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ENGINE F9Q
FOREWORD
This Workshop Manual contains procedures for
removal, disassembly, inspection, adjustment,
reassembly and installation, etc. for service
mechanics.
All
information,
illustrations
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
corresponding pages with this sign.
Missing sheets will be supplied upon request.
E
Mitsubishi Motors Corporation Mar. 2001
MITSUBISHI
WORKSHOP MANUAL
and
product
pages
with
the
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pub. No. PWEE0001-A
11A
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Summary of Contents for Mitsubishi F9Q2
- Page 1 Added: File the pages with this sign additionally in your manual. Revised, Deleted: Replace existing pages with corresponding pages with this sign. Missing sheets will be supplied upon request. Pub. No. PWEE0001-A Mitsubishi Motors Corporation Mar. 2001...
- Page 2 INTRODUCTION EXPLANATION OF MANUAL CONTENTS Maintenance and Servicing Procedures (1) A diagram of the component parts is D Removal steps: provided near the front of each section in The part designation number corresponds order to give the reader a better under- to the number in the illustration to indicate standing of the installed condition of removal steps.
- Page 3 INTRODUCTION Indicates the Indicates the Indicates the Indicates the Indicates the group title. section title. group number. section number. 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”.
- Page 4 Jun. 2000 11A-14-1 Jun. 2000 11A-8-1 Mar. 2001 Revised 11A-14-2 and 11A-14-3 Mar. 2001 Revised 11A-9-1 Jun. 2000 11A-14-4 Jun. 2000 11A-10-1 and 11A-10-2 Mar. 2001 Revised Missing sheets will be supplied upon request. Mitsubishi Motors Corporation Mar. 2001 PWEE0001-A Added...
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Page 5: Table Of Contents
........11A-14-1 Mitsubishi Motors Corporation Jun. 2000... - Page 6 11A-0-2 NOTES Mitsubishi Motors Corporation Jun. 2000 PWEE0001...
- Page 7 11A-0-3 F9Q ENGINE - General Information Description Specification Type F9Q1, F9Q2 Number and arrangement of cylinders 4 in-line Total displacement 1870 cm Cylinder bore ´ Stroke 83 ´ 93 Compression ratio Valve mechanism Single overhead camshaft Number of valve Intake...
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Page 8: Specifications
Tappet height mm 34.97 - 34.99 Valve clearance mm Intake 0.20 Exhaust 0.40 Piston Piston outer diameter mm Piston ring thickness mm Piston ring No.1 Piston ring No.2 Oil ring Connecting rod length mm Mitsubishi Motors Corporation Jun. 2000 PWEE0001... -
Page 9: Torque Specifications
8 ± 0.8 EGR valve bolt 24 ± 10 Turbocharger nut 28 ± 2 Manifold nut Water pump and water pipe 10 ± 1 Water pump bolt 39 ± 3 Water inlet pipe bolt Mitsubishi Motors Corporation Mar. 2001 PWEE0001-A Revised... - Page 10 25 ± 2 Oil pump bolt 15 ± 1.5 Cylinder block front plate bolt Piston 50 ± 5 Connecting rod cap bolt Cylinder block 55 ± 5 Flywheel bolt 65 ± 6 Bearing cap bolt Mitsubishi Motors Corporation Mar. 2001 PWEE0001-A Revised...
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Page 11: Special Tools
MB996015 Flywheel stopper Locking the flywheel MB996016 Reamer Reaming valve guides MB996020 Valve guide Pressing in valve guides remover MB996021 Valve stem seal Removal of valve guide seal remover MB996024 Reamer Reaming valve guides Mitsubishi Motors Corporation Jun. 2000 PWEE0001... - Page 12 Belt tension meter Timing belt tension measurements (Use with MUT-II) MB996048 Belt pretensioner Installation of timing belt MB996043 Sprocket stopper Locking the injection pump sprocket MH062464 Gear puller Removal of fuel injection pump gear Mitsubishi Motors Corporation Mar. 2001 PWEE0001-A Revised...
- Page 13 11A-2-3 F9Q ENGINE – Special Tools MB991800 Pulley holder Crankshaft pulley holding MB991802 Pin B Mitsubishi Motors Corporation Mar. 2001 PWEE0001-A Added...
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Page 14: Crankshaft Pulley
20 ± 2 Nm ) 115_ ± 15_ 44 ± 4 Nm Removal steps 1. Alternator 2. Bracket AA" "AA 3. Crankshaft pulley 4. Idler pulley 5. Auto tensioner Mitsubishi Motors Corporation Jun. 2000 PWEE0001 Mitsubishi Motors Corporation Mar. 2001 PWEE0001-A Revised... - Page 15 (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. Mitsubishi Motors Corporation Jun. 2000 PWEE0001 Mitsubishi Motors Corporation Mar. 2001...
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Page 16: Timing Belt
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 Mitsubishi Motors Corporation Jun. 2000 PWEE0001 Mitsubishi Motors Corporation Mar. 2001 PWEE0001-A Revised... - Page 17 Bolt crankshaft is in correct position, the pin will engage with the recess in the crankshaft web. Caution Do not turn the crankshaft with the pin inserted. REN0171 Mitsubishi Motors Corporation Jun. 2000 PWEE0001 Mitsubishi Motors Corporation Mar. 2001 PWEE0001-A...
- Page 18 (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. Mitsubishi Motors Corporation Jun. 2000 PWEE0001 Mitsubishi Motors Corporation Mar. 2001...
- Page 19 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. MB996048 REN0170 Mitsubishi Motors Corporation Jun. 2000 PWEE0001 Mitsubishi Motors Corporation Mar. 2001 PWEE0001-A...
- Page 20 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 Mitsubishi Motors Corporation Jun. 2000 PWEE0001 Mitsubishi Motors Corporation Mitsubishi Motors Corporation Mar.
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Page 21: Oil Separator And Oil Return Pipe 11A-5-1
3. Oil separator hose 13. O-ring 4. Oil separator return hose 14. Turbo nipple 5. Oil separator 15. Gasket 6. O-ring 16. Oil separator return pipe 7. Oil separator holding ring 8. Engine breather pipe Mitsubishi Motors Corporation Jun. 2000 PWEE0001... -
Page 22: Injection Pump And Fuel Injector
5. Fuel injector 13. Engine hanger 6. Adjusting washer 14. Pressure regulator 7. Pressure sensor 15. Injection pump "BA 8. High pressure pipe 16. Injection pump bracket Mitsubishi Motors Corporation Jun. 2000 PWEE0001 Mitsubishi Motors Corporation Mar. 2001 PWEE0001-A Revised... - Page 23 (on the injector side A then on the fuel injection rail side High pressure Fuel injection pipe (3) Tighten the high pressure pipe C. rail REN0178 (4) Tighten the fuel injection rail bolts D. Mitsubishi Motors Corporation Jun. 2000 PWEE0001 Mitsubishi Motors Corporation Mar. 2001 PWEE0001-A Revised...
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Page 24: Vacuum Hose
11A-7-1 F9Q ENGINE - Vacuum Hose 7. VACUUM HOSE REMOVAL AND INSTALLATION REN0179 Removal steps 1. Solenoid valve 2. Vacuum hose 3. Vacuum tank Mitsubishi Motors Corporation Jun. 2000 PWEE0001... -
Page 25: Intake And Exhaust
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 Mitsubishi Motors Corporation Jun. 2000 PWEE0001 Mitsubishi Motors Corporation Mar. 2001 PWEE0001-A Revised... -
Page 26: Water Pump And Water Pipe
3. Gasket 11. O-ring 4. Thermostat case cover 12. Cooling water line pipe 5. Reinforcement 13. O-ring 6. Thermostat case cover gasket 14. Water pump 7. Thermostat 15. Water pump gasket 8. Thermostat case Mitsubishi Motors Corporation Jun. 2000 PWEE0001... -
Page 27: Camshaft And Vacuum Pump
7. Cylinder head cover gasket "BA 8. Oil seal 3. Camshaft position sensor "CA 4. Vacuum pump AA" "AA 9. Bearing cap 5. Vacuum pump gasket 10. Camshaft Mitsubishi Motors Corporation Jun. 2000 PWEE0001 Mitsubishi Motors Corporation Mar. 2001 PWEE0001-A Revised... - Page 28 "BA OIL SEAL INSTALLATION Using the special tool, install the oil seal. MB998304 "CA VACUUM PUMP INSTALLATION Install the vacuum pump while aligning coupling section with the notch in the camshaft. Mitsubishi Motors Corporation Jun. 2000 PWEE0001 Mitsubishi Motors Corporation Mar. 2001 PWEE0001-A...
- Page 29 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 Mitsubishi Motors Corporation Jun. 2000 PWEE0001 Mitsubishi Motors Corporation Mar. 2001 PWEE0001-A Added...
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Page 30: Cylinder Head 11A-11-1
8. Intake valve 3. Tappet 9. Exhaust valve AA" "CA 4. Retainer locks AB" "BA 10. Valve stem seal 5. Valve spring retainer AC" "AA 11. Valve guide AA" "CA 6. Valve spring 12. Cylinder head Mitsubishi Motors Corporation Jun. 2000 PWEE0001... - Page 31 (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 Mitsubishi Motors Corporation Mar. 2001 PWEE0001-A Revised...
- Page 32 "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 REN0074 Mitsubishi Motors Corporation Jun. 2000 PWEE0001...
- Page 33 (5) Tighten bolts 1 – 2 to 25 Nm, then angle-tighten by 213_ ± 7_. REN0183 (6) Carry out the same slackening and torque/angle tightening operations on the remaining bolts 3 – 4, 5 – 6, 7 – 8, 9 – 10. Mitsubishi Motors Corporation Mar. 2001 PWEE0001-A Revised...
- Page 34 (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 The cylinder head may not be reground. Mitsubishi Motors Corporation Mar. 2001 PWEE0001-A Revised...
- Page 35 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 Cylinder at point Cylinder being of balance checked/adjusted Y6087AJ Mitsubishi Motors Corporation Mar. 2001 PWEE0001-A Revised...
- Page 36 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. Mitsubishi Motors Corporation Jun. 2000 PWEE0001...
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Page 37: Oil Pan And Oil Pump
4. Oil cooler adaptor "BA 13. Oil seal 5. Oil cooler "AA 14. Chain pad 6. Drain plug 7. Drain plug gasket 15. Gear "CA 8. Oil pan 16. Chain Mitsubishi Motors Corporation Jun. 2000 PWEE0001 Mitsubishi Motors Corporation Mar. 2001 PWEE0001-A Revised... - Page 38 (C). Remember to fit the chain pad REN0193 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 Mitsubishi Motors Corporation Jun. 2000 PWEE0001 Mitsubishi Motors Corporation Mar. 2001 PWEE0001-A Revised...
- Page 39 (2) Tighten the oil pan bolts to 8 ± 0.8 Nm in the order shown Timing belt side in the illustration. (3) Then tighten them to 14 ± 1 Nm in the same order. Mitsubishi Motors Corporation Jun. 2000 PWEE0001 Mitsubishi Motors Corporation Mar.
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Page 40: Piston
3. Connecting rod lower bearing AB" "AA 9. Piston pin 4. Connecting rod upper bearing "CA 10. Piston "BA 5. Piston ring No. 1 "CA 11. Connecting rod "BA 6. Piston ring No. 2 Mitsubishi Motors Corporation Jun. 2000 PWEE0001... - Page 41 (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 Timing belt side Flywheel side connecting rod. Mark Mitsubishi Motors Corporation Mar. 2001 PWEE0001-A Revised...
- Page 42 (3) Measure the protrusion of No. 1 piston using a dial gauge. NOTE Protrusion Do not take measurement at valve recess. (4) Measure the piston protrusion on the remaining cylinders by following the same procedure. DEN0798 Mitsubishi Motors Corporation Mar. 2001 PWEE0001-A Revised...
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Page 43: Cylinder Block
"AA 7. Crankshaft bearing, upper AA" "DA 1. Flywheel "AA 8. Thrust bearing "CA 2. Oil seal 9. Oil jet 3. Bolt 10. Oil jet "BA 4. Bearing cap 11. Cylinder block "AA 5. Crankshaft bearing, lower Mitsubishi Motors Corporation Jun. 2000 PWEE0001... - Page 44 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 Mitsubishi Motors Corporation Mar. 2001 PWEE0001-A Revised...
- Page 45 (11)Use a cloth to wipe off any excess mixture, both on the inside and the outside of the cylinder block. REN0208 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 Mitsubishi Motors Corporation Mar. 2001 PWEE0001-A Revised...
- Page 46 (3) Locate the oil seal over the oil seal installer guide. (4) Fit the oil seal with oil seal installer MB996038. REN0136 "DA FLYWHEEL INSTALLATION (1) Use special tool MB996015 to hold the flywheel during installation. MB996015 REN0147 Mitsubishi Motors Corporation Jun. 2000 PWEE0001...
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