Mitsubishi Outlander 2003-06

Oil Pan

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Removal & Installation



AWD Vehicles
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the negative battery cable.
  4.  
  5. Remove the engine undercover.
  6.  
  7. Drain the engine oil. Install the oil pan drain plug with a new gasket and tighten to 29 ft. lbs. (39 Nm).
  8.  
  9. Remove or disconnect the following:

    Front exhaust pipe
     
    Center member
     
    Transaxle housing front lower cover stay
     
    Torque converter housing front lower (inspection) cover
     

  10.  


NOTE
There are 2 sizes of oil pan bolts used. Note the locations of the bolts as you remove them.



Lower oil pan mounting bolts. Place a piece of wood at the rear of the lower pan and strike it with a hammer to remove the lower pan.
 
Upper oil pan mounting bolts. Screw bolts into the bolt holes (A) shown in the illustration, then lift and remove the upper oil pan.
 



Click image to see an enlarged view

Fig. To remove the upper oil pan, screw bolts into the bolt holes A, then lift and remove the upper oil pan.



Click image to see an enlarged view

Fig. Exploded view of the upper and lower oil pans used on AWD Outlanders

To install:

  1. Clean the sealing surface on the oil pan and engine block. Apply a continuous 4mm bead of sealant to the oil pan. The oil pan MUST be installed within 15 minutes of applying the sealant.
  2.  
  3. Install or connect the following:

    Upper oil pan to the block and tighten the bolts to 80 inch lbs. (9 Nm)
     
    Lower oil pan to the block and tighten the bolts to 80 inch lbs. (9 Nm)
     


    Click image to see an enlarged view

    Fig. Upper oil pan bolt locations-AWD vehicles



    Click image to see an enlarged view

    Fig. Lower oil pan bolt locations-AWD vehicles

    Torque converter lower (inspection) cover. Torque the bolts to 80 inch lbs. (9 Nm).
     
    Transaxle housing front lower cover stay. Tighten the bolts as shown in the accompanying illustration.
     
    Center member
     
    Front exhaust pipe
     
    Engine undercover
     

  4.  


WARNING
Wait at least 1 hour after tightening the oil pan bolts to refill the crankcase and start the engine.

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

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the negative battery cable.
  4.  
  5. Remove the engine undercover.
  6.  
  7. Drain the engine oil. Install the oil pan drain plug with a new gasket and tighten to 29 ft. lbs. (39 Nm).
  8.  
  9. Remove or disconnect the following:
    NOTE
    There are 2 sizes of oil pan bolts used. Note the locations of the bolts as you remove them.



    Front exhaust pipe
     
    Center member
     
    Transaxle housing front lower cover stay
     
    Torque converter housing front lower (inspection) cover
     



    Lower oil pan mounting bolts. Place a piece of wood at the rear of the lower pan and strike it with a hammer to remove the lower pan.
     
    Upper oil pan mounting bolts. Screw bolts into the bolt holes (A) shown in the illustration, then lift and remove the upper oil pan.

    Click image to see an enlarged view

    Fig. To remove the upper oil pan, screw bolts into the bolt holes A, then lift and remove the upper oil pan-AWD vehicles



    Click image to see an enlarged view

    Fig. Upper and lower oil pans and related components-AWD vehicles

     

  10.  

To install:

  1. Clean the sealing surface on the oil pan and engine block. Apply a continuous 4mm bead of sealant to the oil pan. The oil pan MUST be installed within 15 minutes of applying the sealant.
  2.  
  3. Install or connect the following:
    WARNING
    Wait at least 1 hour after tightening the oil pan bolts to refill the crankcase and start the engine.



    Upper oil pan to the block and tighten the bolts to 80 inch lbs. (9 Nm)
     
    Lower oil pan to the block and tighten the bolts to 80 inch lbs. (9 Nm)

    Click image to see an enlarged view

    Fig. Upper oil pan bolt hole locations-AWD vehicles



    Click image to see an enlarged view

    Fig. Lower oil pan bolt hole locations-AWD vehicles

     
    Torque converter lower (inspection) cover. Torque the bolts to 80 inch lbs. (9 Nm).
     
    Transaxle housing front lower cover stay. Tighten the bolts as shown in the accompanying illustration.
     
    Center member
     
    Front exhaust pipe
     
    Engine undercover
     

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

FWD Vehicles
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the negative battery cable.
  4.  
  5. Remove the engine undercover.
  6.  
  7. Drain the engine oil. Install the oil pan drain plug with a new gasket and tighten to 29 ft. lbs. (39 Nm).
  8.  
  9. Remove or disconnect the following:

    Front exhaust pipe
     
    Torque converter/bell housing inspection cover
     
    Bolts attaching the oil pan to the cylinder block
     

  10.  
  11. Remove the oil pan assembly by using a hammer to tap Mitsubishi Special tool no. MD998727 into the range shown in the illustration of the oil pan and engine block. Slide the tool sideways to separate the oil pan from the block.
  12.  


    Click image to see an enlarged view

    Fig. Use the special tool between the oil pan and block in area B only. Do NOT insert the pan separator tool into area A


To install:

  1. Clean the sealing surface on the oil pan and engine block. Apply a continuous 4mm bead of sealant to the oil pan. The oil pan MUST be installed within 15 minutes of applying the sealant.
  2.  
  3. Install or connect the following:

    Oil pan to the cylinder block and tighten the bolts to 80 inch lbs. (9 Nm)
     
    Torque converter/bell housing inspection cover. Torque the bottom bolts to 19 ft. lbs. (26 Nm) and the flange bolts to 80 inch lbs. (9 Nm). Refer to accompanying illustration.
     


    Click image to see an enlarged view

    Fig. Exploded view of the oil pan and related components

    Front exhaust pipe
     
    Engine undercover
     

  4.  


WARNING
Wait at least 1 hour after tightening the oil pan bolts to refill the crankcase and start the engine.

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

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the negative battery cable.
  4.  
  5. Remove the engine undercover.
  6.  
  7. Drain the engine oil. Install the oil pan drain plug with a new gasket and tighten to 29 ft. lbs. (39 Nm).
  8.  
  9. Remove or disconnect the following:

    Front exhaust pipe
     
    Torque converter/bell housing inspection cover
     
    Bolts attaching the oil pan to the cylinder block
     

  10.  
  11. Remove the oil pan assembly by using a hammer to tap Mitsubishi Special tool no. MD998727 into the range shown in the illustration of the oil pan and engine block. Slide the tool sideways to separate the oil pan from the block.

    Click image to see an enlarged view

    Fig. Oil pan and related components-FWD vehicles



    Click image to see an enlarged view

    Fig. Use the special tool between the oil pan and block in area B only. Do NOT insert the pan separator tool into area A-FWD vehicles

  12.  

To install:

  1. Clean the sealing surface on the oil pan and engine block. Apply a continuous 4mm bead of sealant to the oil pan. The oil pan MUST be installed within 15 minutes of applying the sealant.
  2.  
  3. Install or connect the following:
    WARNING
    Wait at least 1 hour after tightening the oil pan bolts to refill the crankcase and start the engine.



    Oil pan to the cylinder block and tighten the bolts to 80 inch lbs. (9 Nm)
     
    Torque converter/bell housing inspection cover. Torque the bottom bolts to 19 ft. lbs. (26 Nm) and the flange bolts to 80 inch lbs. (9 Nm). Refer to accompanying illustration.
     
    Front exhaust pipe
     
    Engine undercover
     

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

 
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