Oil Pump, Oil Pan & Front Case

Applies to all engine variants (SOHC and DOHC) — the manual heads this section “Oil Pump Replacement: ALL.”

Component removal order

1. Drain plug
2. Gasket
3. Oil pan
4. Oil screen — (Bravo Van) — see note below
5. Gasket
6. Relief plug
7. Gasket
8. Relief spring
9. Relief plunger
10. Oil seal
11. Front case
12. Outer rotor
13. Inner rotor
14. Oil seal

Note: Item 4, “Oil Screen,” is annotated “(Bravo Van)” in the source — this may indicate a component specific to the Bravo Van variant rather than the standard Pajero Mini/our truck’s configuration. (verify printed p.98) before assuming this part applies to a DOHC 4A30 truck.

Torque values (as scanned)

Value as scanned
T=9 (0.9; 80 in-lb)
T=11 (1.1; 97 in-lb)
T=19 (1.9; 168 in-lb)
T=44 (4.5; 32 ft-lb)

(verify printed p.98-99) — these four torque values are recovered from the exploded-view diagrams, but which fastener each applies to (oil pan bolts, front case bolts, drain plug, relief plug) could not be confidently mapped from the OCR. As a reasonableness check: drain plugs on comparable engines commonly run in the 30-45 N·m range, so T=44 (4.5 kgf·m; 32 ft-lb) is plausibly the drain plug — but this is an inference, not a confirmed reading. Do not assign these torques to specific fasteners without checking a clean scan or the parts diagram directly.

Maintenance notes

Oil pan removal

1. Drain oil.
2. Use tool MD998727 to separate pan & gasket.
3. Clean all surfaces before reinstallation.

Oil seal replacement (general)

1. Remove old seal (implied).
2. Coat new seal with engine oil (30W SAE).
3. Install new seal using a socket.

Front oil pump case installation

1. Place a 3mm (0.118in) bead of sealant around the outer edges of the case as shown.
2. Let stand 3 minutes before installation.

Crankshaft (front) oil seal installation

1. Remove old seal and discard.
2. Coat new seal with engine oil (30W SAE).
3. Install new seal using tool MD999570.

Oil pan installation

1. Thoroughly clean all surfaces.
2. Place a 4mm (0.157in) bead of sealant as shown.
3. Let stand 3 minutes before installation.

Oil pump inspection

Inspection	Limit	Action
Rotor clearance (thickness gauge)	0.06-0.18mm (0.002–0.007in)	Over: replace rotors as a set
Distortion (thickness gauge + straight edge)	0.04-0.11mm (0.002–0.004in)	Over: replace components as required
Outer clearance (thickness gauge + straight edge)	0.10-0.17mm (0.004–0.007in)	—

These three limits match the Engine Specifications table (see 34-engine-specifications.md) for oil pump rotor clearance gap, side clearance, and body distortion respectively, confirming those readings.