Mitsubishi F8QT Automobile Parts User Manual
Contents
1. Standard Cylinder head Flatness of cylinder head surface mm Cylinder head gasket Gasket thickness Projecting height of mm piston 0 073 Number of holes 2 Projecting height of piston 0 073 0 206 Number of holes 1 Projecting height of piston 0 206 Number of holes 3 Cylinder block Cylinder diameter mm Class A 80 006 80 024 Class B 80 256 80 274 Pistons Piston to cylinder clearance mm 0 021 0 055 Standard class 79 971 79 985 Standard class B 80 221 80 235 Piston rings Height mm Top 2 5 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 Top 0 30 0 40 Bottom 0 25 0 40 Oil 0 25 0 50 Piston pin Diameter mm Mitsubishi Motors Corporation July 1996 PWEE9602 11A 1 2 Item F8QT ENGINE Specifications Standard Camshaft Cam height Intake 8 5 Exhaust 10 34 Camshaft end play mm 0 048 0 133 Radial clearance mm 0 050 0 150 Valves Valves clearance Checking mm Intake 0 15 0 25 Exhaust 0 35 0 45 Adjusting Intake 0 2 Exhaust 0 4 Valve diameter mm Intake 36 22 Exhaust 31 62 Valve seat angle Intake 60 Exhaust2. 129 REMOVAL SERVICE POINTS MAIN BEARING CAP REMOVAL 1 Remove the retaining bolts NOTE To remove No 1 bearing cap flywheel end with screwdrivers two M7 bolts must be fitted in the bearing cap and two M7 bolts in the cylinder block INSPECTION CRANKSHAFT Ovality and taper of main bearing journals and big end bearing journals 1 Replace the crankshaft if the limit value is exceeded Out of roundness 1 Support the crankshaft 6 at No 1 journal and No 5 journal and measure the out of roundness at No 3 journal Replace the crankshaft if the limit value is exceeded NOTE Turn the crankshaft through one revolution and measure the relative out of roundness of the main bearing journals DEFORMATION OF THE CYLINDER BLOCK 1 Replace the cylinder block if the limit value for deformation is exceeded MAIN BEARINGS Do not reuse the main bearings 8 9 if they are badly worn or otherwise defective NOTE When replacing the bearing always replace the upper and lower bearings as a set PWEE9602 F8QT ENGINE Crankshaft and Cylinder Block 11A 23 3 Mitsubishi Motors Corporation July 1996 INSTALLATION SERVICE POINTS DA THRUST WASHER INSTALLATION 1 Fit the thrust washers 7 at No 2 journal on the crankshaft 6 Caution e Fit the thrust washers 7 with the oil grooves A facing outwards p B CRANKSHAFT MAIN BEARING MAIN BEARING CA
3. 3 Install the oil pan 3 Caution REN0088 e Make sure that the surface to which the sealant A is applied is free of dirt and other impurities e When installing the oil pan make sure that no sealant is applied to other parts or in the oil passages INSPECTION OIL PUMP 1 Check the flatness of the cover with a straight edge Surface sand the cover if necessary REN0089 2 Clearance between the gears and the pump body Fit new gears if the clearance is greater than the specified limit value If the clearance is still greater than the specified limit value fit a new oil pump REN0090 Mitsubishi Motors Corporation July 1996 PWEE9602 F8QT ENGINE Intermediate Shaft and Intermediate Shaft Bearings 11A 17 1 17 INTERMEDIATE SHAFT AND INTERMEDIATE SHAFT BEARINGS R Lubricate all internal parts with engine oil during reassembly 13 of 15 Ws 12 11 15 Nm RENOO91 Removal steps 1 Timing belt 9 Cover 2 Bolt 04 10 Cil seal A p E 4 3 Intermediate shaft sprocket 11 Bolt 4 Bolt 4 12 Lockplate 5 Cover 4 13 Intermediate shaft 6 O ring C PB 14 Outer bearing B 7 Oil pump drive gear D 15 Inner bearing 8 Bolt Mitsubishi Motors Corporation July 1996 PWEE9602 11A 17 2 F8QT ENGINE Intermediate Shaft and Intermediate Shaft Bearings Mitsubishi Motors Corporation July 1996 E 092 REN00
4. SEALING PLUG INSTALLATION Drive in the sealing plugs 28 29 30 to the specified depth When pressing in the sealing plugs 28 29 30 apply sealant Loctite 648 to the corresponding holes in the cylinder head 31 064 p B lt 4 VALVE SEAT INSTALLATION 1 Measure the diameter of the valve seat bores A B in the cylinder head 31 If a measured value does not come within the specified tolerance range select an oversize valve seat from the table below Standard value Intake valve A 37 mm diam Exhaust valve B 32 1 mm diam RENOO65 2 Ream the valve seat bores A B in the cylinder head to the outside diameter of the selected oversize valve seats Oversize valve seats Intake valve diameter 37 3 mm Exhaust valve diameter 32 4 mm Mitsubishi Motors Corporation July 1996 PWEE9602 F8QT ENGINE Camshaft Intake and Exhaust Valves 11A 13 7 067 MB996029 9 000 N Mitsubishi Motors Corporation July 1996 REN0069 REN0070 REN0071 3 4 Heat the cylinder head to about 100 C Install the intake valve seat on valve seat installer MB996022 and exhaust valve seat on valve seat installer MB996023 Immerse the valve seats 24 25 in liquid nitrogen so as to cool them sufficiently Pressing the valve seats 24 25 with the valve seat installers MB996022 and MB996023 in the bores until they abut in the
5. 3 CRANKSHAFT PULLEY REN0143 Removal steps A 1 Crankshaft pulley bolt 2 Crankshaft pulley REMOVAL SERVICE POINT CRANKSHAFT PULLEY BOLT REMOVAL Use special tool MB996015 to hold the flywheel during removal Mitsubishi Motors Corporation July 1996 PWEE9602 11A 3 2 F8QT ENGINE Crankshaft Pulley INSTALLATION SERVICE POINT CRANKSHAFT PULLEY INSTALLATION 1 Use special tool MB996015 to hold the flywheel during installation 6 A MB996015 WA RENO144 2 Apply a locking agent to the screw thread of the bolt Tighten the bolt to the specified torque Mitsubishi Motors Corporation July 1996 PWEE9602 F8QT ENGINE Timing 11A 4 1 4 TIMING BELT REMOVAL AND INSTALLATION A A LOOT RENO001 Removal steps 1 Bolt A p B4 8 Timing belt 2 Bolt Bb lt 9 Camshaft sprocket bolt 3 Nut 10 Camshaft sprocket 4 Engine support bracket 11 Camshaft sprocket key 5 Timing gear case cover 12 Timing belt tensioner 6 Timing gear case cover 13 Timing belt idler 7 Timing gear case cover Mitsubishi Motors Corporation July 1996 PWEE9602 F8QT ENGINE Timing REMOVAL SERVICE POINTS TIMING BELT REMOVAL 1 Turn the crankshaft clockwise so that the piston of No 1 cylinder flywheel end is at TDC with the following marks in line with each other e flywheel clutch housing e rear guard plate camshaft sprocket Scribe a mark on the inje
6. 45 Valve seat width mm Intake 1 8 0 2 Exhaust 1 8 Valve springs Length mm Loading 0 N Loading 250 N Loading 612 N Tappets Diameter tolerance mm 35 Height mm 26 3 Clearance in cylinder block mm 0 025 0 075 Valve guides Inside diameter mm Outside diameter mm Standard no grooves Oversize 1 two grooves Tappet pads Thickness increasing by increments of 0 05 mm Mitsubishi Motors Corporation July 1996 PWEE9602 2 50 3 70 F8QT ENGINE Specifications Item Standard 11A 1 3 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 Taper mm Diameter mm Standard blue 54 785 54 805 Standard red 54 795 54 805 Undersize 1 54 550 54 560 Big end bearing journals Ovality mm Taper mm Diameter mm Standard 48 00 48 02 Undersize 1 47 75 47 77 Bearing recess width mm 20 25 20 95 Relative difference mm Connecting rod big end bearings Axial clearance mm 0 22 0 40 Radial clearance mm 0 031 0 075 Connecting rod
7. Oil return pipe union nut Coolant supply pipe banjo bolt Coolant supply pipe retaining nut Coolant discharge pipe union nut Coolant discharge pipe retaining nut Intake and exhaust manifolds EGR valve EGR pipe Oil pipe union nut Oil pipe retaining nut Manifold nut Mitsubishi Motors Corporation July 1996 PWEE9602 11A 1 6 F8QT ENGINE Specifications Items Rocker cover and cylinder head Rocker cover nut Cylinder head bolt 30 50 4 fully slacken 25 213 2 warm up 120 7 Camshaft intake and exhaust valves Camshaft bearing cap bolt M6 Camshaft bearing cap bolt M8 Glow plug Fuel injection nozzle Vacuum pump Vacuum pump bolt Vacuum hose union nut Oil cooler and oil filter Thermostat housing nut Plug Oil cooler nut pan oil pump and oil jets Oil drain plug Oil pan bolt Oil pump cover bolt Oil pump body bolt Oil jet Intermediate shaft and intermediate shaft bearings Intermediate shaft sprocket bolt Intermediate shaft cover bolt Intermediate shaft lockplate bolt Cover bolt Fuel injection nozzle Injection pipe union nut Nozzle body Retaining nut Mitsubishi Motors Corporation July 1996 PWEE9602 F8QT ENGINE Specifications 11A 1 7 Items Fuel injection pump Inject
8. the locking tool FUEL INJECTION PUMP REMOVAL 1 Remove the injection pipes 2 Remove the three bolts 15 3 Remove the two bolts 16 INSTALLATION SERVICE POINTS 4 INSTALLATION 1 Locate the sprocket with the key on the fuel injection pump shaft Align the sprocket with the mark opposite the pump bracket 2 Locate the sprocket stopper MB996043 between the pump bracket and the sprocket Fasten the tool with the bolt supplied with the set 3 Fit and tighten the nut to the specified torque 4 Locate the flange with the screwed sleeve and nut assembly and tighten to the specified torque with hexagon socket spanner MB996036 PWEE9602 F8QT ENGINE Fuel Injection Pump 11A 19 3 FUEL INJECTION TIMING CHECK MEASURING TOOL INSTALLATION 1 Turn the crankshaft clockwise so that the piston of No 1 cylinder flywheel end is at TDC with the following marks in line with each other e flywheel clutch housing e timing belt cover camshaft sprocket 2 Turn the crankshaft clockwise 1 3 4 revolutions 3 Remove the plug A 4 Fit measuring device adaptor MB996030 e Locate the guide bush B in the pump e Slide the measuring pin C which is part of the measuring tool into the guideway of the pump e Locate and secure the holder D b Position the clock gauge E and make sure that the plunger is pressed in at least 0 2 mm Secure the clock gauge and set it at zero NOTE When turning the
9. 23 carefully to check whether their condition is normal 3 Determine the condition of the valve seat by means of the Minium pattern on the valve 16 17 If abnormal contact is established take the following measures Small deviation Grind the valve so that better contact is obtained iation rrect or rep th nd valv Large deviation the valve and valve 4ME0126 Mitsubishi Motors Corporation July 1996 PWEE9602 F8QT ENGINE Camshaft Intake and Exhaust Valves 11A 13 5 VALVE SEAT Valve seat width 1 Replace the valve seat 24 25 the limit value is exceeded Angle A intake valve seat 60 exhaust valve seat 45 The contact surface B must be 1 7 0 1 mm If the contact surface is too wide correct this with a valve seat cutter 61 Cutter angle Angle C intake valve seat 45 exhaust valve seat 30 Caution e The outside diameter of the cutter for the valve seat must not be more than intake valve seat 37 0 mm exhaust valve seat 32 1 mm After cutting the dimension D must be 0 125 0 025 mm NOTE After correcting or replacing the valve seat 24 25 the valve seat and the valve 16 17 should be matched by grinding them together in order to obtain correct seating CYLINDER HEAD 1 Check the cylinder head gasket surface 31 for distortion Fit a new cylinder head if the limit value is exceeded CORRECTION INTAKE VALVE AND EXHAUST VALVE Cauti
10. TURBOCHARGER REMOVAL AND INSTALLATION REN0038 Removal steps 1 Vacuum hose 7 Union nut 2 Oil supply pipe 8 Coolant discharge pipe 3 Oil return pipe 9 Connector to exhaust downpipe 4 Nut 10 Nut 5 Banjo bolt 11 Turbocharger unit 6 Coolant supply pipe INSTALLATION SERVICE POINTS DA TURBOCHARGER INSTALLATION 1 Before fitting the turbocharger lubricate the parts with engine oil introduced through oil filler opening Mitsubishi Motors Corporation July 1996 PWEE9602 F8QT ENGINE Intake and Exhaust Manifolds 11A 11 1 11 INTAKE AND EXHAUST MANIFOLDS REMOVAL AND INSTALLATION REN0039 Removal steps 1 Vacuum hose 6 Engine hanger 2 EGR valve 7 Bracket 3 EGR pipe 8 Nuts 4 Oil pipe from turbocharger 9 Intake and exhaust manifolds 5 Vacuum hose to turbocharger 10 Gasket Mitsubishi Motors Corporation July 1996 PWEE9602 F8QT ENGINE Rocker Cover and Cylinder Head 11A 12 1 12 ROCKER COVER AND CYLINDER HEAD REMOVAL AND INSTALLATION 8 9 0 725 1 Se SE SE AN 40 Removal steps 1 Engine hanger p C4 8 Cylinder head bolt 2 Thermostat housing 9 Washer 3 Vacuum pump Ap PB 10 Cylinder head 4 Oil filler cap B pAd 11 Cylinder head gasket 5 Nut 6 Rocker cover A Locating dowel gt D lt 7 Rocker cover gasket Mitsubishi Motors Corporation July 1996 PWEE9602 11A 12 2 F8QT ENGINE Rocker Cover and Cylinder Head REMOV
11. cylinder head After the valve seats 24 25 have been installed the valve seats and the valves 16 17 must be matched by lapping gt C VALVE GUIDE INSTALLATION 1 Measure the diameter of the bores for the valve guides 22 23 in the cylinder head 31 If a measured value does not come within the specified tolerance range select the oversize valve guide Standard value Diameter of bore A 13 mm Ream valve guide bore dimension A to the outside diameter of the selected oversize valve guides with reamer MB996016 Oversize valve guide diameter 13 3 mm two grooves Place the cylinder head 31 on a flat surface Locate the valve guides 22 23 with the taper pointing down on valve guide installer MB996029 Press in the valve guides 22 23 until the installer abuts the cylinder head 31 Caution e The pressure exerted on the valve guide must 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 PWEE9602 11A 13 8 F8QT ENGINE Camshaft Intake and Exhaust Valves 6 Clean the valve guide inner bores 22 23 with reamer MB996024 MB996031 gt D lt VALVE STEM SEAL INSTALLATION 1 Lubricate the valve guides 22 23 with engine oil Introduce the valves 16 17 through the valve guides Locate the protective plastic cap over the valve stem 2 Locate the valve st
12. engine with the gauge installed you might damage the clock gauge a DN 2 11 AD The measuring pin and guide bush can only be supplied and used as a set CHECKING THE INJECTION TIMING 1 Turn the crankshaft exactly to TDC clockwise To achieve this e Insert an 8 mm diameter locking pin in the hole of torxbolt e Apply pressure just before TDC on this pin until it engages the recess in the crankshaft 2 Read off the value on the clock gauge This value should not differ more the 0 02 mm as the set value shown on the pump control arm If the value is not obtained the pump has to be adjusted MEASURING TOOL REMOVAL 1 Remove measuring device adaptor MB996030 with the clock gauge Fit the plug with a new O ring Tighten the plug to the 10 Nm Remove the locking pin and fit the torxbolt with a new sealing washer Tighten the plug to 20 Nm PWEE9602 11A 19 4 Mitsubishi Motors Corporation F8QT ENGINE Fuel Injection Pump i AN wA den A A Z July 1996 REN0154 REN0156 FUEL INJECTION PUMP ADJUSTMENT MEASURING TOOL INSTALLATION 1 Turn the crankshaft clockwise so that the piston of No 1 cylinder flywheel end is at TDC with the following marks in line with each other e flywheel clutch housing e timing belt cover camshaft sprocket 2 Remove cover 1 and the bolts of cover 2 8 Locate sprocket stopper MB996043 between the pump bracket and the sprocket Secure t
13. pump sprocket NOTE the direction of rotation of the belt see the arrows on the belt 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 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 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 PWEE9602 11A 4 4 F8QT ENGINE Timing Belt 7 Abnormal wear in teeth 8 Missing tooth 8 068 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 RENO0008 Mitsubishi Motors Corporation July 1996 PWEE9602 F8QT ENGINE Water Pump 11A 5 1 5 WATER PUMP REMOVAL AND INSTALLATION Be A A 09 Removal steps 1 V ribbed belt alternator amp others 2 Bolt 3 Water pump pulley 4 Bolt 5 Water pump 6 W
14. with a thin layer of engine oil 2 Locate the oil seal over the camshaft 3 Fit the oil seal with oil seal installer MB996042 VALVE CLEARANCES ADJUSTMENT VALVE CLEARANCES CHECK The valve clearances have to be checked adjusted in the following sequence Oylinder at point of balance Oylinder being checked adjusted 4 Oylinder at point Cylinder being of balance checked adjusted 027 3 2 1 When changing tappet pads the piston must not be at TDC The crankshaft must be turned on to bring it just past TDC otherwise the valves may strike the piston when the tappets are depressed Cold engine Checking Adjusting Intake valve mm 0 15 0 20 0 20 Exhaust valve mm 0 35 0 45 0 40 Mitsubishi Motors Corporation July 1996 PWEE9602 F8QT ENGINE Vacuum Pump 11A 14 1 14 VACUUM PUMP REMOVAL AND INSTALLATION 08 Removal steps 1 Vacuum hose 2 Bolt 3 Washer 4 Vacuum pump 5 Gasket Mitsubishi Motors Corporation July 1996 PWEE9602 F8QT ENGINE Oil Cooler and Oil Filter 11A 15 1 15 OIL COOLER AND OIL FILTER REMOVAL AND INSTALLATION R Lubricate all internal parts with engine oil during reassembly it y 12 311 7 8 6 5 60 Nm ss 45 O 9 lt io SS S 1 RENOO085 Removal steps 1 Oil filter 7 Thermostat 2 Nut 8 Spring 3 Thermostat housing 9 Nut 4 10 Oil cooler 5 Plug 11 O ring
15. 1 Measure the clearance between the intermediate shaft and the lock plate Replace the part in question if the clearance exceeds the limit value 2 Install the intermediate shaft together with the lock plate gt D lt INTERMEDIATE SHAFT OIL SEAL INSTALLATION 1 Coat the lip of the oil seal with a thin layer of engine oil 2 Locate the oil seal installer guide MB996039 over the intermediate shaft 3 Locate the oil seal over the oil seal installer guide 4 Fit the oil seal with oil seal installer MB996039 p E INTERMEDIATE SHAFT SPROCKET INSTALLATION 1 Use sprocket stopper MB996034 and tighten the retaining bolt to 50 Nm RENO146 Mitsubishi Motors Corporation July 1996 PWEE9602 F8QT ENGINE Fuel Injection Nozzle 11A 18 1 18 FUEL INJECTION NOZZLE REMOVAL AND INSTALLATION 1 REN0099 Removal steps 1 Injection pipe 8 Spring 2 Fuel return pipe 9 Shim A PAM 3 Fuel injection nozzle assembly B 10 Needle valve 4 Heat shield 11 Nozzle tip 5 Nozzle body 12 Retaining nut 6 Washer 13 Nozzle needle lift sensor 7 Push rod for No 1 cylinder only p FUEL INJECTION NOZZLE REMOVAL 1 Remove the fuel injection nozzle with special socket MB996041 2 n d N MB996041 CA YC y Z BEN0100 Mitsubishi Motors Corporation July 1996 PWEE9602 ANS 11A 18 2 Mitsubishi Motors Corporation F8QT ENGINE Fuel Injecti
16. 11A 0 1 ENGINE F8QT SERIES CONTENTS GENERAL INFORMATION 11A 0 3 Ty SPECIFICATIONS en Natan aaa Rad tena ss 11A 1 1 SERVICE SPECIFICATIONS 11A 1 1 TORQUE SPECIFICATIONS 11A 1 5 FORM IN PLACE GASKET 11A 1 8 2 SPECIAL TOOLS uuu lu aana ana te ke EN 11A 2 1 3 CRANKSHAFT PULLEY 11A 3 1 4 TIMING BELT eege Re eink va ornate an same 11A 4 1 5 WATER PUMP geg teenies axe REENEN 11A 5 1 6 THERMOSTAT Soe exe RE cia ARR RE pata eerie 11A 6 1 7 WATER HOSES AND PIPES 11A 7 1 8 ENGINE COOLANT TEMPERATURE SENSOR 11A 8 1 9 GLOW PLUGS Ae ace 11A 9 1 10 TURBOCHARQGER dE 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 EE 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 11 19 1 20 PISTONS AND CONNECTING RODS 11 20 1 21 PIS
17. 6 Sealing washer 12 O ring REMOVAL SERVICE POINTS THERMOSTAT REMOVAL 1 Remove the socket head screw and sealing washer 2 Remove the spring together with the thermostat Check the operation of the thermostat with the aid of a hair drier Renew the part in question if the specified value is not obtained INSTALLATION SERVICE POINTS DA OIL FILTER INSTALLATION 1 Clean that part of the oil cooler 1 which is in contact with the oil filter 2 2 Smear a thin layer of engine oil on the O ring A of the oil filter 2 Mitsubishi Motors Corporation July 1996 PWEE9602 F8QT ENGINE Oil Pan Pump and Jets 11A 16 1 16 OIL PAN OIL PUMP AND OIL JETS REMOVAL AND INSTALLATION 14 R Lubricate all internal parts with engine oil during reassembly 20 Nm g UU 25Nm 3 1 RENO0084 Removal steps 1 Drain plug 8 Driven gear 2 Bolt 9 Idler gear 4 3 pan 10 Spring clip 4 Bolt 11 Washer 5 Oil pump body 12 Compression spring 6 Bolt 13 Plunger 7 Cover 14 Oil jet Mitsubishi Motors Corporation July 1996 PWEE9602 11A 16 2 F8QT ENGINE Oil Pan Oil Pump and Oil Jets INSTALLATION SERVICE POINTS DA OIL PAN INSTALLATION 1 When applying sealant make sure that the cartridge nozzle opening is not larger than 4 mm 2 Apply an even uninterrupted bead of sealant A to the entire circumference of the oil pan flange 3 as shown in the illustration
18. 93 REMOVAL SERVICE POINTS INTERMEDIATE SHAFT SPROCKET REMOVAL 1 Use sprocket stopper MB996034 to hold the sprocket during removal 2 Remove the sprocket and the sprocket key Bp OIL PUMP DRIVE GEAR REMOVAL 1 Remove the oil pump drive gear 7 with the aid of an M12 bolt C OUTER BEARING REMOVAL 1 Remove the outer bearing 14 with bearing puller MB996025 D INNER BEARING REMOVAL 1 Remove the inner bearing 15 with bearing puller MB996026 INSTALLATION SERVICE POINTS BEARING INSTALLATION 1 Install the inner bearing with the aid of bearing installer MB996027 The pin of the installer must engage the oil return passage of the intermediate shaft 13 NOTE Position the inner bearing with the opening at the mark on the installer 2 Check with a piece of wire 1 2 mm diameter that the oil hole is aligned with the drilling in the bearing PWEE9602 F8QT ENGINE Intermediate Shaft and Intermediate Shaft Bearings 11A 17 3 MB996028 p B OUTER BEARING INSTALLATION SS 1 Install the outer bearing with the aid of bearing installer MB996028 The pin of the installer must engage the oil return passage of the intermediate shaft 13 NOTE Position the outer bearing with the opening at the mark on the installer 2 Check with a piece of wire 1 2 mm diameter that the oil hole is aligned with the drilling in the bearing C lt INTERMEDIATE SHAFT LOCK PLATE INSTALLATION
19. AL SERVICE POINTS CYLINDER HEAD REMOVAL 1 Release and then remove the cylinder head bolts 2 Lift the cylinder head straight up over the locating dowels and then remove the cylinder head B CYLINDER HEAD GASKET REMOVAL Caution e When removing the cylinder head gasket take care not to scratch the cylinder head or cylinder block gasket faces INSTALLATION SERVICE POINTS 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 and calculate the average height Then select a cylinder RENO042 head gasket of the correct thickness from the table shown below Piston height Number of holes Gasket thickness above oylinder mm block mm 0 073 1 40 0 073 0 206 1 50 0 206 1 60 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 e f 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 Mitsubishi Motors Corporation July 1996 PWEE9602 F8QT ENGINE Rocker Cover and Cy
20. G TOOL REMOVAL 1 Remove measuring device adaptor MB996030 with the clock gauge Fit the plug with a new O ring Tighten the plug to the 10 Nm Remove the locking pin and fit the torxbolt with a new sealing washer Tighten the plug to 20 Nm PWEE9602 REMOVAL AND INSTALLATION F8QT ENGINE Pistons and Connecting Rods 11A 20 1 20 PISTONS AND CONNECTING RODS 2 Lubricate all internal parts with engine oil during reassembly Removal steps 1 Bolt 2 Connecting rod cap kA 3 Connecting rod lower bearing big end bearing Mitsubishi Motors Corporation RENO110 pA lt q 4 Connecting rod upper bearing big end bearing pBM4 5 Piston and connecting rod assem bly INSPECTION PISTON AND CONNECTING ROD Piston height above cylinder block Caution e Always check the projecting height of the pistons above the cylinder block This has a direct influence on engine performance 1 Turn each piston to TDC 2 Check the projecting height of the piston at each cylinder 8 If the average deviates from the standard value measure the clearance at each piston and connecting rod and the crankshaft PWEE9602 11A 20 2 F8QT ENGINE Pistons and Connecting Rods CONNECTING ROD BEARINGS Caution e Do not fit old connecting rod bearings 3 4 if they are badly worn e f any one of the connecting rod bearings 3 4 is NE defective the bearings should be replaced as a set Clearanc
21. PS INSTALLATION Caution e The main bearing caps are marked 1 Start by installing bearing cap No 2 The bolts should be tightened to the specified torque 2 Check that the crankshaft rotates smoothly 3 Move the crankshaft backwards and forwards in the longitudinal direction and check whether the end play is within the specified tolerance range 4 Fitthe bearing cap in the cylinder block so that the mating faces are positioned about 10 mm away from each other b Centre the bearing cap with the two socket head screws 6 Pack the two recesses in the bearing cap with sealant NOTE The two recesses should be filled down to the bottom edge 7 Tighten the two socket head screws to the specified torque Remove excessive sealant gt C FRONT PLATE INSTALLATION 1 Apply an even uninterrupted bead of sealant to the front plate Maximum bead width 2 mm Caution e Make sure that the surface to which the sealant is applied is free of dirt and other impurities e Check that the two fitted sleeves are present PWEE9602 11 23 4 Mitsubishi Motors Corporation F8QT ENGINE Crankshaft and Cylinder Block Ee r N MB996040 July 1996 135 4 CRANKSHAFT FRONT SEAL INSTALLATION 1 Coat the of the oil seal with a thin layer of engine oil 2 Locate the oil seal installer guide MB996040 over the crankshaft 3 Locate the oil seal over the oil seal installer guide Fit th
22. TONS AND PISTON PINS 11A 21 1 22 PLY WHEEL eeh he 11A 22 1 23 CRANKSHAFT AND CYLINDER BLOCK 11A 23 1 Mitsubishi Motors Corporation July 1996 PWEE9602 11A 0 2 NOTES Mitsubishi Motors Corporation July 1996 PWEE9602 F8QT ENGINE General Information 11A 0 3 GENERAL INFORMATION SECTIONAL VIEW OF ENGINE T m g nd AB IS Lr Mitsubishi Motors Corporation July 1996 Mitsubishi Motors Corporation July 1996 11A 0 5 11A 0 6 Description F8QT ENGINE General Information Specifications Type F8QT diesel engine Number and arrangement of cylinders 4 in line Combustion chamber Swirl chamber Total displacement 1870 cm Oylinder bore x stroke 80 x 93 mm Compression ratio 21 Valve mechanism Single overhead camshaft Number of valves Intake 4 Exhaust 4 Valve 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 Mitsubishi Motors Corporation July 1996 Electric with immobilizer PWEE9602 F8QT ENGINE Specifications 11A 1 1 1 SPECIFICATIONS SERVICE SPECIFICATIONS
23. alve seat Exhaust valve seat Swirl camber Stud Sealing plug Sealing plug Sealing plug 1 Oylinder head 11 13 1 11A 13 2 F8QT ENGINE Camshaft Intake and Exhaust Valves J REN0049 REN0051 REN0052 REMOVAL SERVICE POINTS p RETAINER LOCKS REMOVAL 1 Fit valve spring compressor MB996014 on the cylinder head 31 as shown in the illustration 2 Press down the valve spring retainer 12 and remove the retainer locks 11 VALVE STEM SEAL REMOVAL Remove the seal 15 with valve stem seal remover MB996021 C VALVE GUIDE REMOVAL 1 Support the cylinder head 31 2 Press out the valve guides 23 23 towards the valve seat with valve guide remover MB996020 Dp VALVE SEAT REMOVAL 1 Cut two recesses in the valve seats 24 25 The recesses are cut in order to lower the tension in the valve seat 2 Break the valve seat into pieces with the aid of a cold chisel PWEE9602 F8QT ENGINE Camshaft Intake and Exhaust Valves 11A 13 3 REN0057 Mitsubishi Motors Corporation July 1996 REN0058 8 Tap the valve seat through the passage and out of the cylinder head using long drift E SWIRL CHAMBER REMOVAL 1 Insert a round rod in the glow plug hole Remove the swirl chamber by tapping the rod with a hammer INSPECTION CAMSHAFT End play 1 Measure the end play Fit a new cylinder head if the measured value deviates from the speci
24. ar device for applying heat locally to approximately 220 C 2 Fit the flywheel ring gear 2 on the flywheel 3 with the chamfered side facing towards the flywheel A Chamfered side of flywheel ring gear gt B FLYWHEEL INSTALLATION 1 Remove all traces of sealant oil and other substances Caution The flywheel can be fitted in one way only This is because the bolt hole pattern is asymmetrical 2 Coat the mating face of the flywheel to the crankshaft with a locking agent Part No 1161059 1 996015 3 Use new bolts and coat the screw threads with liquid 4 gasket cement Part No 277917 1 nr 4 Use flywheel stopper 996015 and tighten the bolis 53 Nm Mitsubishi Motors Corporation July 1996 PWEE9602 F8QT ENGINE Crankshaft and Cylinder Block 11A 23 1 23 CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION 2 NS 2 d PA 4 J Oh at bacs R Lubricate all internal parts with engine oil during reassembly RENO124 Removal steps 1 Bolt 4 2 Front plate ka 3 Oil seal 4 Bolt A 4 5 Main bearing cap 6 Crankshaft pA 7 Thrust bearing p B lt 4 8 Crankshaft main bearing lower gt Ba 9 Crankshaft main bearing upper p E 10 Oil seal Mitsubishi Motors Corporation July 1996 PWEE9602 11A 23 2 Mitsubishi Motors Corporation F8QT ENGINE Crankshaft and Cylinder Block July 1996 126 127 128
25. ater pump gasket Mitsubishi Motors Corporation July 1996 PWEE9602 F8QT ENGINE Thermostat 11A 6 1 6 THERMOSTAT REMOVAL AND INSTALLATION 10 Nm REN0010 Removal steps Bolt Thermostat cover Plate O ring Thermostat Bolt Thermostat housing O ring Bleedscrew DAM DAM ONDARON INSTALLATION SERVICE POINT 4 INSTALLATION Caution f O rings are soaked in engine oil they will swell up Keep the O rings 4 and 8 free of engine oil when they are being fitted Mitsubishi Motors Corporation July 1996 PWEE9602 F8QT ENGINE Water Hoses and 11A 7 1 7 WATER HOSES AND PIPES REMOVAL AND INSTALLATION RENO0035 Removal steps 1 Water inlet hose 2 Water outlet hose 3 Heater inlet hose 4 Heater outlet hose Mitsubishi Motors Corporation July 1996 PWEE9602 F8QT ENGINE Engine Coolant Temperature Sensor 11A 8 1 8 ENGINE COOLANT TEMPERATURE SENSOR REMOVAL AND INSTALLATION REN0036 Removal steps 1 Wiring harness connector 2 Retaining clip 3 Temperature sensor ECU 4 Temperature sensor instrument panel Mitsubishi Motors Corporation July 1996 PWEE9602 F8QT ENGINE Glow Plugs 11A 9 1 9 GLOW PLUGS REMOVAL AND INSTALLATION RENO0037 Removal steps 1 Nut 2 Glow plug leads Nos 1 and 2 3 Glow plug leads Nos 3 and 4 4 Glow plug Mitsubishi Motors Corporation July 1996 PWEE9602 F8QT ENGINE Turbocharger 11A 10 1 10
26. ction pump mounting bracket 2 Insert an 8 mm diameter locking pin in the threaded hole of torx bolt 2 so that it engages the recess in the crankshaft web 8 Slacken the lock nut of the timing belt tensioner Remove the timing belt B CAMSHAFT SPROCKET BOLT REMOVAL 1 Use special tool MB990767 camshaft sprocket holder with pin MD998715 and remove the retaining bolt INSTALLATION SERVICE POINTS 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 50 Nm gt B TIMING BELT INSTALLATION 1 Turn the camshaft clockwise with special tool MB990767 until the mark on the camshaft sprocket is opposite the mark on the guard plate 2 Turn the crankshaft 1 4 revolution counter clockwise from the TDC position of No 1 cylinder and insert the 8 mm diameter locking pin in the recess in the crankshaft web 3 Align the mark on the injection pump sprocket with the mark on the mounting bracket turn clockwise 005 Mitsubishi Motors Corporation July 1996 PWEE9602 Mitsubishi Motors Corporation July 1996 F8QT ENGINE Timing Belt 11A 4 3 8EN0066 8EN0044 8EN0067 4 Fit the timing belt so that the lines on the belt are aligned with the marks on the crankshaft and camshaft sprockets and the injection
27. d 3 with the oil passage facing away from the combustion chamber in the piston 3 Insert the piston pin 4 Fit the circlip in the piston 7 Mitsubishi Motors Corporation July 1996 PWEE9602 F8QT ENGINE Flywheel 11A 22 1 22 FLYWHEEL REMOVAL AND INSTALLATION Removal steps 4 4 1 MB A 4 2 Flywheel ring gear 3 Flywheel MB996015 deer RENO147 RENO121 Mitsubishi Motors Corporation July 1996 120 REMOVAL SERVICE POINTS p FLYWHEEL REMOVAL Use flywheel stopper MB996015 to hold the flywheel during removal B FLYWHEEL RING GEAR REMOVAL 1 Examinethe flywheel ring gear 2 for damage and abnormal wear and replace if necessary 2 Heat the flywheel ring gear 2 evenly with an oxyacetylene torch or a similar device for applying heat locally and then remove the ring gear by tapping around its entire circumference PWEE9602 11A 22 2 F8QT ENGINE Flywheel INSPECTION FLYWHEEL Axial throw 1 If the axial throw exceeds the limit value check the flywheel for a loose bolt 1 or for a defective connection to the crankshaft Repair or replace as necessary Deformation of the friction surface 1 If necessary replace the flywheel 3 NOTE A new flywheel is always supplied complete with the ring gear 4ME0270 INSTALLATION SERVICE POINTS FLYWHEEL RING GEAR INSTALLATION 1 Heat the flywheel ring gear 2 with an oxyacetylene torch or simil
28. e between connecting rod and crankshaft 1 Replace the part in question if the clearance exceeds 4 241 the limit value dy 4ME0242 PISTON CONNECTING ROD AND CYLINDER BLOCK 1 Measure the cylinder bores Measure four times at 45 intervals and at right angles to the gasket face just under the top piston ring travel limit Add the results of these measurements together and divide the total by eight Measure once just above the lower travel limit Divide this value by two Add the values together this is the cylinder diameter INSTALLATION SERVICE POINTS DA CONNECTING ROD BEARING INSTALLATION 1 Lubricate the bearings with engine oil Caution Make sure that no engine oil runs in between the bearing connecting rod and bearing cap Mitsubishi Motors Corporation July 1996 PWEE9602 F8QT ENGINE Pistons and Connecting Rods 11A 20 3 p B PISTON AND CONNECTING ROD INSTALLATION Caution e Ensure that the piston ring gaps A are correctly positioned e Takecarenotto damage the piston crown combustion chamber B e Take care not to strike the connecting rod against the oil jet RENO0113 1 Lightly coat the big end journal cylinder wall and piston with engine oil 2 Fit the connecting rod with the mark facing towards the intermediate shaft side 3 Fit the connecting rod cap with the mark facing towards the intermediate shaft side 4 Fit new bolts and tighten them to the specified torq
29. e oil seal with oil seal installer MB996040 pE CRANKSHAFT REAR 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 8 Locate the oil seal over the oil seal installer guide 4 Fit the oil seal with oil seal installer MB996038 PWEE9602 NOTES
30. e test Fit a new injection nozzle if the problem persists 3 Check that the nozzle does not drip after injecting fuel Caution e Do not expose your hands or any other parts of your body to the injection nozzle spray PWEE9602 F8QT ENGINE Fuel Injection Nozzle 11A 18 3 Leakage test 1 Increase the pressure to 11 MPa by operating the lever of the nozzle tester Maintain the pressure for 10 seconds No fuel must dribble out of the nozzle during this test 2 If dribbling starts within this 10 second period disassemble 2 and clean the injection nozzle 3 and repeat the test Fit lt a new injection nozzle if the problem persists 4ME0208 REMOVAL SERVICE POINTS p FUEL INJECTION NOZZLE DISASSEMBLY Caution e Remove any carbon deposits from the injection nozzle 3 before starting disassembly assembly and adjustment Before disassembly test the fuel injection nozzle for abnormal injection pressure abnormal spray pattern and leakage If the fuel injection nozzle is operating correctly it does not have to be disassembled Bp NEEDLE VALVE NOZZLE REMOVAL Caution A 10 e Donottouch the sliding surface A of the needle valve 2 R 10 e Make sure that the original combination of needle valve 10 and nozzle tip 11 are reassembled 4ME0209 CLEANING NEEDLE VALVE NOZZLE TIP 1 Wash the removed needle valve 10 and nozzle tip 11 in clean paraffin and remove any carbon deposits with the tool Pr
31. em oil seal 15 Press in the valve N stem oil seal 15 vertically until it abuts the cylinder head 31 with valve stem seal installer MB996031 Remove SSS the protective cap Caution db S e avoid damaging valve stem oil seal the valves 16 17 must not be removed again p E RETAINER LOCKS INSTALLATION 1 Fit valve spring compressor MB996014 on the cylinder head 31 as shown in the illustration 2 Press down the valve spring retainer 12 and fit the retainer locks 11 p F CAMSHAFT BEARING CAPS INSTALLATION 1 Apply a sealant to the No 1 and No 5 bearing caps 2 Fit the camshaft bearing caps in the correct sequence the caps are numbered Apply a locking agent to the upper five bolts Tighten the bolts to the specified torques REN0076 Mitsubishi Motors Corporation July 1996 PWEE9602 F8QT ENGINE Camshaft Intake and Exhaust Valves 11A 13 9 G SWIRL CHAMBER INSTALLATION NOTE First check that the dowel pin is still in the swirl chamber If the dowel pin is no longer present a new swirl chamber 26 will have to be fitted 1 Measure the difference in height between the swirl chambers and the cylinder head with slip gauge MB996018 and dial indicator The difference in height must be between 0 01 and 0 04 mm 2 Fit the glow plugs 18 and connect up the wiring p H CAMSHAFT OIL SEAL INSTALLATION 1 Coat the lip of the oil seal
32. fied value Difference between cam height and base circle diameter 1 Fit a new camshaft 7 if the limit value is exceeded A Cam height B Base circle diameter Radial play 1 Support the camshaft 7 at No 1 journal C and No 5 journal D and measure the warp at No 3 journal E Fit a new camshaft if the limit value is exceeded NOTE The true warp is half of the value indicated by the dial indicator when the camshaft 7 is rotated once PWEE9602 11A 13 4 F8QT ENGINE Camshaft Intake and Exhaust Valves INTAKE AND EXHAUST VALVES Examining the valve stem for wear 1 Replace the valve if the valve stem diameter is smaller than the limit value or if there is evidence of uneven wear NOTE If the valve 16 17 is new it should be matched with the valve seat 24 25 by grinding them together 4ME0122 Valve seat angle and valve seat margin 1 Replace the valve 16 17 if the limit value is exceeded after correcting the valve seat angle A Valve seat angle B Valve seat margin 4ME0123 VALVE AND VALVE GUIDE 1 Replace the part in question if the clearance exceeds the limit value VALVE AND VALVE SEAT 1 Smear a layer of Minium evenly on the valve seating A surface of the valve seats 24 25 2 Press the valve 16 17 once against the valve seat 24 25 making sure that the valve does not rotate B Grinding tool NOTE Before checking the valve contact examine the valve 16 17 and the valve guide 22
33. gs 4 5 6 must be located in the lower part of the cylinder bore which is subjected to less wear e Replace the piston rings 4 5 6 as a set CLEARANCE BETWEEN PISTON RING AND PISTON RING GROOVE 1 Replace the part in question if the clearance exceeds the limit value Caution e Always use new piston rings for measuring e Remove all traces of carbon deposits from the piston ring grooves in the piston 7 before measuring Measure the lateral clearance around the entire circumference of the piston ring groove e The piston rings must be replaced as a set PWEE9602 F8QT ENGINE Pistons and Piston Pins 11A 21 3 CURVATURE AND TWIST OF CONNECTING ROD 1 Measure the curvature and the twist of the connecting rod 3 Replace the connecting rod if the limit values are exceeded Caution e Installed connecting rod 3 with upper and lower connecting rod bearings in place in the connecting rod alignment tool e Tighten the connecting rod cap in accordance with the specified procedure INSTALLATION SERVICE POINTS PISTON RING INSTALLATION 1 Fit the oil ring 6 2 Fit the No 2 piston ring 5 8 Fit the No 1 piston ring 4 Lubricate the piston rings with engine oil Position the piston ring gaps at an angle of 120 to each other REN0113 p B PISTON PIN INSTALLATION 1 Fit the circlip in the piston 7 2 Smear a thin layer of engine oil on the piston pin 2 before fitting Install the connecting ro
34. he tool with the two bolts supplied with the set Bolt F is not needed now ADJUSTMENT OF THE INJECTION TIMING 1 Insert Hexagon socket spanner MB996036 in the nut assembly Loosen nut assembly approx 1 4 of turn clockwise until it is possible to move the flange 2 2 Remove sprocket stopper MB996043 8 Fit sprocket adaptor MB996037 in the three holes of the flange Turn the tool with the flange until the jaws of the tool engage the three internal recesses of the sprocket 4 Turn the tool by hand with the flange clockwise until the stop Remove sprocket adaptor MB996037 PWEE9602 F8QT ENGINE Fuel Injection Pump 11A 19 5 b Turn the crankshaft clockwise 1 3 4 revolutions 6 Remove the plug A 7 Fit measuring device adaptor MB996030 e Locate the guide bush B in the pump e Slide the measuring pin C which is part of the measuring tool into the guideway of the pump e Locate and secure the holder D 8 Position the clock gauge E and make sure that the plunger is pressed in at least 0 2 mm Secure the clock gauge and set it at zero Caution e When turning the engine with the gauge installed a AN pi you might damage the clock gauge NOTE The measuring pin and guide bush can only be supplied and used set 9 Turn the crankshaft exactly to clockwise To achieve this e Insert an 8 mm diameter locking pin in the hole of torxbolt e Apply pressure just before TDC o
35. ion pipe union nut Screwed sleeve nut assembly Nut Injection pump bolt Bolt Pistons and connecting rods Connecting rod cap bolt Flywheel Flywheel bolt Crankshaft and cylinder block Main bearing cap bolt Front plate bolt Mitsubishi Motors Corporation July 1996 PWEE9602 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 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 scrape
36. linder Head RENO0043 l Hd Wes mg i 2 N 2 Q gt la Mitsubishi Motors Corporation ad r REN0046 July 1996 11A 12 3 p B lt 4 CYLINDER HEAD INSTALLATION 1 2 3 Select a suitable cylinder head gasket 11 Rotate the crankshaft so that the piston of No 1 cylinder is positioned a quarter stroke past TDC Fit the cylinder head over the locating dowels gt C CYLINDER HEAD BOLT INSTALLATION 1 When installing the cylinder head bolts check that the length of the shank of each bolt without the washer is within the limit value All the cylinder head bolts must be renewed as soon as any of them exceeds the permitted length Limit max 120 5 mm Fit the washers Lubricate the bolt threads and washers with engine oil Insert the cylinder head bolts and fasten them finger tight The cylinder head bolts should be torque tightened in three stages Tighten in the first stage e first to 30 Nm e thenangle tighten to 50 4 ina single uninterrupted movement NOTE Wait at least three minutes to allow the head gasket to bed down properly Now slacken all the bolts completely Then tighten to the second stage torque e first to 25 Nm e then angle tighten the bolts to 213 7 in a single uninterrupted movement The cylinder head can only be retorqued after letting the engine warm up to its operating temperature Tightening torque for
37. n this pin until it engages the recess in the crankshaft 10 turn the flange with sprocket adaptor MB996037 counterclockwise until the adjustment value is obtained as shown on the pump 0 02 mm Mitsubishi Motors Corporation July 1996 PWEE9602 11A 19 6 F8QT ENGINE Fuel Injection Pump 11 Locate sprocket stopper MB996043 Fix the bracket with the two bolts supplied with the set Secure the bracket with bolt F so that it is free from play Caution The pump sprocket must not be displaced the pointer of the micrometer must not move 12 Insert Hexagon socket spanner MB996036 the nut assembly and tighten the assembly steadily turning counter clockwise to 70 Nm 13 Remove sprocket stopper MB996043 the locking pin and clock gauge Check the injection timing CHECKING THE INJECTION TIMING 1 Turn the crankshaft 1 3 4 revolutions clockwise 2 Position the clock gauge and make sure that the plunger is pressed in at least 0 2 mm Secure the clock gauge and set it at zero 3 Turn the crankshaft exactly to TDC clockwise To achieve this Insert an 8 mm diameter locking pin in the hole of torxbolt e Apply pressure just before TDC on this pin until it engages the recess in the crankshaft 4 Read off the value on the clock gauge This value should not differ more than 0 02 mm as the set value shown on the pump control arm If the value is not obtained the pump has to be adjusted MEASURIN
38. oceed as follows a Remove the carbon deposits on the tip of the needle valve 10 with the small cleaning rod B special tool Caution e Do not use a wire brush of other hard metal 4ME0210 tools for cleaning b Remove the carbon deposits in the oil hole C of the nozzle tip 11 with the scraper tool D 4ME0211 Mitsubishi Motors Corporation July 1996 PWEE9602 11A 18 4 F8QT ENGINE Fuel Injection Nozzle c Clean the seating E of the nozzle tip 11 with the special scraper tool F F Caution e Take care not to damage the seating face d Use Fuso carbon deposit cleaning agent to remove encrusted carbon deposits 4ME0212 e Remove the carbon deposits in the injection hole of the nozzle tip 11 by rotating the needle cleaner 44 H H special tool in the injection hole J Diameter of cleaning needle less than 1 0 mm 4ME0213 0 Remove the carbon deposits on the outside of the nozzle tip 11 with the wire brush G special tool 4ME0214 INSPECTION NEEDLE VALVE NOZZLE TIP 1 Wash the needle valve 10 and nozzle tip 11 in clean paraffin clean oil before reassembly 2 Pull out the needle valve 10 about 1 3 of its total length release it and check whether the needle valve slides back in under the action of gravity Repeat this procedure several times and rotate the needle valve slightly each time 3 If the needle valve 10 does not slide back in wash it again and repeat the test If necessar
39. on e The amount of material removed by grinding should be restricted to a minimum e Replace the valve 16 17 if the margin of the valve seat after grinding is smaller than the limit value e After the grinding operation the valve 16 17 should i be matched with the valve seat 24 25 by lapping 4ME0130 them together in order to obtain correct seating Mitsubishi Motors Corporation July 1996 PWEE9602 11A 13 6 F8QT ENGINE Camshaft Intake and Exhaust Valves VALVE AND VALVE SEAT 1 The valve and the valve seat must be lapped as follows a Smear a thin layer of lapping compound evenly on the valve seating surface A of the valve seat 24 25 Caution e Make sure that no lapping compound is smeared on the stem C of the valve 16 17 e First use an average grade lapping compound 120 150 and then a finer grade more than 200 S e Mix lapping compound with a small quantity of engine oil to facilitate even application b Tap the valve 16 17 a few times with the grinding tool against the valve 24 25 while continuing to rotate the tool slightly B Grinding tool c Remove the lapping compound with paraffin d Coat the seating surface of the valve seat 24 25 with a thin layer of engine oil in order to lap the valve and valve seat with oil e Inspect the contact surface between the valve 15 16 and the valve seat 24 25 f If necessary replace the valve seat 24 25 INSTALLATION SERVICE POINTS
40. on Nozzle July 1996 4ME0206 4ME0207 INSPECTION FUEL INJECTION NOZZLE 1 Connect the nozzle tester to injection nozzle 3 and carry out the tests described below Caution e Before starting the tests operate the lever of the nozzle tester two or three times to bleed air from the nozzle Valve opening pressure test 1 Slowly push down the nozzle tester lever The pressure gauge pointer will gradually rise and then deflect suddenly at a certain value Make a note of the pressure at which the pointer suddenly deflects 2 If this pressure value deviates from the standard value disassemble the nozzle Clean and reassemble the nozzle Then adjust to the specified pressure by fitting a different shim 9 3 A difference in shim thickness of 0 05 mm changes the opening pressure by 5 kPa Shims are available in thicknesses from 1 00 to 1 95 mm increasing by increments of 0 05 mm 4 Fit a new fuel injection nozzle 3 if the pressure value is still incorrect after adjustment Spray pattern test 1 Move the nozzle tester lever with a fast short stroke four to six strokes per second so that a continuous spray of fuel is obtained from the nozzle A The fuel exits the nozzle in a straight thin spray pattern correct B Excessive spray angle incorrect C Spray deflected to one side incorrect D Interrupted spray form incorrect 2 If necessary disassemble and clean the injection nozzle and repeat th
41. r 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 but 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 a
42. reas Observe the procedure described in the text when applying the FIPG Mitsubishi Motors Corporation July 1996 PWEE9602 F8QT ENGINE Special Tools 11A 2 1 2 SPECIAL TOOLS Number Name Use MB990767 Camshaft sprocket holder Removal of camshaft sprocket MB991614 Angle gauge Tightening cylinder head bolts MB996014 Valve spring compressor Removal of valve spring split cones MB996015 Flywheel stopper Locking the flywheel MB996016 Reaming valve guides MB996018 Slip gauge Measuring the crankshaft end play MB996020 Valve guide remover Pressing in valve guides MB996021 Valve stem seal remover Removal of valve guide seal Mitsubishi Motors Corporation MB996022 July 1996 Valve seat installer PWEE9602 Pressing in intake valve seat 11A 2 2 F8QT ENGINE Special Tools Number Name Use 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 MB996027 Bearing installer Installation of intermediate shaft inner bearing MB996028 Bearing installer Installation of intermediate shaft outer bearing MB996029 Valve guide installer Pressing in valve guides MB996030 Meas
43. s Length mm 144 0 02 Small end inside diameter mm 26 013 26 025 Squareness top bottom mm Straightness mm Mitsubishi Motors Corporation July 1996 PWEE9602 11A 1 4 F8QT ENGINE Specifications Item Standard Flywheel Axial throw measured at a radius of 80 mm mm 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 Loading 10 2 N Loading 70 N Lubrication system Oil capacity exclusive of oil filter L Oil capacity inclusive of oil filter L Difference between MAX MIN marks on dipsitck L Oil pressure with new filter and hot engine 13 r s 1 000 rpm min kPa 50 r s 3 000 rpm Mitsubishi Motors Corporation July 1996 PWEE9602 F8QT ENGINE Specifications 11A 1 5 TORQUE SPECIFICATIONS Items Crankshaft pulley Crankshaft pulley bolt Timing belt Camshaft sprocket bolt Water pump Water pump pulley bolt Water pump bolt Thermostat Thermostat cover bolt Thermostat housing bolt Bleedscrew Glow plugs Glow plug Glow plug nut Turbocharger Turbocharger nut Exhaust downpipe connector nut Oil supply pipe union nut
44. the third stage e let the engine warm up engine cooling fan starts to turn e then angle tighten the cylinder head bolts to 120 7 in a single uninterrupted movement PWEE9602 11A 12 4 Mitsubishi Motors Corporation F8QT ENGINE Rocker Cover and Cylinder Head July 1996 D lt ROCKER COVER GASKET INSTALLATION 1 Lightly smear the corners of the rocker cover gasket with a sealant 2 Locate the gasket on the rocker cover 3 Fit the rocker cover Caution e Make sure the gasket is still properly located PWEE9602 F8QT ENGINE Camshaft Intake and Exhaust Valves 13 CAMSHAFT INTAKE AND EXHAUST VALVES REMOVAL AND INSTALLATION d Lubricate internal parts with engine oil during reassembly Removal steps 1 Bolt pF4 2 1 camshaft bearing cap pF4 3 2 camshaft bearing cap 4 No 3 camshaft bearing cap 5 No 4 camshaft bearing cap Fa 6 No 5 camshaft bearing cap 7 Camshaft KH 8 Oil seal 9 Tappet pad 0 Tappet 4 PE 11 12 13 14 4B 0 4 15 16 Mitsubishi Motors Corporation Retainer locks Valve spring retainer Valve spring Valve spring collar Valve stem seal Intake valve July 1996 17 4C 4C 4D 4E PWEE9602 Co 9 REN0048 Exhaust valve Glow plug Injection nozzle Shield Water pipe Intake valve guide Exhaust valve guide Intake v
45. ue NOTE Check that the crankshaft rotates smoothly RENO114 Mitsubishi Motors Corporation July 1996 PWEE9602 F8QT ENGINE Pistons and Piston Pins 11A 21 1 21 PISTONS AND PISTON PINS REMOVAL AND INSTALLATION Lubricate all internal parts with engine oil during reassembly NG REN0115 Removal steps 1 Circlip A KA 2 Piston pin 3 Connecting MB PAM 4 Piston ring 1 MB A 4 5 Piston ring No 2 B pPAd 6 Oil ring 7 Piston REMOVAL SERVICE POINTS PISTON PIN REMOVAL 1 Remove the circlips 2 Remove the piston pin 2 Mitsubishi Motors Corporation July 1996 PWEE9602 11A 21 2 F8QT ENGINE Pistons and Piston Pins MH060014 Mitsubishi Motors Corporation July 1996 4ME0256 4ME0258 Bp PISTON RING REMOVAL INSPECTION PISTON PIN CONNECTING ROD PISTON 1 Measure the clearance between the piston pin 2 and the piston 7 Replace the part in question if the clearance exceeds the limit value PISTON RING GAP 1 Insert the piston rings 4 5 6 in the cylinder bore of the cylinder block with the aid of the piston 7 2 Hold the piston rings 4 5 6 in this position and measure the ring gap with a feeler gauge Fit new piston rings if the measured value exceeds the limit value Caution e Use the piston 7 so that the piston rings 4 5 6 are aligned in the cylinder bore at right angles to the wall e The piston rin
46. uring device adapter Adjustment of fuel injection pump Mitsubishi Motors Corporation MB996031 July 1996 Valve stem seal installer PWEE9602 Installation of valve guide seal F8QT ENGINE Special Tools Number Name 11A 2 3 Use 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 sleeve nut assembly 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 Mitsubishi Motors Corporation MB996041 July 1996 Special socket PWEE9602 Removal of fuel injectors 11 2 4 F8QT ENGINE Special Tools Number Name Use MB996042 Oil seal installer Installation of camshaft oil seal MB996043 Sprocket stopper Locking the injection pump sprocket Mitsubishi Motors Corporation MD998715 July 1996 Pulley holder pin PWEE9602 Retaining the camshaft sprocket use together with MB990767 F8QT ENGINE Crankshaft Pulley 11A 3 1
47. y replace the needle valve 10 and nozzle tip 11 as a set INSTALLATION SERVICE POINTS o PA lt FUEL INJECTION NOZZLE INSTALLATION Rb Fit new heat shields in the cylinder head with the raised edge facing towards the swirl chamber Fit the fuel injection nozzle and tighten them to 70 Nm Fit the fuel return hoses on the fuel injection nozzle YC y Z BEN0100 Mitsubishi Motors Corporation July 1996 PWEE9602 F8QT ENGINE Fuel Injection Pump 11A 19 1 19 FUEL INJECTION PUMP ER S s e 14 e 42 13 RENO101 Removal steps 1 Screwed sleeve nut assembly 10 Vacuum hose 2 Flange 11 Vacuum hose 3 Nut 12 Wiring harness connector 4 Washer 13 Wiring harness connector A 5 Sprocket 14 Wiring harness connector 6 Injection pipe 15 Bolt 7 Throttle cable 16 Bolt 8 Fuel return pipe B 17 Fuel injection pump 9 Fuel supply pipe Mitsubishi Motors Corporation July 1996 PWEE9602 11A 19 2 104 Mitsubishi Motors Corporation F8QT ENGINE Fuel Injection Pump July 1996 REMOVAL SERVICE POINTS MA SPROCKET REMOVAL 1 Locate the sprocket stopper MB996043 between the pump bracket and the sprocket Fasten the tool with the bolts supplied with the set 2 Remove the screwed sleeve and nut assembly with hexagon socket spanner MB996036 release by turning clockwise 3 Remove the nut 4 Pull the sprocket off the shaft with a gear puller Remove
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