Mitsubishi Car 1999-05

Oil Pump

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Inspection




NOTE
The oil pump is responsible for providing constant lubrication to the whole engine and so it is recommended that a new oil pump be installed when rebuilding the engine.

Completely disassemble the oil pump and thoroughly clean all of the components. Inspect the oil pump gears and housing for wear and/or damage. Insure that the pressure relief valve operates properly and there is no binding or sticking due to varnish or debris. If all of the parts are in proper working condition, lubricate the gears and relief valve, and assemble the pump.

Removal & Installation



1.5L And 1.8L Engines


Click image to see an enlarged view

Fig. Exploded view of the oil pump mounting-1.5L engine



Click image to see an enlarged view

Fig. Exploded view of the oil pump mounting-1.8L engine


NOTE
Whenever the oil pump is disassembled or the cover removed, the gear cavity must be filled with petroleum jelly to seal the pump and act as a prime. Do not use grease.

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. 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. Support the engine using a suitable device
  2.  
  3. Remove the front engine mount bracket and accessory drive belts.
  4.  
  5. Remove timing belt upper and lower covers.
  6.  
  7. Remove the timing belt and crankshaft sprocket. Refer to the timing belt procedure in this section.
  8.  
  9. Remove the oil pan and remove the oil screen.
  10.  
  11. Remove the front cover mounting bolts. Note the lengths of the mounting bolts as they are removed for proper installation.
  12.  
  13. Remove the front case assembly and oil pump assembly.
  14.  
  15. Remove the oil pump cover.
  16.  
  17. Remove the inner and outer gears from the front case.
  18.  

To install

  1. Remove all gasket material from the mating surfaces and clean all parts.
  2.  
  3. Thoroughly coat both oil pump gears with clean engine oil and install them in the correct direction of rotation.
  4.  
  5. Install the pump cover and tighten the bolts to 84 inch lbs. (10 Nm).
  6.  
  7. Coat the relief valve and spring with clean engine oil. Install them and tighten the plug to 33 ft. lbs. (45 Nm).
  8.  
  9. Install a new front crankshaft seal and coat the lips of the seal with clean engine oil.
  10.  
  11. Install the front case and oil pump assembly to the engine block using a new gasket. Tighten the bolts to 10 ft. lbs. (14 Nm).
  12.  
  13. Install the oil screen with new gasket. Torque the screen bolts to 14 ft. lbs. (19 Nm).
  14.  
  15. Install the oil pan.
  16.  
  17. Install the crankshaft sprocket and timing belt. Refer to the timing belt procedure in this section.
  18.  
  19. Fill the crankcase to the proper level.
  20.  


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.  



Click image to see an enlarged view

Fig. Exploded view of the oil pump mounting-1.5L engine



Click image to see an enlarged view

Fig. Exploded view of the oil pump mounting-1.8L engine


NOTE
Whenever the oil pump is disassembled or the cover removed, the gear cavity must be filled with petroleum jelly to seal the pump and act as a prime. Do not use grease.

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Drain the engine oil.
    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.

  6.  
  7. Support the engine using a suitable device
  8.  
  9. Remove the front engine mount bracket and accessory drive belts.
  10.  
  11. Remove timing belt upper and lower covers.
  12.  
  13. Remove the timing belt and crankshaft sprocket. Refer to the timing belt procedure in this section.
  14.  
  15. Remove the oil pan and remove the oil screen.
  16.  
  17. Remove the front cover mounting bolts. Note the lengths of the mounting bolts as they are removed for proper installation.
  18.  
  19. Remove the front case assembly and oil pump assembly.
  20.  
  21. Remove the oil pump cover.
  22.  
  23. Remove the inner and outer gears from the front case.
  24.  

To install

  1. Remove all gasket material from the mating surfaces and clean all parts.
  2.  
  3. Thoroughly coat both oil pump gears with clean engine oil and install them in the correct direction of rotation.
  4.  
  5. Install the pump cover and tighten the bolts to 84 inch lbs. (10 Nm).
  6.  
  7. Coat the relief valve and spring with clean engine oil. Install them and tighten the plug to 33 ft. lbs. (45 Nm).
  8.  
  9. Install a new front crankshaft seal and coat the lips of the seal with clean engine oil.
  10.  
  11. Install the front case and oil pump assembly to the engine block using a new gasket. Tighten the bolts to 10 ft. lbs. (14 Nm).
  12.  
  13. Install the oil screen with new gasket. Torque the screen bolts to 14 ft. lbs. (19 Nm).
  14.  
  15. Install the oil pan.
  16.  
  17. Install the crankshaft sprocket and timing belt. Refer to the timing belt procedure in this section.
  18.  
  19. Fill the crankcase to the proper level.
    WARNING
    Operating the engine without the proper amount and type of engine oil will result in severe engine damage.

  20.  
  21. Connect the negative battery cable.
  22.  

1.6L, 2.0L And 2.4L Engines

NOTE
Whenever the oil pump is disassembled or the cover removed, the gear cavity must be filled with petroleum jelly to seal the pump and act as a prime. Do not use grease.



Click image to see an enlarged view

Fig. Holding the silent shaft for oil pump gear removal-2.0L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Rotate the engine so No. 1 cylinder is on Top Dead Center (TDC) of its compression stroke.
  4.  
  5. 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. Using the proper equipment, support the weight of the engine. Remove the front engine mount bracket and accessory drive belts.
  2.  
  3. Remove timing belt upper and lower covers.
  4.  
  5. Remove the timing belt and crankshaft sprocket. Refer to the timing belt procedure in this section.
  6.  
  7. Detach the electrical connector from the oil pressure sending unit and remove the oil pressure sensor. Remove the oil filter and the oil filter bracket.
  8.  
  9. Remove the oil pan, oil screen and gasket.
  10.  



Click image to see an enlarged view

Fig. Use the special socket and holder to remove the balance shaft plug-2.0 engine

  1. Using special tool MD998162, remove the plug cap in the engine front cover.
  2.  
  3. Remove the plug on the side of the engine block. Insert a Phillips screwdriver with a shank diameter of 0.32 in. (8mm) into the plug hole. This will hold the silent shaft.
  4.  
  5. Remove the driven gear bolt that secures the oil pump driven gear to the silent shaft.
  6.  
  7. Remove the front cover mounting bolts. Note the lengths of the mounting bolts as they are removed for proper installation.
  8.  
  9. Remove the front case cover and oil pump assembly. If necessary, the silent shaft can come out with the cover assembly.
  10.  
  11. Remove the oil pump cover, located on the back of the engine front cover. Remove the oil pump drive and driven gears.
  12.  
  13. After disassembling the oil pump, clean all components and remove gasket material from mating surfaces.
  14.  
  15. Assemble the oil pump gears into the front case and rotate it to ensure smooth rotation and no looseness. Be sure there is no ridge wear on the contact surface between the front case and the gear surface of the oil pump front cover.
  16.  

To install

  1. Align the timing mark on the oil pump drive gear with that on the driven gear and install them into the engine front case. Apply engine oil to the gears.
  2.  



Click image to see an enlarged view

Fig. Aligning oil pump timing marks-2.0L engine

  1. Install the oil pump cover and tighten the retainer bolts to 13 ft. lbs. (18 Nm).
  2.  
  3. Using the appropriate driver, install a new crankshaft seal into the front case.
  4.  
  5. Position new front case gasket in place. Set seal guide tool MD998285 on the front end of the crankshaft to protect the seal from damage. Apply a thin coat of oil to the outer circumference of the seal pilot tool.
  6.  
  7. Install the front case assembly through a new front case gasket and temporarily tighten the flange bolts.
  8.  
  9. Mount the oil filter on the bracket with new oil filter bracket gasket in place. Install the bolts with washers and tighten to 14 ft. lbs. (19 Nm).
  10.  
  11. Insert a Phillips screwdriver into the hole in the left side of the engine block to lock the silent shaft in place.
  12.  
  13. Install the oil pump drive gear onto the left silent shaft. Tighten the driven gear bolt to 27 ft. lbs. (37 Nm).
  14.  
  15. Install a new O-ring to the groove in the front case and install the plug cap. Using the special tool MD998162, tighten the cap to 17 ft. lbs. (24 Nm).
  16.  
  17. Install the oil screen in position with new gasket in place.
  18.  
  19. Clean both mating surfaces of the oil pan and the cylinder block. Apply sealant in the groove in the oil pan flange.
  20.  


NOTE
After applying sealant to the oil pan, do not exceed 15 minutes before installing the oil pan.

  1. Install the oil pan to the engine and secure with the retainers. Tighten bolts to 5 ft. lbs. (7 Nm).
  2.  
  3. Install the oil pressure gauge unit and the oil pressure switch. Connect the electrical harness connector.
  4.  
  5. Install the oil cooler. Secure with oil cooler bolt tightened to 31 ft. lbs. (43 Nm).
  6.  
  7. Refill the crankcase.
  8.  
  9. Install new oil filter.
  10.  


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 start the engine.
  2.  
  3. Verify correct oil pressure.
  4.  
  5. Inspect for leaks.
  6.  



Click image to see an enlarged view

Fig. Front case bolt identification-2.0L and 2.4L engines

2.0L DOHC And 2.4L Engines

NOTE
Whenever the oil pump is disassembled or the cover removed, the gear cavity must be filled with petroleum jelly to seal the pump and act as a prime. Do not use grease.

  1. Disconnect the negative battery cable. Rotate the engine so No. 1 cylinder is on Top Dead Center (TDC) of its compression stroke.
  2.  
  3. Drain the engine oil.
  4.  
  5. Using the proper equipment, support the weight of the engine. Remove the front engine mount bracket and accessory drive belts.
  6.  
  7. Remove or disconnect the following:

    Timing belt upper and lower covers
     
    Timing belt and crankshaft sprocket
     
    Electrical connector from the oil pressure sending unit
     
    Oil pressure sensor
     
    Oil filter and the oil filter bracket
     
    Oil pan, oil screen and gasket
     

  8.  
  9. Using special tool MD998162, remove the plug cap in the engine front cover.
  10.  
  11. Remove or disconnect the following:

    Plug on the side of the engine block. Insert a steel rod with a shank diameter of 0.32 in. (8mm) into the plug hole. This will hold the silent shaft.
     
    Driven gear bolt that secures the oil pump driven gear to the silent shaft
     
    Front cover mounting bolts. Note the lengths of the mounting bolts as they are removed for proper installation.
     
    Front case cover and oil pump assembly. If necessary, the silent shaft can come out with the cover assembly.
     
    Oil pump cover, located on the back of the engine front cover. Remove the oil pump drive and driven gears.
     

  12.  
  13. After disassembling the oil pump, clean all components and remove gasket material from mating surfaces.
  14.  
  15. Assemble the oil pump gears into the front case and rotate it to ensure smooth rotation and no looseness. Be sure there is no ridge wear on the contact surface between the front case and the gear surface of the oil pump front cover.

    Click image to see an enlarged view

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



    Click image to see an enlarged view

    Fig. Oil pump and related components-Evolution

  16.  

To install

  1. Align the timing mark on the oil pump drive gear with that on the driven gear and install them into the engine front case. Apply engine oil to the gears.
  2.  
  3. Install the oil pump cover and tighten the retainer bolts to 13 ft. lbs. (18 Nm) on Eclipse models and 17 ft. lbs. (24 Nm) on Galant models.
  4.  
  5. Using the appropriate driver, install a new crankshaft seal into the front case.
  6.  
  7. Position new front case gasket in place. Set seal guide tool MD998285 on the front end of the crankshaft to protect the seal from damage. Apply a thin coat of oil to the outer circumference of the seal pilot tool.
  8.  
  9. Install the front case assembly through a new front case gasket and temporarily tighten the flange bolts.
  10.  
  11. Mount the oil filter on the bracket with new oil filter bracket gasket in place. Install the bolts with washers and tighten to 14 ft. lbs. (19 Nm).
  12.  
  13. Insert a Phillips screwdriver into the hole in the left side of the engine block to lock the silent shaft in place.
  14.  
  15. Install or connect the following:

    Oil pump drive gear onto the left silent shaft. Tighten the driven gear bolt to 27 ft. lbs. (37 Nm).
     
    New O-ring to the groove in the front case and install the plug cap. Tighten the cap to 17 ft. lbs. (24 Nm).
     
    Oil screen in position with new gasket in place
     

  16.  
  17. Clean both mating surfaces of the oil pan and the cylinder block. Apply sealant in the groove in the oil pan flange.
    NOTE
    After applying sealant to the oil pan, do not exceed 15 minutes before installing the oil pan.

  18.  
  19. Install or connect the following:

    Oil pan to the engine and secure with the retainers. Tighten bolts to 60 inch lbs. (7 Nm).
     
    Oil pressure gauge unit and the oil pressure switch
     
    Electrical harness connector
     
    Oil cooler. Oil cooler bolt to 31 ft. lbs. (43 Nm).
     

  20.  
  21. Refill the crankcase. Install new oil filter.
  22.  
  23. Connect the negative battery cable and start the engine. Verify correct oil pressure. Inspect for leaks.
  24.  

2.0L Engine
  1. Drain the engine oil.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Matchmark the installed position of the pump rotors before removing them.



    Negative battery cable
     
    Oil pressure switch
     
    Oil filter
     
    Drain plug and gasket. Discard the gasket.
     
    Cover
     
    Upper oil pan. Remove the 5 in. (127mm) bolt, which is closest to the flywheel/flexplate first, then, the other bolts.
     
    Baffle plate
     
    Lower oil pan. Remove the 5 in. (127mm) bolt, which is closest to the flywheel/flexplate first, then, the other bolts.
     
    Oil screen and gasket
     
    Relief plug and spring
     
    Oil seal
     
    Front case
     
    O-ring
     
    Oil pump case cover
     



    Outer and inner oil pump rotors

    Click image to see an enlarged view

    Fig. Oil pump and related components-2002-2005 Lancer 2.0L Engine

     

  4.  

To install:

  1. Install or connect the following:
    NOTE
    After installation or the front case, wait at least one hour before filling the crankcase with oil or starting the engine.



    Inner and outer rotors, making sure the alignment marks are matched up
     
    Oil pump case cover
     
    O-ring
     



    Front case. Apply a 0.12 inch (3mm) bead of sealant, then tighten the case bolts to 124 inch lbs. (14 Nm).
     
    Oil seal
     
    Relief plunger, spring and plug
     
    Oil screen gasket and screen
     
    Lower oil pan. Refer to the oil pan procedure for sealant application and torque specifications.
     
    Baffle plate
     
    Upper oil pan. Refer to the oil pan procedure for sealant application and torque specifications.
     
    Cover
     
    Drain plug with a new gasket. Tighten the plug to 29 ft. lbs. (35 Nm).
     
    Oil filter
     
    Oil pressure switch
     

  2.  
  3. Fill the engine with the correct amount of oil.
  4.  
  5. Connect the negative battery cable.
  6.  
  7. Start the engine and check for leaks.
  8.  

3.0L Engine

NOTE
Whenever the oil pump is disassembled or the cover removed, the gear cavity must be filled with petroleum jelly to seal the pump and act as a prime. Do not use grease.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove the front engine mount bracket and accessory drive belts.
  8.  
  9. Remove timing belt upper and lower covers.
  10.  
  11. Remove the timing belt and crankshaft sprocket.
  12.  
  13. Remove the oil pan.
  14.  
  15. Remove the oil screen and gasket.
  16.  
  17. Remove the front cover mounting bolts. Note the lengths of the mounting bolts as they are removed for proper installation.
  18.  
  19. Remove the front case cover and oil pump assembly.
  20.  

To install:

  1. Thoroughly clean all gasket material from all mounting surfaces.
  2.  
  3. Apply engine oil to the entire surface of the gears or rotors.
  4.  
  5. Assemble the front case cover and oil pump assembly to the engine block.
  6.  
  7. Install the oil screen with new gasket.
  8.  
  9. Install the oil pan
  10.  
  11. Install the crankshaft sprocket and timing belt. Refer to the timing belt unit repair section.
  12.  
  13. Install the timing belt covers.
  14.  
  15. Install the drive belts and the front engine mount bracket.
  16.  
  17. Connect the negative battery cable, refill the crankcase and check for adequate oil pressure.
  18.  


NOTE
Whenever the oil pump is disassembled or the cover removed, the gear cavity must be filled with petroleum jelly to seal the pump and act as a prime. Do not use grease.

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

    Front engine mount bracket and accessory drive belts
     
    Timing belt upper and lower covers
     
    Timing belt and crankshaft sprocket
     
    Oil pan
     
    Oil screen and gasket
     
    Front cover mounting bolts. Note the lengths of the mounting bolts as they are removed for proper installation.
     
    Front case cover and oil pump assembly
     

  6.  

To install:

  1. Thoroughly clean all gasket material from all mounting surfaces.
  2.  
  3. Apply engine oil to the entire surface of the gears or rotors.
  4.  
  5. Assemble the front case cover and oil pump assembly to the engine block.
  6.  
  7. Install or connect the following:

    Oil screen with new gasket
     
    Oil pan
     
    Crankshaft sprocket and timing belt
     
    Timing belt covers
     
    Drive belts and the front engine mount bracket
     
    Negative battery cable, refill the crankcase and check for adequate oil pressure

    Click image to see an enlarged view

    Fig. Oil pump and related components-3.0L, 3.5L and 3.8L engines

     

  8.  

3.5L And 3.8L Engines
  1. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt
     

  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Splash shield from the wheel well, as needed
     
    Oil filter adapter
     
    Lower and upper oil pans
     
    Lower baffle, oil pump pick-up and upper baffle
     
    Oil pump case mounting bolts and the oil pump case
     
    Oil pump gear cover
     

  6.  
  7. Make matchmarks on the oil pump rotors before removing them.

    Crankshaft seal from the oil pump case
     

  8.  

To install:

  1. Install or connect the following:

    New crankshaft seal in the oil pump cover
     

  2.  
  3. Apply engine oil to the rotors, then align the matchmarks and install the rotors in the oil pump case.

    Rotor cover and tighten the bolts to 84 inch lbs. (10 Nm)

    Click image to see an enlarged view

    Fig. Rear oil pump case sealant application-3.5L engine

     

  4.  
  5. Apply a 0.113 in. (3mm) bead of sealant to the back of the oil pump case. Install the case on the engine and tighten the bolts to 10 ft. lbs. (13 Nm).

    Upper baffle plate and oil pump pick-up using a new gasket-Tighten the baffle bolts to 84 inch lbs. (10 Nm) and the pick-up bolts to 13 ft. lbs. (18 Nm).
     
    Lower baffle in the upper oil pan. Tighten the bolts to 96 inch lbs. (11 Nm).
     
    Oil pans
     
    Oil filter adapter using a new gasket. Tighten the larger bolt to 30 ft. lbs. (41 Nm) and the smaller bolt to 17 ft. lbs. (23 Nm).
     
    Timing belt and remaining components
     

  6.  
  7. Fill the engine with the correct amount of oil.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Start the engine and check for leaks.
  12.  

 
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