Mitsubishi Outlander 2003-06

Oil Pump

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Removal & Installation



  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:

    Oil pan, FWD vehicles
     
    Lower and upper oil pan, AWD vehicles
     
    Oil screen and gasket
     
    Relief spring
     
    Relief plunger
     
    Oil filter bracket and gasket
     
    Plug. Fit Mitsubishi Special tool no. MD998162 on the plug, then hold it in position with special tool MD998783, loosen the plug, then remove the tools.
     


    Click image to see an enlarged view

    Fig. To remove or install the plug, fit special tool MD998162 on the plug and hold it in place with tool MD998783

    O-ring
     
    Flange bolt by removing the plug on the side of the cylinder block. Insert a Phillips screwdriver into the hold to lock the counterbalance shaft, then loosen the flange bolt.
     
    Front case and gasket
     
    Oil pump cover
     
    Oil pump driven gear
     
    Oil pump drive gear
     
    Crankshaft front oil seal
     
    Oil pump oil seal
     
    Left and right counterbalance shafts
     
    Front counterbalance shaft bearing, using Mitsubishi Special tool no. MD998371
     
    Rear left and right counterbalance shaft bearings using Mitsubishi Special tool nos. MD991603 and MD998372
     

  10.  

To install:

  1. Install the left counterbalance shaft rear bearing as follows:
    1. Install Mitsubishi Special tool no. MD991603 to the cylinder block.
    2.  
    3. Apply engine oil to the rear bearing outer surface and bearing hole in the cylinder block.
    4.  
    5. Use Mitsubishi Special tool MD998705 to install the rear bearing. The left rear bearing has no oil holes.
    6.  

  2.  
  3. Install the right counterbalance shaft rear bearing as follows:
    1. Install the guide pin of special tool MD998705 in the threaded hole of the cylinder block.
    2.  
    3. Align the ratchet ball of special tool MD998705 with the oil hold in the rear bearing to install the bearing of the special tool MD998705.
    4.  
    5. Apply engine oil to the bearing outer surface and bearing hole in the cylinder block.
    6.  
    7. Use special tool MD998705 to install the rear bearing. Make sure the oil hole of the bearing is aligned with the oil hole of the cylinder block.
    8.  

  4.  
  5. Install the counterbalance shaft front bearing as follows:
    1. Remove the rear bearing installing part from special tool MD998705.
    2.  
    3. Install the guide pin of special tool MD998705 into the threaded hole of the cylinder block.
    4.  
    5. Align the ratchet ball of the tool with the oil hole in the rear bearing to install the bearing of the special tool.
    6.  
    7. Using the tool, install the rear bearing. Make sure the oil hole of the bearing is aligned with the oil hole of the cylinder block.
    8.  

  6.  
  7. Use a suitable socket wrench to install the counterbalance shaft oil seal into the front case.
  8.  
  9. Install the oil pump oil seal, using a suitable socket to press the seal into place.
  10.  
  11. Use special tool MD998375 to install the front oil seal into the front case.
  12.  
  13. Install the oil pump gears into the front case and make sure the alignment marks line up.
  14.  
  15. Install the oil pump case as follows:
    1. Place special tool MD998285 on the front end of the crankshaft, then apply a thin coating of engine oil to the outer surface of the special tool.
    2.  
    3. Apply engine oil to the lip of the crankshaft front oil seal.
    4.  
    5. Install the front case. Be careful not to damage the oil seal.
    6.  
    7. Install the bolts, noting their different lengths and tighten to 17 ft. lbs. (23 Nm).
    8.  

  16.  
  17. Install the flange bolt, using a screwdriver to lock the counterbalance shaft and tighten to 27 ft. lbs. (36 Nm). Pull out the screwdriver and screw the plug back in.
  18.  
  19. Install the plug as follows:
    1. Install a new O-ring to the groove of the front case.
    2.  
    3. Install the plug to the front case.
    4.  
    5. Fit special tool MD998162 on the plug and hold it in place with tool MD998783.
    6.  
    7. Tighten the plug to 17 ft. lbs. (23 Nm). Remove the special tools.
    8.  

  20.  
  21. Install or connect the following:

    Oil filter bracket and gasket
     
    Relief plunger
     
    Relief spring
     
    Oil screen and gasket
     
    Upper and lower oil pans, AWD vehicles
     
    Oil pan, FWD vehicles
     

  22.  


    Click image to see an enlarged view

    Fig. View of the special tools needed to install the left counterbalance shaft rear bearing



    Click image to see an enlarged view

    Fig. Install the guide pin of special tool MD998705 into the threaded hold of the cylinder block



    Click image to see an enlarged view

    Fig. Use special tool MD998705 to install the rear bearing. Make sure the oil hole of the bearing is aligned with the oil hole of the cylinder block



    Click image to see an enlarged view

    Fig. Remove the rear bearing installing part from special tool MD998705



    Click image to see an enlarged view

    Fig. The front case bolts are all different lengths. Make sure to install the bolts in their proper locations



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:

    Timing belt
     
    Oil pan, FWD vehicles
     
    Lower and upper oil pan, AWD vehicles
     
    Oil screen and gasket
     
    Relief spring
     
    Relief plunger
     
    Oil filter bracket and gasket
     
    Plug. Fit Mitsubishi Special tool no. MD998162 on the plug, then hold it in position with special tool MD998783, loosen the plug, then remove the tools.

    Click image to see an enlarged view

    Fig. To remove or install the plug, fit special tool MD998162 on the plug and hold it in place with tool MD998783

     
    O-ring
     
    Flange bolt by removing the plug on the side of the cylinder block. Insert a Phillips screwdriver into the hold to lock the counterbalance shaft, then loosen the flange bolt.
     
    Front case and gasket
     
    Oil pump cover
     
    Oil pump driven gear
     
    Oil pump drive gear
     
    Crankshaft front oil seal
     
    Oil pump oil seal
     
    Left and right counterbalance shafts
     
    Front counterbalance shaft bearing, using Mitsubishi Special tool no. MD998371
     
    Rear left and right counterbalance shaft bearings using Mitsubishi Special tool nos. MD991603 and MD998372

    Click image to see an enlarged view

    Fig. Oil pump and related components

     

  10.  

To install:

  1. Install the left counterbalance shaft rear bearing as follows:
    1. Install Mitsubishi Special tool no. MD991603 to the cylinder block.
    2.  
    3. Apply engine oil to the rear bearing outer surface and bearing hole in the cylinder block.
    4.  
    5. Use Mitsubishi Special tool MD998705 to install the rear bearing. The left rear bearing has no oil holes.

      Click image to see an enlarged view

      Fig. View of the special tools needed to install the left counterbalance shaft rear bearing

    6.  

  2.  
  3. Install the right counterbalance shaft rear bearing as follows:
    1. Install the guide pin of special tool MD998705 in the threaded hole of the cylinder block.
    2.  
    3. Align the ratchet ball of special tool MD998705 with the oil hold in the rear bearing to install the bearing of the special tool MD998705.
    4.  
    5. Apply engine oil to the bearing outer surface and bearing hole in the cylinder block.
    6.  
    7. Use special tool MD998705 to install the rear bearing. Make sure the oil hole of the bearing is aligned with the oil hole of the cylinder block.

      Click image to see an enlarged view

      Fig. Install the guide pin of special tool MD998705 into the threaded hold of the cylinder block



      Click image to see an enlarged view

      Fig. Use special tool MD998705 to install the rear bearing. Make sure the oil hole of the bearing is aligned with the oil hole of the cylinder block

    8.  

  4.  
  5. Install the counterbalance shaft front bearing as follows:
    1. Remove the rear bearing installing part from special tool MD998705.
    2.  
    3. Install the guide pin of special tool MD998705 into the threaded hole of the cylinder block.
    4.  
    5. Align the ratchet ball of the tool with the oil hole in the rear bearing to install the bearing of the special tool.
    6.  
    7. Using the tool, install the rear bearing. Make sure the oil hole of the bearing is aligned with the oil hole of the cylinder block.

      Click image to see an enlarged view

      Fig. Remove the rear bearing installing part from special tool MD998705

    8.  

  6.  
  7. Use a suitable socket wrench to install the counterbalance shaft oil seal into the front case.
  8.  
  9. Install the oil pump oil seal, using a suitable socket to press the seal into place.
  10.  
  11. Use special tool MD998375 to install the front oil seal into the front case.
  12.  
  13. Install the oil pump gears into the front case and make sure the alignment marks line up.
  14.  
  15. Install the oil pump case as follows:
    1. Place special tool MD998285 on the front end of the crankshaft, then apply a thin coating of engine oil to the outer surface of the special tool.
    2.  
    3. Apply engine oil to the lip of the crankshaft front oil seal.
    4.  
    5. Install the front case. Be careful not to damage the oil seal.
    6.  
    7. Install the bolts, noting their different lengths and tighten to 17 ft. lbs. (23 Nm).

      Click image to see an enlarged view

      Fig. The front case bolts are different lengths. Install bolts in their proper location

    8.  

  16.  
  17. Install the flange bolt, using a screwdriver to lock the counterbalance shaft and tighten to 27 ft. lbs. (36 Nm). Pull out the screwdriver and screw the plug back in.
  18.  
  19. Install the plug as follows:
    1. Install a new O-ring to the groove of the front case.
    2.  
    3. Install the plug to the front case.
    4.  
    5. Fit special tool MD998162 on the plug and hold it in place with tool MD998783.
    6.  
    7. Tighten the plug to 17 ft. lbs. (23 Nm). Remove the special tools.
    8.  

  20.  
  21. 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 filter bracket and gasket
     
    Relief plunger
     
    Relief spring
     
    Oil screen and gasket
     
    Upper and lower oil pans, AWD vehicles
     
    Oil pan, FWD vehicles
     

  22.  
  23. Install the timing belt.
  24.  
  25. Refill the engine with oil. Connect the negative battery cable. Start the engine and check for leaks.
  26.  

 
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