Mitsubishi F9Q2 Instruction manual

Pub. No. PWEE0001-A
11A
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
EMitsubishi Motors Corporation Mar. 2001
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.
Missing sheets will be supplied upon request.

INTRODUCTION
Symbols for Lubrication, Sealants and Adhesives
Information concerning the locations for lu-
brication 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.
: 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
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 under-
standing 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.
DRemoval steps:
The part designation number corresponds
to the number in the illustration to indicate
removal steps.
DDisassembly steps:
The part designation number corresponds
to the number in the illustration to indicate
disassembly steps.
DInstallation steps:
Specified in case installation is impossible
in reverse order of removal steps. Omitted
if installation is possible in reverse order
of removal steps.
DReassembly steps:
Specified in case reassembly is impossible
in reverse order of disassembly steps.
Omitted if reassembly is possible in reverse
order of disassembly steps.
EXPLANATION OF MANUAL CONTENTS
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 stan-
dard values, information regarding the use of special tools, etc.), these are ar-
ranged together as major maintenance and service points and explained in detail.
AA": Indicates that there are essential points for removal or disassembly.
"AA: Indicates that there are essential points for installation or reassembly.

Indicates the
group title.
Indicates the
section title.
Indicates the
group number.
Indicates the
section number.
Indicates the
page number.
Denotes tightening
torque.
Operating procedures, cau-
tions, etc. on removal, instal-
lation, disassembly and
reassembly are described.
Publication number-Revision code
This number corresponds to
the number appearing in
“Removal steps”,
“Disassembly steps”,
“Installation steps” or
“Reassembly steps”.
Denotes non-reusable part.
Issue date
INTRODUCTION

11A-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
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
LIST OF EFFECTIVE PAGES
Page Revision
Code Date Remarks Page Revision Code Date Remarks
Missing sheets willbe suppliedupon request.
PWEE0001-A
EMar. 2001Mitsubishi Motors Corporation Added

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
ENGINE
F9Q SERIES
CONTENTS
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11A-0-2
NOTES
PWEE0001
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F9QENGINE-GeneralInformation 11A-0-3
Description Specification
Type F9Q1,F9Q2
Numberandarrangementofcylinders 4in-line
Totaldisplacement 1870cm3
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)
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F9Q ENGINE - Specifications 11A-1-1
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 -
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 -
PWEE0001
EJun. 2000Mitsubishi Motors Corporation

F9Q ENGINE – Specifications
11A-1-2
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
PWEE0001-A
EMar. 2001Mitsubishi Motors Corporation Revised

F9Q ENGINE – Specifications 11A-1-3
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
Cylinder block
Flywheel bolt 55 ±5
Bearing cap bolt 65 ±6
PWEE0001-A
EMar. 2001Mitsubishi Motors Corporation Revised

F9Q ENGINE - Special Tools 11A-2-1
2. SPECIAL TOOLS
Tool Number Name Use
MB990767 Camshaft sprocket
holder
Removal of camshaft sprocket
MD998715 Pulley holder pin Retaining the camshaft sprocket (use together
with MB990767)
MB991614 Angle gauge Tightening cylinder head bolts
MB996014 Valve spring
compressor
Removal of valve spring split cones
MB996015 Flywheel stopper Locking the flywheel
MB996016 Reamer Reaming valve guides
MB996020 Valve guide
remover
Pressing in valve guides
MB996021 Valve stem seal
remover
Removal of valve guide seal
MB996024 Reamer Reaming valve guides
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F9Q ENGINE – Special Tools
11A-2-2
MB996029 Valve guide
installer Pressing in valve guides
MB996031 Valve stem seal
installer Installation of valve guide seal
MB996038 Oil seal installer Installation of crankshaft oil seal (flywheelend)
MB996040 Oil seal installer Installation of crankshaft oil seal (timing gear
end)
MB991502 MUT-II
sub-assembly DDrive belt tension measurement
DFuel injection timing check and adjustment
DIdle speed check
MB991668 Belt tension meter
set 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
PWEE0001-A
EMar. 2001Mitsubishi Motors Corporation Revised

F9Q ENGINE – Special Tools 11A-2-3
MB991800 Pulley holder Crankshaft pulley holding
MB991802 Pin B
PWEE0001-A
EMar. 2001Mitsubishi Motors Corporation Added

F9Q ENGINE – Crankshaft Pulley 11A-3-1
3. CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
20 ±2 Nm
)115_±15_
4
5
2
3
44 ±4 Nm
1
Removal steps
1. Alternator
2. Bracket
AA""AA3. Crankshaft pulley
4. Idler pulley
5. Auto tensioner
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F9Q ENGINE – Crankshaft Pulley
11A-3-2
REMOVAL SERVICE POINT
AA"CRANKSHAFT PULLEY REMOVAL
(1) Use special tool MB991800 and MB991802 to hold the
crankshaft pulley during removal.
INSTALLATION SERVICE POINT
"AACRANKSHAFT PULLEY INSTALLATION
Caution
DDo 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.
PWEE0001
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EMar. 2001Mitsubishi Motors Corporation Revised
MB991800
MB991802
MB991800
MB991802

F9Q ENGINE – Timing Belt 11A-4-1
4. TIMING BELT
REMOVAL AND INSTALLATION
REN0166
2
3
41
8
5
6
7
9 ±0.9 Nm
60 ±6 Nm
10 ±1 Nm
50 ±5 Nm
Removal steps
1. Timing belt cover, front
AA""BA2. Timing belt
3. Tensioner pulley
4. Crankshaft sprocket
5. Tensioner plate
AB""AA6. Camshaft sprocket
7. Engine cover bracket
8. Timing belt cover, rear
PWEE0001
EJun. 2000Mitsubishi Motors Corporation PWEE0001-A
EMar. 2001Mitsubishi Motors Corporation Revised

F9Q ENGINE – Timing Belt
11A-4-2
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
DThe 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
DDo not turn the crankshaft with the pin inserted.
(4) Slacken the lock nut of the timing belt tensioner.
Remove the timing belt.
AB"CAMSHAFT SPROCKET BOLT REMOVAL
(1) Use special tool MB990767, camshaft sprocket holder
with pin MD998715 and remove the retaining bolt.
INSTALLATION SERVICE POINTS
"AACAMSHAFT 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.
"BATIMING 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
DDo not turn the crankshaft with the pin inserted.
PWEE0001
EJun. 2000Mitsubishi Motors Corporation
Timing
belt cover
Timing mark
Window
PWEE0001-A
EMar. 2001Mitsubishi Motors Corporation Revised
REN0171
Bolt
REN0212
MB990767
MD998715
REN0213
MB990767
MD998715
REN0171
Bolt

F9Q ENGINE – Timing Belt 11A-4-3
(4) Check that the crankshaft groove C is located at the
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.
(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)
(7) Place the tensioner pulley against the belt by tightening
bolt E on the tensioner support.
Caution
DDo not reuse the removed timing belt.
(8) Remove the pin installed in Step 3.
(9) Set the special tools on the crankshaft sprocket.
(10)Tighten the crankshaft to 11 Nm.
(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.
PWEE0001
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EMar. 2001Mitsubishi Motors Corporation Revised
AA
A
BC
REN0168
D
REN0169
E
REN0170
MB996048

F9Q ENGINE – Timing Belt
11A-4-4
(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
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
DMeasure when the belt surface temperature is
close to room temperature.
DMake sure that the water or oil, etc., does not
get on the microphone.
DIf 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.
DIf the measurement is taken with the microphone
touching the belt, the meter will show a value
that differs from the actual value.
(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.
PWEE0001
EJun. 2000Mitsubishi Motors Corporation
Y6035AJ
MB991668
(Microphone)
Lock
nut
10 – 20 mm
M6 bolt
15_
15_
PWEE0001-A
EMar. 2001Mitsubishi Motors Corporation Revised
REN0170
MB996048

F9Q ENGINE – Timing Belt 11A-4-5
(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.
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.
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.
PWEE0001
EJun. 2000Mitsubishi Motors Corporation
Y6035AJ
MB991668
(Microphone)
Lock
nut
10 – 20 mm
M6 bolt
15_
15_
PWEE0001-A
EMar. 2001Mitsubishi Motors Corporation RevisedPWEE0001-A EMar. 2001Mitsubishi Motors Corporation Revised
REN0169
E
REN0172