Mitsubishi F8QT User Manual
ENGINE
F8QT SERIES
CONTENTS
GENERAL INFORMATION 11A-0-3...............................
1. SPECIFICATIONS 11A-1-1...................................
SERVICE SPECIFICATIONS 11A-1-1........................
TORQUE SPECIFICATIONS 11A-1-5........................
FORM-IN-PLACE GASKET 11A-1-8.........................
2. SPECIAL TOOLS 11A-2-1....................................
3. CRANKSHAFT PULLEY 11A-3-1..............................
4. TIMING BELT 11A-4-1.......................................
5. WATER PUMP 11A-5-1......................................
6. THERMOSTAT 11A-6-1......................................
7. WATER HOSES AND PIPES 11A-7-1..........................
8. ENGINE COOLANT TEMPERATURE SENSOR 11A-8-1.........
9. GLOW PLUGS 11A-9-1......................................
10. TURBOCHARGER 11A-10-1...................................
11. INTAKE AND EXHAUST MANIFOLDS 11A-11-1.................
12. ROCKER COVER AND CYLINDER HEAD 11A-12-1..............
13. CAMSHAFT, INTAKE AND EXHAUST VALVES 11A-13-1.........
14. VACUUM PUMP 11A-14-1.....................................
15. OIL COOLER AND OIL FILTER 11A-15-1.......................
16. OIL PAN, OIL PUMP AND OIL JETS 11A-16-1...................
17. INTERMEDIATE SHAFT AND INTERMEDIATE
SHAFT BEARINGS 11A-17-1..................................
18. FUEL INJECTION NOZZLE 11A-18-1...........................
19. FUEL INJECTION PUMP 11A-19-1.............................
20. PISTONS AND CONNECTING RODS 11A-20-1..................
21. PISTONS AND PISTON PINS 11A-21-1.........................
22. FLYWHEEL 11A-22-1.........................................
23. CRANKSHAFT AND CYLINDER BLOCK 11A-23-1...............
11A-0-1
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11A-0-2
NOTES
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F8QT ENGINE -
GENERAL INFORMATION
SECTIONAL VIEW OF ENGINE
General Information
11A-0-3
REN0137
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11A-0-4
F8QT ENGINE -
SECTIONAL VIEW OF ENGINE
General Information
REN0138
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F8QT ENGINE -
SECTIONAL VIEW OF ENGINE
General Information
11A-0-5
REN0139
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11A-0-6
Description Specifications
Type F8QT diesel engine
Number and arrangement of cylinders 4 in-line
Combustion chamber Swirl chamber
F8QT ENGINE -
General Information
Total displacement 1870 cm
Cylinder bore ´ stroke 80 ´ 93 mm
Compression ratio 21
V alve mechanism Single overhead camshaft
Number of valves Intake 4
Exhaust 4
V alve timing Intake opening 0_ BTDC
Intake closing 18_ ABDC
Exhaust opening 41_ BBDC
Exhaust closing 0_ ATDC
Turbocharger Exhaust gas turbocharger
Intercooler (charge cooling) Air-cooled
Fuel injection pump Electric with immobilizer
3
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F8QT ENGINE -
Specifications
1. SPECIFICATIONS
SERVICE SPECIFICATIONS
Item Standard Limit
Cylinder head
Flatness of cylinder head surface mm 0.05 -
Cylinder head gasket
11A-1-1
Gasket thickness
mm
Cylinder block
Cylinder diameter mm Class A 80.006 - 80.024 -
Pistons
Piston-to-cylinder clearance mm 0.021 - 0.055 -
Standard, class A 79.971 - 79.985 -
Standard, class B 80.221 - 80.235 -
Piston rings
Height mm Top 2.5 -
Projecting height of
piston - 0.073
Projecting height of
piston 0.073 - 0.206
Projecting height of
piston 0.206 -
Number of holes; 2 1.4 -
Number of holes; 1 1.5 -
Number of holes; 3 1.6 -
Class B 80.256 - 80.274 -
Bottom 2 -
Oil 3 -
Axial clearance in piston groove mm Top 0.030 - 0.065 -
Bottom 0.030 - 0.065 -
Oil 0.030 - 0.065 -
Fitted gap (in cylinder) mm To p 0.30 - 0.40 -
Bottom 0.25 - 0.40 -
Oil 0.25 - 0.50 -
Piston pin
Diameter mm 26 -
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11A-1-2
Item LimitStandard
Camshaft
Cam height Intake 8.5 -
Camshaft end play mm 0.048 - 0.133 -
Radial clearance mm 0.050 - 0.150 -
Valves
Valves clearance Checking Intake 0.15 - 0.25 mm
Adjusting Intake 0.2 -
V alve diameter mm Intake 36.22 -
F8QT ENGINE -
Exhaust 10.34 -
Exhaust 0.35 - 0.45 -
Exhaust 0.4 -
Exhaust 31.62 -
Specifications
V alve seat angle Intake 60_ -
Exhaust 45_ -
Valve seat width mm Intake 1.8 ± 0.2 -
Exhaust 1.8 -
Valve springs
Length mm Loading 0 N 43.9 -
Loading 250 N 36.8 -
Loading 612 N 26.4 -
Tappets
Diameter (tolerance) mm 35 -
Height mm 26.3 -
Clearance in cylinder block mm 0.025 - 0.075 -
Valve guides
Inside diameter mm 8 -
Outside diameter mm Standard
(no grooves)
Oversize 1
(two grooves)
Tappet pads
Thickness (increasing by increments of 0.05) mm 2.50 - 3.70 -
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13 -
13.3 -
F8QT ENGINE -
Item LimitStandard
Intermediate shaft
Inner bearing mm 39.5 -
Outer bearing mm 40.5 -
End play mm 0.07 - 0.15 -
Crankshaft
End play mm 0.07 - 0.23 -
Thrust washer thickness mm 2.30 - 2.50 -
Radial clearance (main bearings) mm 0.04 - 0.07 -
Main bearing journals
Ovality mm - 0.0025
Taper mm - 0.005
Diameter mm Standard (blue) 54.785 - 54.805 -
Specifications
11A-1-3
Standard (red) 54.795 - 54.805 -
Undersize 1 54.550 - 54.560 -
Big-end bearing journals
Ovality mm - 0.0025
Taper mm - 0.005
Diameter mm Standard 48.00 - 48.02 -
Undersize 1 47.75 - 47.77 -
Bearing recess width mm 20.25 - 20.95 -
Relative difference mm - 0.02
Connecting rod (big-end) bearings
Axial clearance mm 0.22 - 0.40 -
Radial clearance mm 0.031 - 0.075 -
Connecting rods
Length mm 144 ± 0.02 -
Small end inside diameter mm 26.013 - 26.025 -
Squareness, top/bottom mm - 0.04
Straightness mm - 0.1
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11A-1-4
Item LimitStandard
Flywheel
Axial throw measured at a radius of 80 mm mm - 0.07
Oil pump
End play mm 0.02 - 0.08 -
Clearance, gears to pump body (backlash) mm 0.10 - 0.24 -
Bearing clearance, drive shaft mm 0.024 - 0.49 -
Number of teeth on oil pump sprocket 8 -
Oil pressure regulator spring
Length mm Loading 0 N 74.6 -
Lubrication system
F8QT ENGINE -
Loading 10.2 N 48.2 -
Loading 70 N 41.2 -
Specifications
Oil capacity, exclusive of oil filter L 4.8 -
Oil capacity, inclusive of oil filter L 5.3 -
Difference between MAX-MIN marks on dipsitck L 1.7 -
Oil pressure with new filter and hot engine - 13 r/s (1,000 rpm) - 200
(min.) kPa
- 50 r/s (3,000 rpm) - 350
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F8QT ENGINE -
Specifications
TORQUE SPECIFICATIONS
Items Nm
Crankshaft pulley
Crankshaft pulley bolt 120
Timing belt
Camshaft sprocket bolt 50
Water pump
Water pump pulley bolt 20
Water pump bolt 12.5
Thermostat
Thermostat cover bolt 10
Thermostat housing bolt 10
Bleedscrew 0.6
11A-1-5
Glow plugs
Glow plug 22.5
Glow plug nut 5
Turbocharger
Turbocharger nut 45
Exhaust downpipe connector nut 45
Oil supply pipe union nut 35
Oil return pipe union nut 25
Coolant supply pipe banjo bolt 25
Coolant supply pipe retaining nut 28.7
Coolant discharge pipe union nut 25
Coolant discharge pipe retaining nut 8
Intake and exhaust manifolds
EGR valve 19.5
EGR pipe 19.5
Oil pipe union nut 30
Oil pipe retaining nut 8
Manifold nut 25
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11A-1-6
Items Nm
Rocker cover and cylinder head
Rocker cover nut 5
Cylinder head bolt 30 + 50_ ± 4_ + fully slacken + 25 + 213_ ± 2_
Camshaft, intake and exhaust valves
Camshaft bearing cap bolt (M6) 10
Camshaft bearing cap bolt (M8) 20
Glow plug 22.5
Fuel injection nozzle 70
Vacuum pump
V acuum pump bolt 22
Vacuum hose union nut 22
F8QT ENGINE -
Specifications
+ (warm up) 120_ ± 7_
Oil cooler and oil filter
Thermostat housing nut 60
Plug 35
Oil cooler nut 60
Oil pan, oil pump and oil jets
Oil drain plug 15
Oil pan bolt 13
Oil pump cover bolt 12
Oil pump body bolt 22
Oil jet 20
Intermediate shaft and intermediate shaft bearings
Intermediate shaft sprocket bolt 50
Intermediate shaft cover bolt 15
Intermediate shaft lockplate bolt 15
Cover bolt 15
Fuel injection nozzle
Injection pipe union nut 22.5
Nozzle body 70
Retaining nut 70
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F8QT ENGINE -
Items Nm
Fuel injection pump
Injection pipe union nut 22.5
Screwed sleeve/nut assembly 90
Nut 70
Injection pump bolt 22.5
Bolt 20
Pistons and connecting rods
Connecting rod cap bolt 45
Flywheel
Flywheel bolt 53
Crankshaft and cylinder block
Main bearing cap bolt 65
Specifications
11A-1-7
Front plate bolt 12.5
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11A-1-8
F8QT ENGINE -
Specifications
FORM-IN-PLACE GASKET
The engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket
fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead
size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick
a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the
fluid feed line. To eliminate the possibly of leaks from a joint, therefore, it is absolutely necessary to
apply the gasket evenly without a break, while observing the correct bead size.
The FIPG used in the engine is a room temperature vulcanization (RTV) type. Since the RTV hardens
as it reacts with the moisture in the atmospheric air, it is normally used in the metallic flange areas.
Disassembly
The parts assembled with the FIPG can be easily disassembled without use of a special method. In
some cases, however, the sealant between the joined surfaces may have to be broken by lightly striking
with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the
joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces.
For removal of the oil pan, the special tool “Oil Pan Remover” is available. Be sure to use the special
tool to remove the oil pan.
Surface Preparation
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper
or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure
that there are no oils, greases and foreign substances deposited on the application surfaces. Do not
forget to remove the old sealant remained in the bolt holes.
Form-In-Place Gasket Application
When assembling parts with the FIPG, you must observe some precautions, bu t the procedures is very
simple as in the case of a conventional precut gasket.
Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the
bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is
hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When
the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do
not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time
(about one hour) has passed after installation is completed.
The FIPG applications procedure may vary on different areas. Observe the procedure described in the
text when applying the FIPG.
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F8QT ENGINE -
Special Tools
2. SPECIAL TOOLS
Tool Number Name Use
11A-2-1
MB990767 Camshaft sprocket
holder
MB991614 Angle gauge Tightening cylinder head bolts
MB996014 Valve spring
compressor
MB996015 Flywheel stopper Locking the flywheel
Removal of camshaft sprocket
Removal of valve spring split cones
MB996016 Reamer Reaming valve guides
MB996018 Slip gauge Measuring the crankshaft end play
MB996020 Valve guide
remover
MB996021 Valve stem seal
remover
Pressing in valve guides
Removal of valve guide seal
MB996022 Valve seat installer Pressing in intake valve seat
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11A-2-2
Tool UseNameNumber
MB996023 Valve seat installer Pressing in intake valve seat
MB996024 Reamer Reaming valve guides
MB996025 Bearing puller Removal of intermediate shaft outer bearing
MB996026 Bearing puller Removal of intermediate shaft inner bearing
F8QT ENGINE -
Special Tools
MB996027 Bearing installer Installation of intermediate shaft inner bearing
MB996028 Bearing installer Installation of intermediate shaft outer bearing
MB996029 Valve guide
installer
MB996030 Measuring device
adapter
Pressing in valve guides
Adjustment of fuel injection pump
MB996031 Valve stem seal
installer
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Installation of valve guide seal
Tool UseNameNumber
MB996032 Tension gauge Measuring timing belt deflection
MB996033 Tension gauge Measuring timing belt deflection
MB996034 Sprocket stopper Removal of intermediate shaft sprocket
MB996036 Hexagon socket Removal of injection pump sprocket screwed
F8QT ENGINE -
Special Tools
sleeve/nut assembly
11A-2-3
MB996037 Sprocket adapter Adjustment of fuel injection pump
MB996038 Oil seal installer Installation of crankshaft oil seal (flywheel end)
MB996039 Oil seal installer Installation of intermediate shaft oil seal
MB996040 Oil seal installer Installation of crankshaft oil seal (timing gear
end)
MB996041 Special socket Removal of fuel injectors
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11A-2-4
Tool UseNameNumber
MB996042 Oil seal installer Installation of camshaft oil seal
MB996043 Sprocket stopper Locking the injection pump sprocket
MD998715 Pulley holder pin Retaining the camshaft sprocket (use together
F8QT ENGINE -
Special Tools
with MB990767)
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F8QT ENGINE -
3. CRANKSHAFT PULLEY
Crankshaft Pulley
11A-3-1
120 Nm
2
1
Removal steps
AA""AA 1. Crankshaft pulley bolt
2. Crankshaft pulley
REN0143
REMOVAL SERVICE POINT
AA"
Use special tool MB996015 to hold the flywheel during
removal.
MB996015
REN0144
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CRANKSHAFT PULLEY BOLT REMOVAL
PWEE9602
11A-3-2
F8QT ENGINE -
MB996015
REN0144
Crankshaft Pulley
INSTALLATION SERVICE POINT
"AA
(1) Use special tool MB996015 to hold the flywheel during
(2) Apply a locking agent to the screw thread of the bolt.
CRANKSHAFT PULLEY INSTALLATION
installation.
Tighten the bolt to the specified torque.
REN0145
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F8QT ENGINE -
4. TIMING BELT
REMOVAL AND INSTALLATION
Timing Belt
11A-4-1
12
50 Nm
10
11
9
8
13
REN0001
Removal steps
1. Bolt
2. Bolt
3. Nut
4. Engine support bracket
5. Timing gear case cover
6. Timing gear case cover
7. Timing gear case cover
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AA""BA
AB""AA
8. Timing belt
9. Camshaft sprocket bolt
10. Camshaft sprocket
11. Camshaft sprocket key
12. Timing belt tensioner
13. Timing belt idler
11A-4-2
REN0002
F8QT ENGINE -
REMOVAL SERVICE POINTS
AA"
(1) Turn the crankshaft clockwise so that the piston of No.
(2) Insert an 8 mm diameter locking pin in the threaded hole
(3) Slacken the lock nut of the timing belt tensioner.
TIMING BELT REMOVAL
1 cylinder (flywheel end) is at TDC, with the following
marks in line with each other:
D flywheel/clutch housing;
D rear guard plate/camshaft sprocket.
Scribe a mark on the injection pump mounting bracket.
of torx bolt2so that it engages the recess in the crankshaft
web.
Remove the timing belt.
Timing Belt
50 Nm
REN0004
MB990767
REN0003
MB990767
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
(1) Smear the retaining bolt with a locking agent.
"BA
(1) Turn the camshaft clockwise with special tool MB990767
(2) Turn the crankshaft 1/4 revolution counter-clockwise from
(3) Align the mark on the injection pump sprocket with the
CAMSHAFT SPROCKET BOLT INSTALLATION
Use special tool MB990767, camshaft sprocket holder
with pin MD998715 to stop the sprocket turning and then
tighten the camshaft sprocket retaining bolt to 50 Nm.
TIMING BELT INSTALLATION
until the mark on the camshaft sprocket is opposite the
mark on the guard plate.
the TDC position of No. 1 cylinder and insert the 8 mm
diameter locking pin in the recess in the crankshaft web.
mark on th e mounting bracket (turn clockwise).
REN0005
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REN0006
MB996032
MB996033
F8QT ENGINE -
(4) Fit the timing belt so that the lines on the belt are aligned
with the marks on t h e crankshaft and camshaft sprockets
and the injection pump sprocket.
NOTE
D the direction of rotation of th e belt (see the arrows
on the belt);
D the sequence in which the belt is fitted around the
sprockets.
(5) Fit the special tool on the timing belt and the timing belt
tensioner.
(6) Tension the timing belt with the aid of an M6 bolt.
Standard value: 7 .5 mm
(7) Tighten the lock nut to the specified torque.
Timing Belt
11A-4-3
REN0007
INSPECTION
TIMING BELT
Should either of the following defects be evident, replace
the belt with a new one:
(1) Hardened back surface rubber.
Glossy, non-elastic and so hard that no mark is produced
when scratched with a fingernail.
8EN0066
3
4
2
5
8EN0044
(2) Cracked back surface rubber.
(3) Cracked or separated canvas.
(4) Cracked tooth bottom.
(5) Cracks in back surface of belt.
(6) Abnormal wear on the sides of the belt. A normal belt
should have clear-cut sides as if cut by a sharp knife.
8EN0067
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