Mitsubishi Montero, Sport 1998-06

Oil Pan

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Removal & Installation



2.4L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery
     
    Engine under cover
     
    Bell housing cover
     
    Oil pan
     

  6.  

To install:

  1. Before installing, thoroughly clean the oil pan and cylinder block mating surfaces.
  2.  
  3. Apply liquid gasket around the surface of the oil pan.
    NOTE
    Assemble the oil pan to the cylinder block within 15 minutes after applying the liquid gasket.

  4.  
  5. Install or connect the following:

    Oil pan. Torque the bolts to 61 inch lbs. (6.9 Nm).
     
    Bell housing cover. Torque the bolts to 78 inch lbs. (8.8 Nm).
     
    Engine under cover
     
    Negative battery cable
     

  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery
     
    Engine under cover
     
    Bell housing cover
     
    Oil pan
     

  6.  

To install:

  1. Before installing, thoroughly clean the oil pan and cylinder block mating surfaces.
  2.  
  3. Apply liquid gasket around the surface of the oil pan.
    NOTE
    Assemble the oil pan to the cylinder block within 15 minutes after applying the liquid gasket.

  4.  
  5. Install or connect the following:

    Oil pan. Torque the bolts to 61 inch lbs. (6.9 Nm).
     
    Bell housing cover. Torque the bolts to 78 inch lbs. (8.8 Nm).
     
    Engine under cover
     
    Negative battery cable
     

  6.  

3.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery
     
    Engine under cover
     
    Alternator and belt
     
    Stabilizer bar
     
    Front exhaust pipe
     
    Actuator assembly and heat protector
     
    Oil dipstick
     
    Crossmember assembly
     
    Automatic transmission oil dipstick assembly
     
    Exhaust pipe support bracket
     
    Transmission stay
     
    Oil pan, lower
     
    Oil screen and baffle plate
     
    Oil pan upper
     

  6.  

To install:

  1. Before installing, thoroughly clean the oil pan and cylinder block mating surfaces.
  2.  
  3. Apply liquid gasket around the surface of the oil pan.
    NOTE
    Assemble the oil pan to the cylinder block within 15 minutes after applying the liquid gasket.

  4.  
  5. Install or connect the following:

    Oil pan upper. Torque the bolts to 53 inch lbs. (6.0 Nm).
     
    Oil screen and baffle plate. Torque the bolts to 14 ft. lbs. (19 Nm).
     
    Oil pan, lower. Torque the bolts to 53 inch lbs. (6.0 Nm).
     
    Transmission stay. Torque the bolts to 26 ft. lbs. (35 Nm).
     
    Exhaust pipe support bracket. Torque the bolts to 35 ft. lbs. (49 Nm).
     
    Automatic transmission oil dipstick assembly. Torque the bolts to 33 ft. lbs. (44 Nm).
     
    Crossmember assembly. Torque the bolts to 80 ft. lbs. (108 Nm).
     
    Oil dipstick. Torque the bolts to 35 ft. lbs. (48 Nm).
     
    Actuator assembly and heat protector
     
    Front exhaust pipe
     
    Stabilizer bar
     
    Alternator and belt
     
    Engine under cover
     
    Negative battery

    Click image to see an enlarged view

    Fig. Apply a bead of sealant around the oil pan flange as shown-all engines are similar

     

  6.  

12-Valve
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the under skid plate
  4.  
  5. Remove the front exhaust pipe.
  6.  
  7. Drain the engine oil.
  8.  
  9. Remove or disconnect the following:

    Starter
     
    Transmission stay (RH)
     
    Transmission stay (LH)
     
    Vacuum hose
     
    Bolt
     
    Front suspension crossmember
     
    Bolt
     

    1. After removing the mounting bolt, lower the front axle assembly as far as possible and so that there is enough space to remove the oil pan.

      Click image to see an enlarged view

      Fig. Removing oil pan bolts and lowering front axle



      Oil pan
       

    2.  
    3. Remove the oil pan bolts.
    4.  
    5. Tap the general special tool between the oil pan and the cylinder block.
    6.  
    7. Slide the special tool by tapping it at an angle to remove the oil pan.
      CAUTION
      Using a screwdriver or chisel in place of the special tool can damage the gasket seat surface and cause oil leakage.



      Click image to see an enlarged view

      Fig. Removing the oil pan 3.0L 12V (1996)



      Click image to see an enlarged view

      Fig. Removing oil pan with special tools

    8.  

  10.  

To install:

To install the oil pan, reverse the removal procedure. Take note of the following:

  1. Remove the sealant from the oil pan and cylinder block mating surfaces.
  2.  
  3. Degrease the sealant coated surface and the engine mating surface.
  4.  
  5. Apply Mitsubisih Genuine Part No. MD970389 or equivalent around the gasket surface of the oil pan.
    NOTE
    The sealant should be applied in a continuous bead approximately .16 inch (4 mm) in diameter.

  6.  
  7. Install the oil pan to the cylinder block within 15 minutes after applying the sealant.
    CAUTION
    Tighten the oil pan mounting bolt in the order illustrated. After installing the oil pan, wait at least 30 minutes before starting the engine.



    Click image to see an enlarged view

    Fig. Applying sealant to the oil pan and identifying tightening sequence

  8.  

24-Valve
Lower
  1. Remove the under skid plate.
  2.  
  3. Remove the front exhaust pipe (Federal).
  4.  
  5. Remove the warm-up three-way catalytic converter.
  6.  
  7. Drain the engine oil.
  8.  
  9. Remove the lower oil pan (1).
    1. Remove the oil pan, lower installation bolt.
    2.  
    3. Place a wooden block to the oil pan, lower as shown and remove by tapping with a hammer.
      CAUTION
      The use of an oil pan remover (MD998727) can damage the oil pan, upper (aluminum made).



      Click image to see an enlarged view

      Fig. Removing and installing lower oil pan 3.0L 24V (1996)



      Click image to see an enlarged view

      Fig. Removing the lower oil pan with a wooden block

    4.  

  10.  

To install:

To install the lower oil pan, reverse the removal procedures. Note the following for oil pan installation:

  1. Remove the sealant from the oil pan and cylinder block mating surfaces.
  2.  
  3. Degrease the sealant-coated surface and the engine mating surface.
  4.  
  5. Apply Mitsubishi Genuine Part No. MD970389 or equivalent sealant around the gasket surface of the oil pan as specified.
    NOTE
    The sealant should be applied in a continuous bead approximately 0.16 inch (4 mm) in diameter.

  6.  
  7. Assemble the oil pan to the cylinder block within 30 minutes after applying the sealant.
  8.  
  9. Tighten the oil pan mounting bolts in the order shown.

    Click image to see an enlarged view

    Fig. Applying sealant and identifying bolt installation order

  10.  

Upper
  1. Remove the lower oil pan.
  2.  
  3. Remove the front differential carrier.
  4.  
  5. Remove or disconnect the following:

    Cover
     
    Oil level gauge guide
     
    Oil pan, upper
     

    1. Install a bolt 0.39 x 1.5 inch (10 x 38 mm) to link the oil pan, upper with the transmission in the hole of the oil pan, upper as shown in the illustration, and then tighten the bolt to remove the upper oil pan.

      Click image to see an enlarged view

      Fig. Installing bolt to remove upper oil pan

    2.  

  6.  
  7. Oil screen

    Click image to see an enlarged view

    Fig. Removing and installing upper oil pan and screen

  8.  

To install:

To install, reverse the removal procedure. Note the following for oil pan installation:

  1. Remove the sealant from the oil pan and cylinder block mating surfaces.
  2.  
  3. Degrease the sealant-coated surface and the engine mating surface.
  4.  
  5. Apply Mitsubishi Genuine Part No. MD970389 or equivalent sealant around the gasket surface of the oil pan.
    NOTE
    The sealant should be applied in a continuous bead approximately 0.16 inch (4 mm) in diameter.

  6.  
  7. Install the oil pan to the cylinder block within 30 minutes after applying the sealant.
  8.  
  9. Tighten the oil pan mounting bolts in the order shown.
    CAUTION
    The bolt holes for bolts 15 and 16 are cut away on the transmission side, so be careful not to insert these bolts at an angle.



    Click image to see an enlarged view

    Fig. Applying sealant and identifying bolt pattern for upper oil pan installation

  10.  

3.5L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Skid plate and the engine undercover
     
    Front exhaust pipe, if necessary
     
    Catalytic converter
     
    Lower oil pan
     
    Front differential carrier
     
    Cover
     
    Oil dipstick
     
    Oil pan upper
     
    Oil screen
     

  6.  

To install:

  1. Before installing, thoroughly clean the oil pan and cylinder block mating surfaces.
  2.  
  3. Apply liquid gasket around the surface of the oil pan.
  4.  


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

  1. Install or connect the following:

    Oil screen. Torque the bolts to 13 ft. lbs. (19 Nm).
     
    Oil pan upper. Torque the bolts to 48 inch lbs. (6 Nm).
     
    Oil dipstick. Torque the bolts to 39 inch lbs. (4.8 Nm).
     
    Cover. Torque the bolts to 84-108 inch lbs. (10-12 Nm).
     
    Front differential carrier
     
    Lower oil pan. Torque the bolts to 84-108 inch lbs. (10-12 Nm).
     
    Catalytic converter
     
    Front exhaust pipe, if necessary. Torque the bolts to 35 ft. lbs. (49 Nm).
     
    Skid plate and the engine undercover
     
    Negative battery cable
     

  2.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Skid plate and the engine undercover
     
    Front exhaust pipe, if necessary
     
    Catalytic converter
     
    Lower oil pan
     
    Front differential carrier
     
    Cover
     
    Oil dipstick
     
    Oil pan upper
     
    Oil screen
     

  6.  

To install:

  1. Before installing, thoroughly clean the oil pan and cylinder block mating surfaces.
  2.  
  3. Apply liquid gasket around the surface of the oil pan.
    NOTE
    Assemble the oil pan to the cylinder block within 15 minutes after applying the liquid gasket.

  4.  
  5. Install or connect the following:

    Oil screen. Torque the bolts to 13 ft. lbs. (19 Nm).
     
    Oil pan upper. Torque the bolts to 48 inch lbs. (6 Nm).
     
    Oil dipstick. Torque the bolts to 39 inch lbs. (4.8 Nm).
     
    Cover. Torque the bolts to 84-108 inch lbs. (10-12 Nm).
     
    Front differential carrier
     
    Lower oil pan. Torque the bolts to 84-108 inch lbs. (10-12 Nm).
     
    Catalytic converter
     
    Front exhaust pipe, if necessary. Torque the bolts to 35 ft. lbs. (49 Nm).
     
    Skid plate and the engine undercover
     
    Negative battery cable
     

  6.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Skid plate and the engine undercover
     
    Front exhaust pipe, if necessary
     
    Catalytic converter
     
    Lower oil pan
     
    Front differential carrier
     
    Cover
     
    Oil dipstick
     
    Oil pan upper
     
    Oil screen
     

  6.  

To install:

  1. Before installing, thoroughly clean the oil pan and cylinder block mating surfaces.
  2.  
  3. Apply liquid gasket around the surface of the oil pan.
    NOTE
    Assemble the oil pan to the cylinder block within 15 minutes after applying the liquid gasket.

  4.  
  5. Install or connect the following:

    Oil screen. Torque the bolts to 13 ft. lbs. (19 Nm).
     
    Oil pan upper. Torque the bolts to 48 inch lbs. (6 Nm).
     
    Oil dipstick. Torque the bolts to 39 inch lbs. (4.8 Nm).
     
    Cover. Torque the bolts to 84-108 inch lbs. (10-12 Nm).
     
    Front differential carrier
     
    Lower oil pan. Torque the bolts to 84-108 inch lbs. (10-12 Nm).
     
    Catalytic converter
     
    Front exhaust pipe, if necessary. Torque the bolts to 35 ft. lbs. (49 Nm).
     
    Skid plate and the engine undercover
     
    Negative battery cable
     

  6.  

3.8L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Skid plate and the engine undercover
     
    Starter motor
     
    Right and left halfshaft connections
     
    Front differential No. 2 crossmember
     
    Drain plug, gasket and cover
     
    Transmission fluid dipstick assembly and O-ring
     
    Engine oil dipstick and O-ring
     
    Oil pan retainers and oil pan. Screw the M10 bolts holding the oil pan to the transmission assembly into the bolt holes shown in the illustration to remove the pan.
     


    Click image to see an enlarged view

    Fig. Screw the M10 bolts that hold the oil pan to the transmission assembly into the bolt holes shown by arrows-3.8L engine

    Oil screen
     
    Oil pan gasket
     

  6.  


    Click image to see an enlarged view

    Fig. Exploded view of the oil pan and related components-3.8L engine


To install:

  1. Before installing, thoroughly clean the oil pan and cylinder block mating surfaces.
  2.  
  3. Apply liquid gasket around the surface of the oil pan.
  4.  


NOTE
Assemble the oil pan to the cylinder block within 30 minutes after applying the liquid gasket.

  1. Install or connect the following:

    Oil screen. Torque the bolts to 12-16 ft. lbs. (16-22 Nm).
     


    Click image to see an enlarged view

    Fig. Oil pan bolt tightening sequence-3.8L engine

    Oil pan. Torque the bolts, in sequence, to specifications shown the illustration. The bolt holes for bolts 13 and 14 are cut away on the transmission side. Be sure you do not insert the bolts at an angle.
     
    Engine oil dipstick and O-ring
     
    Transmission fluid dipstick assembly and O-ring
     
    Drain plug, gasket and cover
     
    Front differential No. 2 crossmember
     
    Right and left halfshaft connections
     
    Skid plate and the engine undercover
     
    Negative battery cable
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil. Drain the transmission fluid.
  4.  
  5. Remove or disconnect the following:
    CAUTION
    Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative battery cable is disconnected.



    Negative battery cable
     



    Skid plate and the engine undercover
     
    Starter motor
     
    Right and left halfshaft connections
     
    Front differential No. 2 crossmember
     
    Drain plug, gasket and cover
     
    Transmission fluid dipstick assembly and O-ring
     
    Engine oil dipstick and O-ring
     
    Oil pan retainers and oil pan. Screw the M10 bolts holding the oil pan to the transmission assembly into the bolt holes shown in the illustration to remove the pan.

    Click image to see an enlarged view

    Fig. Screw the M10 bolts that hold the oil pan to the transmission assembly into the bolt holes shown by arrows-3.8L engine

     
    Oil screen
     
    Oil pan gasket

    Click image to see an enlarged view

    Fig. Oil pan and related components-3.8L engine

     

  6.  

To install:

  1. Before installing, thoroughly clean the oil pan and cylinder block mating surfaces.
  2.  
  3. Apply liquid gasket around the surface of the oil pan.
    NOTE
    Assemble the oil pan to the cylinder block within 30 minutes after applying the liquid gasket.

  4.  
  5. Install or connect the following:

    Oil screen. Torque the bolts to 12-16 ft. lbs. (16-22 Nm).

    Click image to see an enlarged view

    Fig. Oil pan bolt torque sequence-3.8L engine

     
    Oil pan. Torque the bolts, in sequence, to specifications shown the illustration. The bolt holes for bolts 13 and 14 are cut away on the transmission side. Be sure you do not insert the bolts at an angle.
     
    Engine oil dipstick and O-ring
     
    Transmission fluid dipstick assembly and O-ring
     
    Drain plug, gasket and cover
     
    Front differential No. 2 crossmember
     
    Right and left halfshaft connections
     
    Skid plate and the engine undercover
     
    Negative battery cable
     

  6.  

 
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