Mitsubishi Engine F9Q Workshop Manual

GENERAL INFORMATION 11A-0-3...............................

1. SPECIFICATIONS 11A-1-1...................................

2. SPECIAL TOOLS 11A-2-1....................................

3. CRANKSHAFT PULLEY 11A-3-1..............................

4. TIMING BELT 11A-4-1.......................................

5. OIL SEPARATOR AND OIL RETURN PIPE 11A-5-1.............

6. INJECTION PUMP AND FUEL INJECTOR 11A-6-1..............

7. VACUUM HOSE 11A-7-1.....................................

8. INTAKE AND EXHAUST 11A-8-1..............................

9. WATER PUMP AND WATER PIPE 11A-9-1.....................

10. CAMSHAFT AND VACUUM PUMP 11A-10-1....................

11. CYLINDER HEAD 11A-11-1...................................

12. OIL PAN AND OIL PUMP 11A-12-1.............................

13. PISTON 11A-13-1............................................

14. CYLINDER BLOCK 11A-14-1..................................

11A-0-1

ENGINE

F9Q SERIES

CONTENTS

SERVICE SPECIFICATIONS 11A-1-1........................

TORQUE SPECIFICATIONS 11A-1-2.........................

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11A-0-2

NOTES

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F9QENGINE-

Description Specification

Type F9Q1,F9Q2

Numberandarrangementofcylinders 4in-line

GeneralInformation

11A-0-3

Totaldisplacement 1870cm

Cylinderbore´Stroke 83´93

Compressionratio 19

Valvemechanism Singleoverheadcamshaft

Numberofvalve Intake 4

Exhaust 4

Valvetiming Intakeopening BTDC3

Intakeclosing ABDC21

Exhaustopening BBDC46

Exhaustclosing BTDC6

Turbocharger Exhaustgasturbocharger

Fuelinjectionsystem Directinjectionsystem(commonrailfuelinjection)

3

_

_

_

_

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F9Q ENGINE – Specifications

1. SPECIFICATIONS

SERVICE SPECIFICATIONS

Item Standard Limit

Timing belt

Timing belt tension Hz 90 ± 15 –

Camshaft and vacuum pump

End play mm 0.05 – 0.13 –

Cylinder head

Piston protrusion above cylinder block mm 0.653 – 0.786 –

Valve stem diameter mm 6.98 – 6.99 –

Valve seat angle 45_ –

Valve projection mm –0.03 – 0.21 –

Cylinder head overall height mm 161.9 – 162.1 –

11A-1-1

Flatness of cylinder head gasket surface mm 0.05 –

Valve spring free height mm 45.8 –

Valve guide inner diameter mm 7.00 – 7.02 –

Valve guide outer diameter mm 12.03 – 12.05 –

Valve guide installation height mm 80.7 – 81.4 –

Tappet height mm 34.97 – 34.99 –

Valve clearance mm Intake 0.20 –

Exhaust 0.40 –

Piston

Piston outer diameter mm 80 –

Piston ring thickness mm Piston ring No.1 2.5 –

Piston ring No.2 2.0 –

Oil ring 3.0 –

Connecting rod length mm 139 –

Piston protrusion mm 0.50 – 0.62 –

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11A-1-2

F9Q ENGINE – Specifications

TORQUE SPECIFICATIONS

Item Nm

Crankshaft pulley

Bracket bolt 44 ± 4
Crankshaft pulley 20 ± 2 ) 115_ ± 15_

Timing belt

Timing belt cover 9 ± 0.9
Tensioner pulley nut 50 ± 5
Tensioner plate bolt 10 ± 1
Camshaft sprocket bolt 60 ± 6

Oil separator and oil return pipe

Oil return pipe bolt 12 ± 1
Turbocharger oil feed pipe bolt 24 ± 10
Turbo nipple 26 ± 2

Injection pump and fuel injector

High pressure pipe nut 25 ± 2
Pressure sensor 25 ± 0.2
Injection rail mounting bolt 25 ± 2
Injection pump pulley 15 ± 1 + 60_ ± 10_
Injection pump bracket bolt 62 ± 6

Pressure regulator 35 ± 5

Intake and exhaust

Engine hanger bolt 20 ± 2
Flap box bolt 8 ± 0.8
EGR valve bolt 8 ± 0.8
Turbocharger nut 24 ± 10
Manifold nut 28 ± 2

Water pump and water pipe

Water pump bolt 10 ± 1
Water inlet pipe bolt 39 ± 3

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F9Q ENGINE – Specifications

Item Nm

Camshaft and vacuum pump

Engine hanger bolt 13 ± 1
Glow plug 15 ± 1
Camshaft position sensor screw 8.8 ± 1.5
Cylinder head cover bolt 12 ± 1
Bearing cap bolt 20 ± 2

Oil pan and oil pump

Oil pan bolt 14 ± 1
Oil pump bolt 25 ± 2
Cylinder block front plate bolt 15 ± 1.5

Piston

Connecting rod cap bolt 50 ± 5

11A-1-3

Cylinder block

Flywheel bolt 55 ± 5
Bearing cap bolt 65 ± 6

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2. SPECIAL TOOLS

F9Q ENGINE -

Special Tools

11A-2-1

Tool

Number Name Use

MB990767 Camshaft sprocket

holder

MD998715 Pulley holder pin Retaining the camshaft sprocket (use together

MB991614 Angle gauge Tightening cylinder head bolts

MB996014 Valve spring

compressor

Removal of camshaft sprocket

with MB990767)

Removal of valve spring split cones

MB996015 Flywheel stopper Locking the flywheel

MB996016 Reamer Reaming valve guides

MB996020 Valve guide

remover

MB996021 Valve stem seal

remover

Pressing in valve guides

Removal of valve guide seal

MB996024 Reamer Reaming valve guides

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11A-2-2

F9Q ENGINE – Special Tools

MB996029 Valve guide

installer

MB996031 Valve stem seal

installer

MB996038 Oil seal installer Installation of crankshaft oil seal (flywheel end)

MB996040 Oil seal installer Installation of crankshaft oil seal (timing gear

Pressing in valve guides

Installation of valve guide seal

end)

MB991502 MUT-II

sub-assembly

MB991668 Belt tension meter

set

MB996048 Belt pretensioner Installation of timing belt

MB996043 Sprocket stopper Locking the injection pump sprocket

D Drive belt tension measurement
D Fuel injection timing check and adjustment
D Idle speed check

Timing belt tension measurements (Use with
MUT-II)

MH062464 Gear puller Removal of fuel injection pump gear

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Tool UseNameNumber

MB991800 Pulley holder Crankshaft pulley holding

MB991802 Pin B

F9Q ENGINE – Special Tools

11A-2-3

MB996050 Connecting rod

bearing installer

Installation of connecting rod bearing

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F9Q ENGINE – Crankshaft Pulley

3. CRANKSHAFT PULLEY

REMOVAL AND INSTALLATION

3

20 ± 2 Nm
) 115 _ ± 15_

4

11A-3-1

5

2

Removal steps

1. Alternator

2. Bracket

AA""AA 3. Crankshaft pulley

4. Idler pulley

5. Auto tensioner

1

44 ± 4 Nm

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11A-3-2

MB991800

MB991802

MB991800

MB991802

F9Q ENGINE – Crankshaft Pulley

REMOVAL SERVICE POINT

AA" CRANKSHAFT PULLEY REMOVAL

(1) Use special tool MB991800 and MB991802 to hold the

crankshaft pulley during removal.

INSTALLATION SERVICE POINT

"AA CRANKSHAFT PULLEY INSTALLATION

Caution
D Do not reuse the crankshaft pulley bolt.

(1) Use special tool MB991800 and MB991802 to hold the

crankshaft pulley during installation.

(2) Apply a coat of locking agent to the screw thread of the

bolt.

(3) Retighten the loosened bolt to 20 Nm in the tightening

sequence shown.

(4) Tighten the bolt further 115_ ± 15_ using an angle gauge.

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F9Q ENGINE – Timing Belt

4. TIMING BELT

REMOVAL AND INSTALLATION

9 ± 0.9 Nm

11A-4-1

4

60 ± 6 Nm

2

6

50 ± 5 Nm

1

10 ± 1 Nm

3

5

8

Removal steps

1. Timing belt cover, front

AA""BA 2. Timing belt

3. Tensioner pulley

4. Crankshaft sprocket

5. Tensioner plate

AB""AA 6. Camshaft sprocket

7. Engine cover bracket

8. Timing belt cover, rear

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REN0166

11A-4-2

Timing
belt cover

Bolt

Timing mark

Window

F9Q ENGINE – Timing Belt

REMOVAL SERVICE POINTS

AA" TIMING BELT REMOVAL

(1) Turn the crankshaft clockwise to align the timing mark

of the camshaft sprocket with the center of the window
of the timing belt cover.

Caution
D The crankshaft must always be turned clockwise.

(2) Turn the crankshaft clockwise so that the piston of No.

1 cylinder is in the TDC on the compression stroke.

(3) Remove the bolt at the rear right side of the cylinder

block and insert an 8 mm diameter pin into the bolt hole.
If the crankshaft is in correct position, the pin is engaged
with the recess in the crankshaft web.

Caution
D Do not turn the crankshaft with the pin inserted.

(4) Slacken the lock nut of the timing belt tensioner.

REN0171

Remove the timing belt.

MD998715

MD998715

E

MB990767

Bolt

AB" CAMSHAFT SPROCKET BOLT REMOVAL

(1) Use special tool MB990767, camshaft sprocket holder

with pin MD998715 and remove the retaining bolt.

Caution
D Hold the camshaft sprocket with the special tools

taking care not to let them hit against the camshaft
position sensor.

REN0212

INSTALLATION SERVICE POINTS

"AA CAMSHAFT SPROCKET BOLT INSTALLATION

(1) Smear the retaining bolt with a locking agent.

Use special tool MB990767, camshaft sprocket holder
with pin MD998715 to stop the sprocket turning and then

tighten the camshaft sprocket retaining bolt to 60 ± 6

MB990767

REN0213

REN0171

May 2002Mitsubishi Motors Corporation Revised

Nm.

Caution
D Hold the camshaft sprocket with the special tools

taking care not to let them hit against the camshaft
position sensor.

"BA TIMING BELT INSTALLATION

(1) Turn the crankshaft to place the piston of No. 1 cylinder

in the TDC on the compression stroke.

(2) Remove the bolt at the rear right side of the cylinder

block.

(3) Insert an 8 mm diameter pin into the bolt hole. If the

crankshaft is in correct position, the pin will engage with
the recess in the crankshaft web.

Caution
D Do not turn the crankshaft with the pin inserted.

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F9Q ENGINE – Timing Belt

11A-4-3

(4) Check that the crankshaft groove C is located at the

A

A

A

center between the two ribs A on the cylinder block front
plate, and that the portion B of the crankshaft is in the
illustrated position.

C

B

(5) Check that the tensioner is securely positioned on the

pin D.

(6) Fit the timing belt, aligning marks on the belt with the

marks on the camshaft and crankshaft sprockets. (77
teeth inserted between the two marks on the belt)

D

E

MB996048

REN0168

(7) Place the tensioner pulley against the belt by tightening

bolt E on the tensioner support.

Caution
D Do not reuse the removed timing belt.

(8) Remove the pin installed in Step 3.

REN0169

(9) Set the special tools on the crankshaft sprocket.
(10)Tighten the crankshaft to 11 Nm.

REN0170

(11)Connect the special tool (MB991704) to the MUT-II. Then,

connect the MUT-II to the battery.
(12)Connect the MUT-II to the diagnosis connector.
(13)Turn the crankshaft clockwise to set the No. 1 cylinder

to top dead center on the compression stroke.
(14)Select “Belt tension measurement” from the MUT-II menu

screen.

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11A-4-4

15_

15_

MB991668
(Microphone)

10 – 20 mm

M6 bolt

F9Q ENGINE – Timing Belt

(15)Slacken the lock nut of the timing belt tensioner.
(16)Tension the timing belt with the aid of an M6 bolt.
(17)As shown in the illustration, keep the microphone

(MB991668) 10 to 20 mm away from the back side of

the belt perpendicularly (within an inclination of ±15

degrees).
(18)With your finger tip, lightly tap on the belt at the centre

Lock
nut

Y6035AJ

between the tensioner and crankshaft sprocket in the

location shown by the arrow in the illustration to check

whether the belt frequency is within the standard value.

Standard value: 90 ± 15 Hz

Caution

D Measure when the belt surface temperature is

close to room temperature.

D Make sure that the water or oil, etc., does not

get on the microphone.

D If a strong wind blow or noise is made close to

the microphone during measurement, the meter
will show a value that differs from the actual value.

D If the measurement is taken with the microphone

touching the belt, the meter will show a value
that differs from the actual value.

MB996048

(19)Turn the clockwise crankshaft twice.
(20)Insert a pin having a diameter of approx. 8 mm into the

bolt hole to block the crankshaft.
(21)Reconfirmation turn the crankshaft clockwise to set the

No. 1 cylinder to TDC on the compression stroke.
(22)Remove 8 mm pin.

(23)Set the special tool on the crankshaft sprocket.
(24)Give a preload to the belt by a torque of 11 Nm.

REN0170

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15_

F9Q ENGINE – Timing Belt

(25)Connect the special tool (MB991704) to the MUT-II and

the microphone (MB991668).
(26)Check the belt tension. If the belt tension is otherwise

adjust it again.

11A-4-5

15_

MB991668
(Microphone)

10 – 20 mm

M6 bolt

Lock
nut

Y6035AJ

Standard value: 90 ± 15 Hz

(27)Tighten the tension lock nut to a torque of 50 Nm.

NOTE

The tension lock nut must be torque tightened to avoid

any slackening which could damage the engine.

(28)Removal tool to MUT-II.

(29)Remove bolt E on the tensioner support.

E

REN0169

INSPECTION

TIMING BELT TENSIONER AND IDLER

(1) Check that the tensioner and idler rotate smoothly without

excessive play or abnormal noise. Replace them with

new ones if necessary.

REN0172

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F9Q ENGINE -

Oil Separator and Oil Return Pipe

5. OIL SEPARATOR AND OIL RETURN PIPE

REMOVAL AND INSTALLATION

11A-5-1

12

24±10 Nm

26±2Nm

14

13

13

15

1

2

3

10

8

5

7

6

12±1Nm

9

Removal steps

1. Oil dipstick

2. Oil dipstick seal

3. Oil separator hose

4. Oil separator return hose

5. Oil separator

6. O-ring

7. Oil separator holding ring

8. Engine breather pipe

11

4

16

REN0173

9. Oil return pipe

10. Oil return pipe gasket

11. O-ring

12. Turbocharger oil feed pipe

13. O-ring

14. Turbo nipple

15. Gasket

16. Oil separator return pipe

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F9Q ENGINE – Injection Pump and Fuel Injector

6. INJECTION PUMP AND FUEL INJECTOR

REMOVAL AND INSTALLATION

11A-6-1

15 ± 1 Nm
) 60_ ± 10_

12

62 ± 6 Nm

16

25 ± 0.2 Nm

13

4

7

1

25 ± 2 Nm

35 ± 5 Nm

14

2

3

5

6

10

11

25 ± 2 Nm

9

Removal steps

1. Clip

2. Fuel return ramp

"BA 3. High pressure pipe

4. Fuel injector flange

5. Fuel injector

6. Adjusting washer

7. Pressure sensor

"BA 8. High pressure pipe

9. Pressure limiter

10. Pressure limiter nipple

"BA 11. Fuel injection rail

8

15

25 ± 2 Nm

REN0174

AA""AA 12. Injection pump sprocket

13. Engine hanger

14. Pressure regulator

15. Injection pump

16. Injection pump bracket

NOTE

When the fuel injectors and fuel injection rail are
removed, put caps on their high pressure pipe
connecting ports to prevent dust from entering the
fuel line. Leave the caps installed until the injectors
and fuel injection rail are reinstalled.

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11A-6-2

MB996043

MH062464

Bolt

F9Q ENGINE – Injection Pump and Fuel InjectorF9Q ENGINE – Injection Pump and Fuel Injector

REMOVAL SERVICE POINT

AA" INJECTION PUMP SPROCKET REMOVAL

(1) Set the special tools on the injection pump sprocket.

(2) For preparatory work, replace the center bolt of the special

tool MH062464 with a sufficiently longer bolt.
(3) Remove the injection pump sprocket using the special

tool.

MB996043

High pressure pipe

High pressure

C

pipe

D

Fuel injection
rail

B

A

REN0178

INSTALLATION SERVICE POINT

"AA INJECTION PUMP SPROCKET INSTALLATION

(1) Using the special tools shown in the illustration, lock the

injection pump sprocket in position.
(2) Tighten the injection pump sprocket nut to the specified

torque.

"BA HIGH PRESSURE PIPE / FUEL INJECTION RAIL

INSTALLATION

(1) Position the fuel injection rail and finger tighten the

mounting bolts (the rail should be floating).
(2) Position all the high pressure pipes and finger tighten

then.

Tighten all the high pressure injection pipe connection

(on the injector side A then on the fuel injection rail side

B).
(3) Tighten the high pressure pipe C.
(4) Tighten the fuel injection rail bolts D.

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F9Q ENGINE -

7. VACUUM HOSE

REMOVAL AND INSTALLATION

Vacuum Hose

11A-7-1

3

2

1

Removal steps

1. Solenoid valve

2. Vacuum hose

3. Vacuum tank

REN0179

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F9Q ENGINE – Intake and Exhaust

8. INTAKE AND EXHAUST

REMOVAL AND INSTALLATION

11A-8-1

1

20 ± 2 Nm

10

28 ± 2 Nm

6

9

5

6

24 ± 10 Nm

2

8 ± 0.8 Nm

3

8

7

4

8 ± 0.8 Nm

Removal steps

1. Engine hanger

2. Flap box

3. EGR valve

4. EGR valve gasket

5. EGR hose

6. EGR hose clamp

7. Turbocharger

8. Intake manifold

9. Exhaust manifold

10. Manifold gasket

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F9Q ENGINE -

Water Pump and Water Pipe

9. WATER PUMP AND WATER PIPE

REMOVAL AND INSTALLATION

11A-9-1

2

10±1Nm

12

14

13

15

9

3

1

6

5

4

8

7

11

39±3Nm

Removal steps

1. Clip

2. Engine coolant temperature sensor

3. Gasket

4. Thermostat case cover

5. Reinforcement

6. Thermostat case cover gasket

7. Thermostat

8. Thermostat case

10

REN0181

9. Thermostat case gasket

10. Cooling water line pipe

11. O-ring

12. Cooling water line pipe

13. O-ring

14. Water pump

15. Water pump gasket

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F9Q ENGINE – Camshaft and Vacuum Pump

10. CAMSHAFT AND VACUUM PUMP

REMOVAL AND INSTALLATION

11A-10-1

12 ± 1 Nm

6

7

20 ± 2 Nm

9

2

15 ± 1 Nm

8

13 ± 1 Nm

3

10

8.8 ± 1.5 Nm

5

1

4

REN0182

Removal steps

1. Engine hanger

2. Glow plug

3. Camshaft position sensor

"CA 4. Vacuum pump

5. Vacuum pump gasket

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AA""AA 9. Bearing cap

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"BA 8. Oil seal

6. Cylinder head cover

7. Cylinder head cover gasket

10. Camshaft

11A-10-2

Timing belt side

F9Q ENGINE – Camshaft and Vacuum PumpF9Q ENGINE – Camshaft and Vacuum Pump

REMOVAL SERVICE POINT

AA" BEARING CAP REMOVAL

Remove the bearing cap bolts by loosening them in two or
three steps in the order shown in the illustration.

INSTALLATION SERVICE POINTS

"AA BEARING CAP INSTALLATION

(1) Apply sealant Loctite 518 on the bearing cap at a position

where it comes in contact with the cylinder head.

Timing belt side

MB998304

(2) Tighten the bearing cap bolts to a torque of 20"2 Nm

in the sequence given in the illustration.

REN0183

"BA OIL SEAL INSTALLATION

Using the special tool, install the oil seal.

"CA VACUUM PUMP INSTALLATION

Install the vacuum pump while aligning coupling section with
the notch in the camshaft.

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F9Q ENGINE – Camshaft and Vacuum Pump

INSPECTION

CAMSHAFT

Measure the end play. Replace the camshaft if the
measurement does not meet the standard value.

Standard value: 0.05 – 0.13 mm

REN0184

11A-10-3

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F9QENGINE-

11.CYLINDERHEAD

REMOVALANDINSTALLATION

1

_

_

30Nm+50

®

Fullyloosen

25Nm+213

®

±

4

_

_

7

±

10

11

CylinderHead

3

4

5

11A-11-1

2

Removalsteps

"EA
"DA

AA""CA

AA""CA

1.Cylinderheadbolt

2.Cylinderheadgasket

3.Tappet

4.Retainerlocks

5.Valvespringretainer

6.Valvespring

12

AB""BA
AC""AA

6

7

8

9

REN0185

7.Valvespringseat

8.Intakevalve

9.Exhaustvalve

10.Valvestemseal

11.Valveguide

12.Cylinderhead

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11A-11-2

MB996014

F9Q ENGINE – Cylinder Head

REMOVAL SERVICE POINTS

AA" RETAINER LOCKS REMOVAL

(1) Fit valve spring compressor MB996014 on the cylinder

head as shown in the illustration.
(2) Press down the valve spring retainer and remove the

retainer locks.

REN0049

AB" VALVE STEM SEAL REMOVAL

Remove the seal with valve stem seal remover MB996021.

MB996021

MB996020

REN0050

AC" VALVE GUIDE REMOVAL

(1) Support the cylinder head.
(2) Press out the valve guides towards the valve seat with

valve guide remover MB996020.

REN0051

INSTALLATION SERVICE POINTS

"AA VALVE GUIDE INSTALLATION

(1) Measure the diameter of the bores for the valve guides

in the cylinder head. If a measured value does not come

within the specified tolerance range, select the oversize

valve guide.

Standard value:

Diameter of bore (A): 12 mm

REN0069

(2) Ream valve guide bore (dimension A) to the outside

diameter of the selected oversize valve guides with reamer

MB996016.

Oversize valve guide diameter = 12.3 mm

(two grooves)

(3) Place the cylinder head on a flat surface.

REN0070

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F9Q ENGINE -

F9Q ENGINE -

Cylinder Head

Cylinder Head

11A-11-3

MB996029
9,000 N

MB996024

MB996031

REN0071

REN0072

REN0073

(4) Locate the valve guides with the taper pointing down,

on valve guide installer MB996029.

(5) Press in the valve guides until the installer abuts the

cylinder head.

Caution

The pressure exerted on the valve guide must

D

be at least 9,000 N. If the pressure is lower, the
valve guide must be removed. Ream the valve
guide bore in the cylinder head to the next oversize
and press in the corresponding valve guide.

(6) Clean the valve guide inner bores with reamer MB996024.

"BA

VALVE STEM SEAL INSTALLATION

(1) Lubricate the valve guides with engine oil.

Introduce the valves through the valve guides.
Locate the protective plastic cap over the valve stem.

(2) Locate the valve stem oil seal. Press in the valve stem

oil seal vertically until it abuts the cylinder head with valve
stem seal installer MB996031. Remove the protective
cap.

Caution

To avoid damaging the valve stem oil seal, the

D

valves must not be removed again.

"CA

RETAINER LOCKS INSTALLATION

(1) Fit valve spring compressor MB996014 on the cylinder

head as shown in the illustration.

(2) Press down the valve spring retainer and fit the retainer

locks.

MB996014

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REN0074

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11A-11-4

F9Q ENGINE – Cylinder Head

"DA CYLINDER HEAD GASKET INSTALLATION

(1) Select a cylinder head gasket of the correct thickness

according to the projecting height of the pistons. The

available cylinder head gaskets are shown in the table

below. The thickness of the gasket is indicated by the

number of holes near the end of the gasket (see the

illustration). Measure the projecting height of the pistons.

Based on the highest projection, select a cylinder head

gasket of the correct thickness from the table shown below.

REN0042

Highest piston
height above
cylinder block mm

< 0.653 2 1.35

0.653 – 0.786 1 1.45

0.786 > 3 1.55

Number of holes Gasket thickness

mm

When only the gasket is to be replaced, check the hole

pattern on the old gasket and select a gasket with the

same number of holes.

Caution

D If a piston or connecting rod, etc. has been

replaced, always measure the projecting height
of the pistons because this may have changed
after replacing these parts.

"EA CYLINDER HEAD BOLT INSTALLATION

Timing belt side

Caution
D Do not reuse the cylinder head bolts once removed.

(1) Fit the washers.
(2) Tighten all the bolts to 30 Nm, then angle-tighten by 50_

± 4_ in the order shown in the illustration at left.

(3) Wait three minutes for gasket to settle.
(4) Slacken bolts 1 – 2 until they are completely free.
(5) Tighten bolts 1 – 2 to 25 Nm, then angle-tighten by 213_

REN0183

± 7_.

(6) Carry out the same slackening and torque/angle tightening

operations on the remaining bolts 3 – 4, 5 – 6, 7 – 8,

9 – 10.

E

Mar. 2001Mitsubishi Motors Corporation Revised

PWEE0001-A

45_

F9Q ENGINE – Cylinder Head

INSPECTION

INTAKE AND EXHAUST VALVES

(1) Measure the valve stem diameter and replace the valve

if the measurement does not meet the standard value.

Standard value: 6.98 – 6.99 mm

4ME0122

(2) Measure the valve seat angle and correct if it does not

meet the standard value.

Standard value: 45_

REN0186

11A-11-5

(3) Insert the valve in the cylinder head and measure the

valve projection from the cylinder head bottom surface.

Replace the valve if the measurement does not meet

the standard value.

Standard value: –0.03 – 0.21 mm

REN0187

CYLINDER HEAD

(1) Check the cylinder head bottom surface for distortion.

Replace the cylinder head if the measurement does not

meet the standard value.

Standard value: 0.05 mm

Caution

D The cylinder head may not be reground.

(2) Measure the cylinder head height. Replace the cylinder

head if the measurement does not meet the standard

value.

Standard value: 161.9 – 162.1 mm

Caution

D The cylinder head may not be reground.

E

Mar. 2001Mitsubishi Motors Corporation Revised

PWEE0001-A

11A-11-6

F9Q ENGINE – Cylinder Head

90_

Out of square

Free height

1EN0264

REN0189

VALVE SPRING

(1) Measure the valve spring free height. If the measurement

does not meet the standard value, replace the valve

spring.

Standard value: 45.8 mm

VALVE GUIDE

(1) Measure the inner and outer diameters of the valve guide

to confirm that they are within the standard value range.

Standard value:

Inner diameter 7.00 – 7.02 mm
Outer diameter 12.03 – 12.05 mm

(2) Check that the dimension shown in the illustration meets

the standard value when the valve guide is installed in

the cylinder head.

Standard value: 80.7 – 81.4 mm

VALVE SEAT

Measure at the positions shown in the illustration.

Standard value:

Seat angle 90_
Seat width 1.8 mm

1.8 mm

Exterior diameter

Cylinder at point
of balance

E

Cylinder being
checked/adjusted

Exterior diameter intake:

Intake 36.9 mm
Exhaust 33.6 mm

TAPPET

Measure the tappet height to check that it meets the standard
value.

Standard value: 34.97 – 34.99 mm

REN0190

VALVE CLEARANCE CHECK AND ADJUSTMENT

(1) The valve clearances have to be checked/adjusted in

the following sequence.

Cylinder at point of balance

1 4

2 3

3 2

Y6087AJ

Mar. 2001Mitsubishi Motors Corporation Revised

4 1

PWEE0001-A

Cylinder being checked/
adjusted

F9Q ENGINE -

F9Q ENGINE -

F9Q ENGINE -

(2) Measure the valve clearance.

Standard value:

Cylinder Head

Cylinder Head

Cylinder Head

11A-11-7

Adapter

Wall
thickness (X)

REN0013

Micrometer

Y6091AJ

Cold engine

Intake valve mm 0.15- 0.20 0.20

Exhaust valve mm 0.35- 0.45 0.40

Checking Adjusting

(3) If the valve clearance is outside the standard value, adjust

by replacing the tappets using the following procedure.

(4) Take valve clearance measurement again at the cylinder

where the valve clearance is not within the tolerance,
and record the measured value.

(5) Measure the wall thickness (X) of the tappet using a

micrometer, and record the measured value.

(6) Based on the measurements, select a tappet which will

bring the valve clearance to the standard value.

Wall thickness of tappet to be selected =

Wall thickness (X) of tappet having been installed
at checking + (Measured value - Standard value)

NOTE

1. Always use new tappets.

2. Tappets are available in thickness from 7.550 mm to

8.150 mm, increasing by increments of 0.025 mm.

(7) Remove the camshaft. Install the selected tappet.
(8) Install the camshaft.
(9) Rotate the camshaft one turn, then check that the valve

clearance meets the standard value.

E

Jun. 2000Mitsubishi Motors Corporation

PWEE0001

F9Q ENGINE – Oil Pan and Oil Pump

12. OIL PAN AND OIL PUMP

REMOVAL AND INSTALLATION

14

12

13

15 ± 1.5 Nm

11A-12-1

2

1

4

3

15

16

17

11

5

15 ± 1 Nm

10

25 ± 2 Nm

9

8

14 ± 1 Nm

7

6

Removal steps

1. Oil pressure switch

2. Gasket

3. Oil filter

4. Oil cooler adaptor

5. Oil cooler

6. Drain plug

7. Drain plug gasket

"CA 8. Oil pan

9. Oil pan gasket

E

May 2002Mitsubishi Motors Corporation Revised

PWEE0001-B

AA" 10. Oil plate

11. Oil pump

AB""AA 12. Cylinder block plate, front

13. Gasket

"BA 14. Oil seal
"AA 15. Chain pad

16. Gear

17. Chain

11A-12-2

F9Q ENGINE – Oil Pan and Oil Pump

REMOVAL SERVICE POINT

AA" OIL PLATE REMOVAL

(1) Remove the oil plate mounting bolts.
(2) Slide the oil plate toward the flywheel and then lift it off.

AB" CYLINDER BLOCK FRONT PLATE REMOVAL

(1) Remove the cylinder block front plate.

NOTE

Use care not to lose the pad attached on the cylinder

block front plate.

REN0192

C

INSTALLATION SERVICE POINTS

"AA CYLINDER BLOCK PLATE, FRONT

INSTALLATION

Caution

D If there is a gasket installed between the cylinder

block and cylinder block front plate, replace it
with a new gasket without using sealant. If there
is no gasket, apply sealant as mentioned below.

REN0193

(1) Apply sealant to the cylinder block front plate.

Specified sealant:

Rhodorseal 5661 or equivalent

NOTE

Do not apply too much sealant to avoid the risk of blocking

the oilways in zone (C). Remember to fit the chain pad

on the cylinder block front plate.

REN0192

"BA CRANKSHAFT FRONT OIL SEAL INSTALLATION

(1) Use the special tool to install the oil seal.

MB996040

REN0135

E

May 2002Mitsubishi Motors Corporation Revised

PWEE0001-B

F9Q ENGINE – Oil Pan and Oil Pump

"CA OIL PAN INSTALLATION

(1) Fit the oil pan on the cylinder block with a new gasket

while aligning their flywheel side edges with each other.

Caution

D Be sure to perform the alignment at the flywheel

side. Otherwise, the clutch housing could be
damaged when the engine is combined with the
transmission.

REN0194

11A-12-3

Timing belt side

1

2

6

17

21

18

14

13

985

10

(2) Tighten the oil pan bolts to 8 ± 0.8 Nm in the order shown

4

3

12

16

20

19

15

11

7

in the illustration.

(3) Then tighten them to 14 ± 1 Nm in the same order.

Jun. 2000Mitsubishi Motors Corporation

E

E

Mar. 2001Mitsubishi Motors Corporation Added

PWEE0001

PWEE0001-A

13. PISTON

REMOVAL AND INSTALLATION

8

F9Q ENGINE – Piston

11A-13-1

5

6

7

10

9

11

2

50 ± 5 Nm

1

4

3

REN0195

Removal steps

1. Connecting rod bolt

AA" 2. Connecting rod cap

"CA 3. Connecting rod lower bearing
"CA 4. Connecting rod upper bearing
"BA 5. Piston ring No. 1
"BA 6. Piston ring No. 2

E

May 2002Mitsubishi Motors Corporation Revised

7. Oil ring

AB""AA 8. Snap ring
AB""AA 9. Piston pin

"DA 10. Piston
"DA 11. Connecting rod

PWEE0001-B

11A-13-2

Cylinder No.

DEN0050

F9Q ENGINE – Piston

REMOVAL SERVICE POINTS

AA" CONNECTING ROD CAP REMOVAL

(1) Mark the cylinder number on the side of the connecting

rod big end for correct reassembly.

Caution

D Do not use a scriber tool for the marking, in order

to avoid starting any cracks in the connecting
rods.
Use an indelible pencil instead.

AB" PISTON PIN REMOVAL

(1) Remove the snap ring securing the piston pin.

Timing belt side

Marking

REN0196

Class mark

Flywheel side

REN0229

REN0231

INSTALLATION SERVICE POINTS

"AA PISTON PIN INSTALLATION

When replacing a piston, be sure to use a new piston with
the same class mark as that on the existing piston. The class
mark is located as shown in the illustration. Also replace
the piston pin, piston rings and snap rings with new ones.

Class mark

K 47.046

L 47.088

M 47.130

N 47.172

P 47.217

A

NOTE

Class “K” and “P” pistons are not available as service

parts.

1. If the existing piston is a class “K” piston, install a
class “L” piston.

2. If the existing piston is a class “P” piston, install a
class “N” piston.

(1) Apply engine oil to the piston pin before inserting it into

the piston and connecting rod.

Height (A) (mm)

Caution
D Set the connecting rod with its marked side

positioned as shown in the illustration.

(2) Install the snap rings to secure the piston pin.

Mark

E

May 2002Mitsubishi Motors Corporation Revised

PWEE0001-B

F9Q ENGINE – Piston

11A-13-3

"BA PISTON RING INSTALLATION

1

1

2

3

2

3

REN0198

(1) Install the piston rings with the side having T (top mark)

upward.

(2) Arrange the piston ring end gaps as shown in the

illustration.

Special tool: MB996050

Base

Bearing

MB996050

Guide

"CA CONNECTING ROD BEARING INSTALLATION

(1) Set the special tools and a connecting rod as shown

in the illustration.

NOTE
Engage the support with the guide pins on the base snugly
to hold the connecting rod securely.

Support

REN0232

(2) Set a bearing on the guide and slide the guide in the

direction of arrow.

REN0233

(3) Firmly press the guide against the connecting rod to install

the bearing in position in the connecting rod.
(4) Slide back the guide and remove the connecting rod.
(5) Repeat the above procedure for all the remaining

connecting rods.

MB996050

MB996050

E

REN0234

(6) Set a bearing cap on the special tool as shown in the

Bearing cap

REN0238

May 2002Mitsubishi Motors Corporation Revised

illustration.

PWEE0001-B

11A-13-4

Bearing cap

MB996050

MB996050

Bearing

F9Q ENGINE – Piston

(7) Slide the support until the bearing cap comes in contact

with the guide pins on the base.

REN0235

(8) Set a bearing on the guide as shown in the illustration

and slide the guide in the direction of arrow.

REN0236

MB996050

Timing belt side

REN0237

Mark

Flywheel side

(9) Firmly press the guide against the bearing cap to install

the bearing in position in the bearing cap.
(10)Slide back the guide and remove the bearing cap.
(11)Repeat the above procedure for all the remaining bearing

caps.

"DA PISTON AND CONNECTING ROD INSTALLATION

(1) Fit the connecting rod/piston assemblies into the cylinder

block using a bush, taking care to ensure the fitting

direction is correct (V towards flywheel).
(2) Fit the connecting rods onto the lubricated crankshaft

crankpins.
(3) Fit each connecting rod bearing cap with its marked side

located in the same side with the marked side of the

connecting rod.

(4) Tighten the new connecting rod bearing cap bolts to a

torque of 50 Nm.

50 Nm

REN0114

E

May 2002Mitsubishi Motors Corporation Added

PWEE0001-B

F9Q ENGINE – Piston

11A-13-5

INSPECTION

PISTON

(1) Measure the piston diameter at a point where A = 39 mm

A

REN0199

Standard value: 80 mm

PISTON RING

(1) Measure the thickness of the piston rings to check for

wear.

Standard value

Piston ring No. 1: 2.5 mm
Piston ring No. 2: 2.0 mm
Oil ring: 3.0 mm

REN0200

Protrusion

DEN0798

PISTON PROTRUSION

(1) Clean the piston crown to remove deposits.
(2) Turn the crankshaft in the direction of operation to bring

No. 1 piston to TDC.
(3) Measure the protrusion of No. 1 piston using a dial gauge.

If the measurement is out of specification, replace the

piston with a new one.

If the protrusion is still out of specification, replace the

cylinder block.

Standard value: 0.50 – 0.62 mm

NOTE

Do not take measurement at valve recess.

(4) Measure the piston protrusion on the remaining cylinders

by following the same procedure.

E

May 2002Mitsubishi Motors Corporation Added

PWEE0001-B

F9Q ENGINE -

14. CYLINDER BLOCK

REMOVAL AND INSTALLATION

Cylinder Block

11

11A-14-1

2

7

10

8

9

6

1

5

55±5Nm

AA""DA

"CA

"BA
"AA

E

3

65±6Nm

Removal steps

1. Flywheel

2. Oil seal

3. Bolt

4. Bearing cap

5. Crankshaft bearing, lower

Jun. 2000Mitsubishi Motors Corporation

PWEE0001

4

6. Crankshaft

"AA
"AA

7. Crankshaft bearing, upper

8. Thrust bearing

9. Oil jet

10. Oil jet

11. Cylinder block

REN0202

11A-14-2

F9Q ENGINE – Cylinder Block

REMOVAL SERVICE POINT

AA" FLYWHEEL REMOVAL

Use special tool MB996015 to hold the flywheel during
removal.

MB996015

REN0147

INSTALLATION SERVICE POINTS

"AA CRANKSHAFT BEARING INSTALLATION

(1) Install the bearings having an oil groove to the cylinder

block.
(2) Install the bearings having no oil groove on the bearing

caps.

Thrust bearing

REN0211

REN0203

REN0204

(3) Install the thrust bearings at the No. 2 upper bearing

with the grooved side towards the crank web.

"BA BEARING CAP INSTALLATION

(1) Install the bearing caps No. 3, 4 and 5. Each bearing

cap is provided with a embossed identification number.

Install the bearing caps in the correct positions according

to the identification numbers.
(2) Use engine oil to lubricate the threads and under the

heads of the mounting bolts for the crankshaft bearing

caps. Tighten the bearing cap bolts No.3, 4, 5 to a torque

of 65 Nm. Fit the bearing cap No.2 without torque

tightening the bolts.
(3) Check the crankshaft side clearance.

Standard value: 0.07 – 0.23 mm

NOTE

If the measurement is out of specification, adjust by thrust

bearing. Four sizes of thrust bearings are available: 2.30,

2.35, 2.40 and 2.45 mm.

(4) Tighten the bolts of the bearing cap No. 2 to a torque

of 65 Nm.

REN0205

E

Mar. 2001Mitsubishi Motors Corporation Revised

PWEE0001-A

F9Q ENGINE – Cylinder Block

11A-14-3

(5) Wipe the portions (shown as (A) in the illustration) on

the cylinder block and crankshaft bearing cap with shop

towel dampened with solvent.

Wait to dry the cleaned area and then proceed to the

next step.

A

(6) Lightly coat the lower faces of the cylinder block at B

with Rhodorseal 5661.

B

(7) Fit the crankshaft bearing cap No. 1 and torque tighten

to 65 Nm.

REN0207

REN0208

(8) Mix 45 ml of Rhodorseal 5661 (approximately half a 100

grammes tube) with half measure of hardener using a

small stick to give a slightly pink coloured, uniform mixture.
(9) Put the mixture into the syringe and inject it into the

crankshaft bearing cap grooves.
(10)Allow the mixture to ooze out slightly from either side

of the grooves in the crankshaft bearing cap to be sure

that the mixture injected has completely filled the sealing

groove.
(11)Use a cloth to wipe off any excess mixture, both on the

inside and the outside of the cylinder block.

REN0209

(12)Leave to dry for a few moments then cut the surplus

from the sealing face.
(13)Check that the crankshaft turns freely.

REN0210

E

Mar. 2001Mitsubishi Motors Corporation Revised

PWEE0001-A

11A-14-4

F9Q ENGINE -

F9Q ENGINE -

Cylinder Block

Cylinder Block

MB996038

REN0136

MB996015

REN0147

"CA

OIL SEAL INSTALLATION

(1) Coat the lip of the oil seal with a thin layer of engine

oil.

(2) Locate the installer oil seal guide MB996038 over the

crankshaft.
(3) Locate the oil seal over the oil seal installer guide.
(4) Fit the oil seal with oil seal installer MB996038.

"DA

FLYWHEEL INSTALLATION

(1) Use special tool MB996015 to hold the flywheel during

installation.

E

Jun. 2000Mitsubishi Motors Corporation

PWEE0001

MITSUBISHI

ENGINE F9Q

WORKSHOP MANUAL

FOREWORD

This Workshop Manual contains procedures for
removal, disassembly, inspection, adjustment,
reassembly and installation, etc. for service
mechanics.

All information, illustrations and product
descriptions contained in this manual are current
as at the time of publication. We, however, reserve
the right to make changes at any time without prior
notice or obligation.

FILING INSTRUCTION

Please keep these manual pages in the

binder No. BN940001.
File these pages according to the signs
“Added”, “Revised” and “Deleted” on the “List
of effective pages” which are interpreted
below.

Added:

File the pages with this sign additionally in
your manual.

Revised, Deleted:

Replace the existing pages with the
corresponding pages with this sign.

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11A

Missing sheets will be supplied upon request.

E Mitsubishi Motors Corporation May 2002

Pub. No. PWEE0001-B

INTRODUCTION

EXPLANATION OF MANUAL CONTENTS

Maintenance and Servicing Procedures

(1) A diagram of the component parts is

provided near the front of each section in
order to give the reader a better under­standing of the installed condition of
component parts.

(2) The numbers provided within the diagram

indicate the sequence for maintenance and
servicing procedures.

: Indicates a non-reusable part.
The tightening torque is provided where
applicable.

D

Removal steps:
The part designation number corresponds
to the number in the illustration to indicate
removal steps.

D

Disassembly steps:
The part designation number corresponds
to the number in the illustration to indicate
disassembly steps.

D

Installation steps:
Specified in case installation is impossible
in reverse order of removal steps. Omitted
if installation is possible in reverse order
of removal steps.

D

Reassembly steps:
Specified in case reassembly is impossible
in reverse order of disassembly steps.
Omitted if reassembly is possible in reverse
order of disassembly steps.

Classification of Major Maintenance/Service Points

When there are major points relative to maintenance and servicing procedures
(such as essential maintenance and service points, maintenance and service stan­dard values, information regarding the use of special tools, etc.), these are ar­ranged together as major maintenance and service points and explained in detail.

AA"
"AA

Symbols for Lubrication, Sealants and Adhesives

Information concerning the locations for lu­brication and for application of sealants and
adhesives is provided, by using symbols, in
the diagram of component parts, or on the
page following the component parts page,
and explained.

: Indicates that there are essential points for removal or disassembly.
: Indicates that there are essential points for installation or reassembly.

: Grease

(multipurpose grease unless there is
a brand or type specified)

: Sealant or adhesive

: Brake fluid, automatic transmission fluid

or air conditioner compressor oil

: Engine oil or gear oil

INTRODUCTION

Indicates the
group title.

Indicates the
section title.

Indicates the
group number.

Indicates the
section number.

Indicates the
page number.

Denotes tightening
torque.

Denotes non-reusable part.

This number corresponds to
the number appearing in
“Removal steps”,
“Disassembly steps”,
“Installation steps” or
“Reassembly steps”.

Operating procedures, cau­tions, etc. on removal, instal­lation, disassembly and
reassembly are described.

Issue date

Publication number-Revision code

LIST OF EFFECTIVE PAGES

Page Revision

Code

1 1A-0-1 to 11A-0–3 Jun. 2000

11A-1-1 B May 2002 Revised

1 1A-1-2 and 11A-1-3 A Mar. 2001
11A-2-1 Jun. 2000
1 1A-2-2 A Mar. 2001

11A-2-3 B May 2002 Revised

1 1A-3-1 and 11A-3-2 A Mar. 2001
1 1A-4-1 A Mar. 2001

11A-4-2 B May 2002 Revised

1 1A-4-3 to 11A-4-5 A Mar. 2001
11A-5-1 Jun. 2000

11A-6-1 B May 2002 Revised

1 1A-6-2 A Mar. 2001
11A-7-1 Jun. 2000
1 1A-8-1 A Mar. 2001

Date Remarks Page Revision

Code

Date Remarks

11A-9-1 Jun. 2000
1 1A-10-1 to 11A-10-3 A Mar. 2001
11A-11-1 Jun. 2000
1 1A-11-2 A Mar. 2001
11A-11-3 Jun. 2000
1 1A-11-4 to 11A-11-6 A Mar. 2001
11A-11-7 Jun. 2000

11A-12-1 and 11A-12-2 B May 2002 Revised

1 1A-12-3 A Mar. 2001

11A-13-1 to 11A-13-3 B May 2002 Revised
11A-13-4 and 11A-13-5 B May 2002 Added

11A-14-1 Jun. 2000
1 1A-14-2 and 11A-14-3 A Mar. 2001
11A-14-4 Jun. 2000

Missing sheets will be supplied upon request.

E

May 2002Mitsubishi Motors Corporation Revised

PWEE0001-B