Page 1
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 Mar. 2001
Pub. No. PWEE0001-A
Page 2
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
Page 3
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
Page 4
LIST OF EFFECTIVE PAGES
Page Revision
Code
1 1A-0-1 to 11A-0–3 Jun. 2000
11A-1-1 Jun. 2000
11A-1-2 and 11A-1-3 A Mar. 2001 Revised
11A-2-1 Jun. 2000
11A-2-2 A Mar. 2001 Revised
11A-2-3 A Mar. 2001 Added
11A-3-1 and 11A-3-2 A Mar. 2001 Revised
11A-4-1 to 11A-4-5 A Mar. 2001 Revised
11A-5-1 Jun. 2000
11A-6-1 and 11A-6-2 A Mar. 2001 Revised
11A-7-1 Jun. 2000
11A-8-1 A Mar. 2001 Revised
11A-9-1 Jun. 2000
11A-10-1 and 11A-10-2 A Mar. 2001 Revised
Date Remarks Page Revision
Code
Date Remarks
11A-10-3 A Mar. 2001 Added
11A-11-1 Jun. 2000
11A-11-2 A Mar. 2001 Revised
11A-11-3 Jun. 2000
11A-11-4 to 11A-11-6 A Mar. 2001 Revised
11A-11-7 Jun. 2000
11A-12-1 and 11A-12-2 A Mar. 2001 Revised
11A-12-3 A Mar. 2001 Added
11A-13-1 Jun. 2000
11A-13-2 and 11A-13-3 A Mar. 2001 Revised
11A-14-1 Jun. 2000
11A-14-2 and 11A-14-3 A Mar. 2001 Revised
11A-14-4 Jun. 2000
Missing sheets will be supplied upon request.
E
Mar . 2001Mitsubishi Motors Corporation Added
PWEE0001-A
Page 5
ENGINE
F9Q SERIES
CONTENTS
GENERAL INFORMATION 11A-0-3...............................
1. SPECIFICATIONS 11A-1-1...................................
SERVICE SPECIFICATIONS 11A-1-1........................
TORQUE SPECIFICATIONS 11A-1-2.........................
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
E
Jun. 2000Mitsubishi Motors Corporation
PWEE0001
Page 6
11A-0-2
NOTES
E
Jun. 2000Mitsubishi Motors Corporation
PWEE0001
Page 7
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
_
_
_
_
E
Jun.2000MitsubishiMotorsCorporation
PWEE0001
Page 8
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 -
11A-1-1
Valve seat angle 45
Valve projection mm - 0.03 - 0.21 -
Cylinder head overall height mm 161.9 - 162.1 -
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 -
E
Jun. 2000Mitsubishi Motors Corporation
PWEE0001
Page 9
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
E
Mar . 2001Mitsubishi Motors Corporation Revised
PWEE0001-A
Page 10
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
E
Mar . 2001Mitsubishi Motors Corporation Revised
PWEE0001-A
Page 11
F9Q ENGINE -
Special Tools
2. SPECIAL TOOLS
Tool Number Name Use
11A-2-1
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
E
Jun. 2000Mitsubishi Motors Corporation
PWEE0001
Page 12
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
E
Mar . 2001Mitsubishi Motors Corporation Revised
PWEE0001-A
Page 13
F9Q ENGINE – Special Tools
MB991800 Pulley holder Crankshaft pulley holding
MB991802 Pin B
11A-2-3
E
Mar . 2001Mitsubishi Motors Corporation Added
PWEE0001-A
Page 14
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
Jun. 2000Mitsubishi Motors Corporation
E
E
Mar . 2001Mitsubishi Motors Corporation Revised
PWEE0001
PWEE0001-A
Page 15
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.
Jun. 2000Mitsubishi Motors Corporation
E
E
Mar . 2001Mitsubishi Motors Corporation Revised
PWEE0001
PWEE0001-A
Page 16
F9Q ENGINE – Timing Belt
4. TIMING BELT
REMOVAL AND INSTALLATION
9 ± 0.9 Nm
11A-4-1
60 ± 6 Nm
2
6
3
50 ± 5 Nm
5
8
4
1
10 ± 1 Nm
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
Jun. 2000Mitsubishi Motors Corporation
E
E
Mar . 2001Mitsubishi Motors Corporation Revised
PWEE0001
PWEE0001-A
7
REN0166
Page 17
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
MB990767
Bolt
REN0212
MB990767
REN0213
AB" CAMSHAFT SPROCKET BOLT REMOVAL
(1) Use special tool MB990767, camshaft sprocket holder
with pin MD998715 and remove the retaining bolt.
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
Nm.
"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
REN0171
Jun. 2000Mitsubishi Motors Corporation
E
E
Mar . 2001Mitsubishi Motors Corporation Revised
D Do not turn the crankshaft with the pin inserted.
PWEE0001
PWEE0001-A
Page 18
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.
Jun. 2000Mitsubishi Motors Corporation
E
E
Mar . 2001Mitsubishi Motors Corporation Revised
PWEE0001
PWEE0001-A
Page 19
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
Jun. 2000Mitsubishi Motors Corporation
E
E
Mar . 2001Mitsubishi Motors Corporation Revised
PWEE0001
PWEE0001-A
Page 20
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
Jun. 2000Mitsubishi Motors Corporation
Mar . 2001Mitsubishi Motors Corporation RevisedPWEE0001-A
E
E
E
Mar . 2001Mitsubishi Motors Corporation Revised
PWEE0001
PWEE0001-A
Page 21
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
4
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
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
E
Jun. 2000Mitsubishi Motors Corporation
PWEE0001
Page 22
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
15
4
7
1
25 ± 2 Nm
35 ± 5 Nm
14
3
11
8
25 ± 2 Nm
2
5
6
10
9
25 ± 2 Nm
REN0174
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
Jun. 2000Mitsubishi Motors Corporation
E
E
Mar . 2001Mitsubishi Motors Corporation Revised
PWEE0001
PWEE0001-A
AA""AA 12. Injection pump sprocket
"BA 11. Fuel injection rail
9. Pressure limiter
10. Pressure limiter nipple
13. Engine hanger
14. Pressure regulator
15. Injection pump
16. Injection pump bracket
Page 23
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
C
Fuel injection
rail
High pressure pipe
B
D
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.
Jun. 2000Mitsubishi Motors Corporation
E
E
Mar . 2001Mitsubishi Motors Corporation Revised
PWEE0001
PWEE0001-A
Page 24
F9Q ENGINE -
7. VACUUM HOSE
REMOVAL AND INSTALLATION
Vacuum Hose
11A-7-1
3
2
1
REN0179
Removal steps
1. Solenoid valve
2. Vacuum hose
3. Vacuum tank
E
Jun. 2000Mitsubishi Motors Corporation
PWEE0001
Page 25
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
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
4
8 ± 0.8 Nm
Jun. 2000Mitsubishi Motors Corporation
E
E
Mar . 2001Mitsubishi Motors Corporation Revised
PWEE0001
PWEE0001-A
Page 26
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
10
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
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
E
Jun. 2000Mitsubishi Motors Corporation
PWEE0001
Page 27
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
Jun. 2000Mitsubishi Motors Corporation
E
E
Mar . 2001Mitsubishi Motors Corporation Revised
PWEE0001
PWEE0001-A
AA""AA 9. Bearing cap
"BA 8. Oil seal
6. Cylinder head cover
7. Cylinder head cover gasket
10. Camshaft
Page 28
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.
Jun. 2000Mitsubishi Motors Corporation
E
E
Mar . 2001Mitsubishi Motors Corporation Revised
PWEE0001
PWEE0001-A
Page 29
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
Jun. 2000Mitsubishi Motors Corporation
E
E
Mar . 2001Mitsubishi Motors Corporation Added
PWEE0001
PWEE0001-A
Page 30
F9QENGINE-
11.CYLINDERHEAD
REMOVALANDINSTALLATION
1
_
_
30Nm+50
®
Fullyloosen
25Nm+213
®
±
4
_
_
7
±
10
11
CylinderHead
3
4
5
11A-11-1
"EA
"DA
AA""CA
AA""CA
2
Removalsteps
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
E
Jun.2000MitsubishiMotorsCorporation
PWEE0001
Page 31
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
E
Mar . 2001Mitsubishi Motors Corporation Revised
PWEE0001-A
Page 32
F9Q ENGINE -
F9Q ENGINE -
Cylinder Head
Cylinder Head
11A-11-3
MB996031
MB996029
9,000 N
MB996024
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
E
REN0074
Jun. 2000Mitsubishi Motors Corporation
PWEE0001
Page 33
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
Page 34
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
REN0187
(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
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
Page 35
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
Cylinder at point
of balance
E
Exterior diameter
Cylinder being
checked/adjusted
Mar . 2001Mitsubishi Motors Corporation Revised
REN0190
Y6087AJ
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
VALVE CLEARANCE CHECK AND ADJUSTMENT
(1) The valve clearances have to be checked/adjusted in
the following sequence.
Cylinder at point of balance Cylinder being checked/
adjusted
1 4
2 3
3 2
4 1
PWEE0001-A
Page 36
F9Q ENGINE -
F9Q ENGINE -
F9Q ENGINE -
(2) Measure the valve clearance.
Standard value:
Cold engine Checking Adjusting
Intake valve mm 0.15- 0.20 0.20
Exhaust valve mm 0.35- 0.45 0.40
(3) If the valve clearance is outside the standard value, adjust
REN0013
(4) Take valve clearance measurement again at the cylinder
Cylinder Head
Cylinder Head
Cylinder Head
11A-11-7
by replacing the tappets using the following procedure.
where the valve clearance is not within the tolerance,
and record the measured value.
Adapter
Wall
thickness (X)
Micrometer
Y6091AJ
(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
Page 37
F9Q ENGINE – Oil Pan and Oil Pump
12. OIL PAN AND OIL PUMP
REMOVAL AND INSTALLATION
13
12
15 ± 1.5 Nm
11A-12-1
2
1
14
15
16
11
4
5
3
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
Jun. 2000Mitsubishi Motors Corporation
E
E
Mar . 2001Mitsubishi Motors Corporation Revised
PWEE0001
PWEE0001-A
AA" 10. Oil plate
AB""AA 12. Cylinder block plate, front
"BA 13. Oil seal
"AA 14. Chain pad
9. Oil pan gasket
11. Oil pump
15. Gear
16. Chain
Page 38
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
(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
REN0193
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
Jun. 2000Mitsubishi Motors Corporation
E
E
Mar . 2001Mitsubishi Motors Corporation Revised
PWEE0001
PWEE0001-A
Page 39
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
17
21
Timing belt side
13
18
14
985
10
(2) Tighten the oil pan bolts to 8 ± 0.8 Nm in the order shown
4
1
3
2
6
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
Page 40
13. PISTON
REMOVAL AND INSTALLATION
8
F9Q ENGINE -
Piston
11A-13-1
5
6
7
10
9
50±5Nm
4
3
11
2
1
REN0195
AA"
E
"BA
"BA
Removal steps
1. Connecting rod bolt
2. Connecting rod cap
3. Connecting rod lower bearing
4. Connecting rod upper bearing
5. Piston ring No. 1
6. Piston ring No. 2
Jun. 2000Mitsubishi Motors Corporation
PWEE0001
AB""AA
AB""AA
"CA
"CA
7. Oil ring
8. Snap ring
9. Piston pin
10. Piston
11. Connecting rod
Page 41
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.
Marking
Mark
REN0196
INSTALLATION SERVICE POINTS
"AA PISTON PIN INSTALLATION
(1) Apply engine oil to the piston pin before inserting it into
the piston and connecting rod.
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.
"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.
Timing belt side Flywheel side
Mark
E
Mar . 2001Mitsubishi Motors Corporation Revised
"CA 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.
PWEE0001-A
Page 42
F9Q ENGINE – Piston
11A-13-3
(4) Tighten the new connecting rod bearing cap bolts to a
torque of 50 Nm.
50 Nm
REN0114
INSPECTION
PISTON
(1) Measure the piston diameter at a point where A = 39
A
mm
Standard value: 80 mm
REN0200
Protrusion
REN0199
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
PISTON PROTRUSION
(1) Clean the piston crown to remove deposits.
(2) Turn the crankshaft in the direction of operation to bring
piston No. 1 to TDC.
(3) Measure the protrusion of No. 1 piston using a dial gauge.
NOTE
Do not take measurement at valve recess.
(4) Measure the piston protrusion on the remaining cylinders
by following the same procedure.
DEN0798
E
Mar . 2001Mitsubishi Motors Corporation Revised
PWEE0001-A
Page 43
F9Q ENGINE -
14. CYLINDER BLOCK
REMOVAL AND INSTALLATION
Cylinder Block
11
11A-14-1
2
7
8
10
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
Page 44
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
Page 45
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
Page 46
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
Loading...