NOTE
    After removing the upper oil pan retaining bolts, screw two M10 bolts securing the upper oil pan to the transaxle assembly, then remove the upper oil pan.



    Click image to see an enlarged view

    Fig. Transaxle to engine bolt location and installation-2004-2005 Eclipse 3.04L Engine



    Click image to see an enlarged view

    Fig. Oil pan and related components-2004-2005 Eclipse 3.04L Engine

  10.  

To install:

  1. Clean the sealing surface on the oil pan and engine block. Apply a continuous bead of sealant to the oil pan.
  2.  
  3. Install the upper oil pan. Torque the bolts to specification.
    NOTE
    The bolt holes for bolt 13 and 14 are cut away on the transaxle side. Be careful not to insert these bolts at an angle.



    Click image to see an enlarged view

    Fig. Upper oil pan torque sequence-2004-2005 Eclipse 3.0L Engine



    Click image to see an enlarged view

    Fig. Lower oil pan torque sequence-2004-2005 Eclipse 3.0L Engine

  4.  
  5. Install the lower oil pan. Torque the bolts to specification.
  6.  
  7. Continue the installation in the reverse order of the removal procedure.
  8.  

  1. Remove or disconnect the following:

    Negative battery cable
     
    Oil pan drain plug and drain the engine oil
     
    Left side crossmember.
     
    Starter motor
     
    Roll stopper stay bracket, from the rear transaxle stay bracket
     
    Transaxle stay brackets
     
    Bell housing lower cover
     
    Oil pan mounting bolts
     
    The engine oil pan
     

  2.  

To install:

  1. Apply a 0.16 in. (4mm) continuous bead of sealer around the surface of the oil pan.
    NOTE
    Assemble the oil pan to the cylinder block within 15 minutes after applying the sealant.

  2.  
  3. Install the oil pan mounting bolts. Following proper sequence, tighten mounting bolts to 48 inch lbs. (6 Nm).
  4.  
  5. Install or connect the following:

    Lower bell housing cover and the starter motor
     
    Transaxle stay brackets and connect the roll stopper bracket
     
    Crossmember(s) and tighten the mounting bolts to 43-51 ft. lbs. (60-70 Nm)
     

  6.  
  7. Fill the engine with the proper amount of oil.
  8.  
  9. Connect the negative battery cable and check for leaks.
  10.  

3.5L Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine oil.
  4.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Remove the mounting bolts from the lower oil pan.
  2.  
  3. Place a block of wood against the side of the pan and tap the block with a hammer to break the seal and remove the lower pan.
  4.  
  5. Remove the starter.
  6.  
  7. Remove the dipstick tube.
  8.  
  9. Unbolt the upper oil pan.
  10.  


WARNING
Do not pry or use seal breaker tool to remove the oil pan. Damage to the aluminum surface can result.

  1. Screw a bolt into the threaded hole to force the oil pan from the engine block and remove the pan.
  2.  
  3. Remove the bolt used to remove the pan.
  4.  



Click image to see an enlarged view

Fig. Install a bolt in the threaded hole to force the oil pan from the engine block-3.5L engine

To install:

  1. Clean and degrease the sealing surfaces of the upper oil pan and engine block.
  2.  
  3. Apply a bead of silicone sealant along the mounting surface of the upper oil pan.
  4.  



Click image to see an enlarged view

Fig. Apply sealant and tighten the bolts in the order shown-3.5L engine, upper oil pan shown

  1. Install the upper oil pan. Tighten the bolts in sequence to 4 ft. lbs. (6 Nm).
  2.  
  3. Install the dipstick tube using a new O-ring.
  4.  
  5. Install the starter assembly.
  6.  
  7. Clean and degrease the sealing surface of the lower oil pan.
  8.  
  9. Place a bead of sealant on the mounting surface of the lower oil pan. Install the lower pan. Tighten the bolts in sequence to 7-9 ft. lbs. (10-12 Nm).
  10.  



Click image to see an enlarged view

Fig. Apply sealant and tighten the bolts in the order shown-3.5L engine, lower oil pan shown

  1. Install the drain plug using a new washer. Tighten the drain plug to 29 ft. lbs. (39 Nm).
  2.  
  3. Lower the vehicle and fill the crankcase to the correct level.
  4.  


WARNING
Operating the engine without the proper amount and type of engine oil will result in severe engine damage.

  1. Connect the negative battery cable.
  2.  
  3. Start the engine and check for leaks.
  4.  

 
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