Mitsubishi F8QT manual

GENERAL INFORMA TION 1 1A-0-3 ............................... 1. SPECIFICA TIONS 1 1A-1-1 ................................... SERVICE SPECIFICA TIONS 1 1A-1-1 ........................ T ORQUE SPECIFICA TIONS 1 1A-1-5 ........................ FORM-IN-PLACE GASKET 1 1A-1-8 ......................... 2. SPECIAL T OOLS 1 1A-2-1 .........................[...]

1 1A-0-2 NOTES PWEE9602 E July 1996 Mitsubishi Motors Corporation[...]

F8QT ENGINE - General Information 1 1A-0-3 GENERAL INFORMA TION SECTIONAL VIEW OF ENGINE REN0137 PWEE9602 E July 1996 Mitsubishi Motors Corporation[...]

F8QT ENGINE - General Information 1 1A-0-4 SECTIONAL VIEW OF ENGINE REN0138 PWEE9602 E July 1996 Mitsubishi Motors Corporation[...]

F8QT ENGINE - General Information 1 1A-0-5 SECTIONAL VIEW OF ENGINE REN0139 PWEE9602 E July 1996 Mitsubishi Motors Corporation[...]

F8QT ENGINE - General Information 1 1A-0-6 Description Specifications T ype F8QT diesel engine Number and arrangement of cylinders 4 in-line Combustion chamber Swirl chamber T otal displacement 1870 cm 3 Cylinder bore ´ stroke 80 ´ 93 mm Compression ratio 21 V alve mechanism Single overhead camshaft Number of valves Intake 4 Exhaust 4 V alve timi[...]

F8QT ENGINE - Specifications 1 1A-1-1 1. SPECIFICA TIONS SERVICE SPECIFICA TIONS Item Standard Limit Cylinder head Flatness of cylinder head surface mm 0.05 - Cylinder head gasket Gasket thickness mm Projecting height of piston - 0.073 Number of holes; 2 1.4 - Projecting height of piston 0.073 - 0.206 Number of holes; 1 1.5 - Projecting height of p[...]

F8QT ENGINE - Specifications 1 1A-1-2 Item Limit 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 - V alves V alves clearance Checking Intake 0.15 - 0.25 - mm Exhaust 0.35 - 0.45 - Adjusting Intake 0.2 - Exhaust 0.4 - V alve diameter mm Intake 36.22 - Exhaust 31.62 - V [...]

F8QT ENGINE - Specifications 1 1A-1-3 Item Limit Standard Intermediate shaft Inner bearing mm 39.5 - Outer bearing mm 40.5 - End play m m 0.07 - 0.15 - Crankshaft End play m m 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 T aper mm - 0.005 Diameter [...]

F8QT ENGINE - Specifications 1 1A-1-4 Item Limit Standard Flywheel Axial throw measured at a radius of 80 mm mm - 0.07 Oil pump End play m m 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[...]

F8QT ENGINE - Specifications 1 1A-1-5 TORQUE SPECIFICA TIONS Items Nm Crankshaft pulley Crankshaft pulley bolt 120 Timing belt Camshaft sprocket bolt 50 W ater pump W ater pump pulley bolt 20 W ater pump bolt 12.5 Thermostat Thermostat cover bolt 10 Thermostat housing bolt 10 Bleedscrew 0.6 Glow plugs Glow plug 22.5 Glow plug nut 5 T urbocharger T [...]

F8QT ENGINE - Specifications 1 1A-1-6 Items Nm Rocker cover and cylinder head Rocker cover nut 5 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) 10 Camshaft bearing cap bolt (M8) 20 Glow plug 22.5 Fuel injection nozzle 70 V acuum pump[...]

F8QT ENGINE - Specifications 1 1A-1-7 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 Front plate bolt 12.5 PWEE9602 E July 1996 Mit[...]

F8QT ENGINE - Specifications 1 1A-1-8 FORM-IN-PLACE GASKET The engine has several areas where the form-in-place gasket (FIPG) is in use. T o 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. T oo thin a bead could cau[...]

F8QT ENGINE - Special T ools 1 1A-2-1 2. SPECIAL TOOLS T ool Number Name Use MB990767 Camshaft sprocket holder Removal of camshaft sprocket MB991614 Angle gauge T ightening cylinder head bolts MB996014 V alve spring compressor Removal of valve spring split cones MB996015 Flywheel stopper Locking the flywheel MB996016 Reamer Reaming valve guides MB9[...]

F8QT ENGINE - Special T ools 1 1A-2-2 T ool Us e Name Number MB996023 V alve 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[...]

F8QT ENGINE - Special T ools 1 1A-2-3 T ool Us e Name Number MB996032 T ension gauge Measuring timing belt deflection MB996033 T ension 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 adapt[...]

F8QT ENGINE - Special T ools 1 1A-2-4 T ool Us e Name Number 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 with MB990767) PWEE9602 E July 1996 Mitsubishi Motors Corporation[...]

F8QT ENGINE - Crankshaft Pulley 1 1A-3-1 3. CRANKSHAFT PULLEY REN0143 1 2 120 Nm Removal steps A A "" A A 1. Crankshaft pulley bolt 2. Crankshaft pulley REMOV AL SERVICE POINT A A " CRANKSHAFT PULLEY BOL T REMOV AL Use special tool MB996015 to hold the flywheel during removal. PWEE9602 E July 1996 Mitsubishi Motors Corporation REN014[...]

F8QT ENGINE - Crankshaft Pulley 1 1A-3-2 INST ALLA TION SERVICE POINT " A A CRANKSHAFT PULLEY INST ALLA TION (1) Use special tool MB996015 to hold the flywheel during installation. (2) Apply a locking agent to the screw thread of the bolt. T ighten the bolt to the specified torque. PWEE9602 E July 1996 Mitsubishi Motors Corporation REN0144 MB9[...]

F8QT ENGINE - Timing Belt 1 1A-4-1 4. TIMING BEL T REMOV AL AND INST ALLA TION REN0001 50 Nm 12 10 11 13 8 9 Removal steps 1. Bolt 2. Bolt 3. Nut 4. Engine support bracket 5. T iming gear case cover 6. T iming gear case cover 7. T iming gear case cover A A "" B A 8. T iming belt A B "" A A 9. Camshaft sprocket bolt 10. Camshaft [...]

F8QT ENGINE - Timing Belt 1 1A-4-2 REMOV AL SERVICE POINTS A A " TIMING BEL T REMOV AL (1) T urn 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: D flywheel/clutch housing; D rear guard plate/camshaft sprocket. Scribe a mark on the injection pump mounting [...]

F8QT ENGINE - Timing Belt 1 1A-4-3 (4) Fit the timing belt so that the lines on the belt are aligned with t he marks on th e crankshaft a nd camshaft sprockets and t he injection pump sprocket. NOTE D the direction of rotation of t he belt (see t he arrows on th e belt); D the sequence in which the belt is fitted around the sprockets. (5) Fit the s[...]

F8QT ENGINE - Timing Belt 1 1A-4-4 (7) Abnormal wear in teeth. (8) Missing tooth. TIMING BEL T TENSIONER AND IDLER (1) Check that the tensioner a nd idler rotate smoothly without excessive play or abnormal noise. Replace them with new ones if necessary . PWEE9602 E July 1996 Mitsubishi Motors Corporation 8EN0068 REN0008[...]

F8QT ENGINE - W ater Pump 1 1A-5-1 5. W A TER PUMP REMOV AL AND INST ALLA TION REN0009 20 Nm 12.5 Nm Removal steps 1. V -ribbed belt (alternator & others) 2. Bolt 3. W ater pump pulley 4. Bolt 5. W ater pump 6. W ater pump gasket PWEE9602 E July 1996 Mitsubishi Motors Corporation[...]

F8QT ENGINE - Thermostat 1 1A-6-1 6. THERMOST A T REMOV AL AND INST ALLA TION REN0010 10 Nm 0.6 Nm 10 Nm Removal steps 1. Bolt 2. Thermostat cover 3. Plate " A A 4. O-ring 5. Thermostat 6. Bolt 7. Thermostat housing " A A 8. O-ring 9. Bleedscrew INST ALLA TION SERVICE POINT " A A O-RING INST ALLA TION Caution D If O-rings are soaked [...]

F8QT ENGINE - W ater Hoses an d Pipes 1 1A-7-1 7. W A TER HOSES AND PIPES REMOV AL AND INST ALLA TION REN0035 Removal steps 1. W ater inlet hose 2. W ater outlet hose 3. Heater inlet hose 4. Heater outlet hose PWEE9602 E July 1996 Mitsubishi Motors Corporation[...]

F8QT ENGINE - Engine Coolant T emperature Sensor 1 1A-8-1 8. ENGINE COOLANT TEMPERA TURE SENSOR REMOV AL AND INST ALLA TION REN0036 Removal steps 1. Wiring harness connector 2. Retaining clip 3. T emperature sensor , ECU 4. T emperature sensor , instrument panel PWEE9602 E July 1996 Mitsubishi Motors Corporation[...]

F8QT ENGINE - Glow Plugs 1 1A-9-1 9. GLOW PLUGS REMOV AL AND INST ALLA TION REN0037 5N m 22.5 Nm Removal steps 1. Nut 2. Glow plug leads, Nos. 1 and 2 3. Glow plug leads, Nos. 3 and 4 4. Glow plug PWEE9602 E July 1996 Mitsubishi Motors Corporation[...]

F8QT ENGINE - T urbocharger 1 1A-10-1 10. TURBOCHARGER REMOV AL AND INST ALLA TION REN0038 45 Nm 35 Nm 45 Nm 25 Nm 8N m 28.7 Nm 25 Nm 25 Nm Removal steps 1. V acuum hose 2. Oil supply pipe 3. Oil return pipe 4. Nut 5. Banjo bolt 6. Coolant supply pipe 7. Union nut 8. Coolant discharge pipe 9. Connector-to-exhaust downpipe 10. Nut " A A 1 1. T [...]

F8QT ENGINE - Intake and Exhaust Manifolds 1 1A-1 1-1 1 1. INT AKE AND EXHAUST MANIFOLDS REMOV AL AND INST ALLA TION REN0039 25 Nm 30 Nm 19.5 Nm 19.5 Nm 8N m Removal steps 1. V acuum hose 2. EGR valve 3. EGR pipe 4. Oil pipe from turbocharger 5. V acuum hose to turbocharger 6. Engine hanger 7. Bracket 8. Nuts 9. Intake and exhaust manifolds 10. Gas[...]

F8QT ENGINE - Rocker Cover and Cylinder Head 1 1A-12-1 12. ROCKER COVER AND CYLINDER HEAD REMOV AL AND INST ALLA TION REN0040 5N m Removal steps 1. Engine hanger 2. Thermostat housing 3. V acuum pump 4. Oil filler cap 5. Nut 6. Rocker cover " D A 7. Rocker cover gasket " C A 8. Cylinder head bolt 9. W asher A A "" B A 10. Cylind[...]

F8QT ENGINE - Rocker Cover and Cylinder Head 1 1A-12-2 REMOV AL SERVICE POINTS A A " CYLINDER HEAD REMOV AL (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. A B " CYLINDER HEAD GASKET REMOV AL Caution D When removing the cylinder head ga[...]

F8QT ENGINE - Rocker Cover and Cylinder Head 1 1A-12-3 " B A CYLINDER HEAD INST ALLA TION (1) Select a suitable cylinder head gasket 11 . (2) Rotate the crankshaft so that the piston of No. 1 cylinder is positioned a quarter-stroke past TDC. (3) Fit the cylinder head over the locating dowels. " C A CYLINDER HEAD BOL T INST ALLA TION (1) W[...]

F8QT ENGINE - Rocker Cover and Cylinder Head 1 1A-12-4 " D A ROCKER COVER GASKET INST ALLA TION (1) Lightly smear th e corners of the rocker cover gasket with a sealant. (2) Locate the gasket on the rocker cover . (3) Fit t he rocker cover . Caution D Make sure the gasket is still properly located. PWEE9602 E July 1996 Mitsubishi Motors Corpor[...]

F8QT ENGINE - Camshaft, Intake and Exhaust V alves 1 1A-13-1 13. CAMSHAFT , INT AKE AND EXHAUST V AL VES REMOV AL AND INST ALLA TION REN0048 20 Nm 10 Nm 70 Nm 22.5 Nm Lubricate all internal parts with engine oil during reassembly . Removal steps 1. Bolt " F A 2. No. 1 camshaft bearing cap " F A 3. No. 2 camshaft bearing cap " F A 4. [...]

F8QT ENGINE - Camshaft, Intake and Exhaust V alves 1 1A-13-2 REMOV AL SERVICE POINTS A A " RET AINER LOCKS REMOV AL (1) Fit valve spring compressor MB996014 on the cylinder head 31 as shown in the illustration. (2) Press down the valve spring retainer 12 a nd remove t he retainer locks 11 . A B " V AL VE STEM SEAL REMOV AL Remove the seal[...]

F8QT ENGINE - Camshaft, Intake and Exhaust V alves 1 1A-13-3 (3) T ap the valve seat through the passage and out of the cylinder head using a long drift. A E " SWIRL CHAMBER REMOV AL (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 . [...]

F8QT ENGINE - Camshaft, Intake and Exhaust V alves 1 1A-13-4 INT AKE AND EXHAUST V AL VES 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 toget[...]

F8QT ENGINE - Camshaft, Intake and Exhaust V alves 1 1A-13-5 V AL VE SEA T V alve seat width (1) Replace the valve seat 24, 2 5 if 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 t he contact surface is t oo wide, correct this with a valve seat cutter . Cutter a[...]

F8QT ENGINE - Camshaft, Intake and Exhaust V alves 1 1A-13-6 V AL VE AND V AL VE SEA T (1) The valve an d the valve seat must be lapped as follows: (a) S mear a thi n layer of lappi ng com pound evenly on the valv e seati ng sur face A of the val ve s eat 24, 25 . Caution D Make sure that no lapping compound is smeared on the stem C of the valve 16[...]

F8QT ENGINE - Camshaft, Intake and Exhaust V alves 1 1A-13-7 (3) Heat the cylinder head to about +100 _ C. (4) Install the intake valve seat on valve seat installer MB996022 and exhaust valve seat on valve seat installer MB996023. (5) Immerse t he valve seats 24, 25 in liquid nitrogen so as to cool them sufficiently . (6) Pressing the valve seats 2[...]

F8QT ENGINE - Camshaft, Intake and Exhaust V alves 1 1A-13-8 (6) Clean the valve guide inner bores 22, 23 with reamer MB996024. " D A V AL VE STEM SEAL INST ALLA TION (1) Lubricate th e valve guides 22, 23 with engine oil. Introduce t he valves 16, 17 through the valve guides. Locate the protective plastic cap over the valve stem. (2) Locate t[...]

F8QT ENGINE - Camshaft, Intake and Exhaust V alves 1 1A-13-9 " G A SWIRL CHAMBER INST ALLA TION 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[...]

F8QT ENGINE - V acuum Pump 1 1A-14-1 14. V ACUUM PUMP REMOV AL AND INST ALLA TION REN0083 22 Nm 22 Nm Removal steps 1. V acuum hose 2. Bolt 3. W asher 4. V acuum pump 5. Gasket PWEE9602 E July 1996 Mitsubishi Motors Corporation[...]

F8QT ENGINE - Oil Cooler an d Oil Filter 1 1A-15-1 15. OIL COOLER AND OIL FIL TER REMOV AL AND INST ALLA TION REN0085 60 Nm 60 Nm 35 Nm Lubricate all internal parts with engine oil during reassembly . Removal steps " A A 1. Oil filter 2. Nut 3. Thermostat housing 4. O-ring 5. Plug 6. Sealing washer A A " 7. Thermostat 8. Spring 9. Nut 10.[...]

F8QT ENGINE - Oil Pan, Oil Pump and Oil Jets 1 1A-16-1 16. OIL P AN, OIL PUMP A ND OIL JETS REMOV AL AND INST ALLA TION REN0084 13 Nm 12 Nm 20 Nm 25 Nm 22 Nm Lubricate all internal parts with engine oil during reassembly . Removal steps 1. Drain plug 2. Bolt " A A 3. Oil pan 4. Bolt 5. Oil pump body 6. Bolt 7. Cover 8. Driven gear 9. Idler gea[...]

F8QT ENGINE - Oil Pan, Oil Pump and Oil Jets 1 1A-16-2 INST ALLA TION SERVICE POINTS " A A OIL P AN INST ALLA TION (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. ([...]

F8QT ENGINE - Intermediate Shaft and Intermediate Shaft Bearings 1 1A-17-1 17. INTERMEDIA TE SHAFT AN D INTERMEDIA TE SHAFT BEARINGS REN0091 15 Nm 50 Nm 15 Nm 15 Nm Lubricate all internal parts with engine oil during reassembly . Removal steps 1. T iming belt 2. Bolt A A "" E A 3. Intermediate shaft sprocket 4. Bolt 5. Cover 6. O-ring A B[...]

F8QT ENGINE - Intermediate Shaft and Intermediate Shaft Bearings 1 1A-17-2 REMOV AL SERVICE POINTS A A " INTERMEDIA TE SHAFT SPROCKET REMOV AL (1) Use sprocket stopper MB996034 to hold the sprocket during removal. (2) Remove the sprocket and t he sprocket key . A B " OIL PUMP DRIVE GEAR REMOV AL (1) Remove th e oil pump drive gear 7 with [...]

F8QT ENGINE - Intermediate Shaft and Intermediate Shaft Bearings 1 1A-17-3 " B A OUTER BEARING INST ALLA TION (1) Install the outer bearing with t he 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 th e [...]

F8QT ENGINE - Fuel Injection Nozzle 1 1A-18-1 18. FUEL INJECTION NOZZLE REMOV AL AND INST ALLA TION REN0099 22.5 Nm 70 Nm 70 Nm Removal steps 1. Injection pipe 2. Fuel return pipe A A "" A A 3. Fuel injection nozzle assembly 4. Heat shield 5. Nozzle body 6. W asher 7. Push rod 8. Spring 9. Shim A B " 10. Needle valve 1 1. Nozzle tip [...]

F8QT ENGINE - Fuel Injection Nozzle 1 1A-18-2 INSPECTION FUEL INJECTION NOZZLE (1) Connect t he nozzle tester to injection nozzle 3 a nd carry out th e tests described below . Caution D Before starting the tests, operate the lever of the nozzle tester two or three times to bleed air from the nozzle. V alve opening pressure test (1) Slowly push down[...]

F8QT ENGINE - Fuel Injection Nozzle 1 1A-18-3 Leakage test (1) Increase the pressure to 1 1 MPa by operating the lever of the nozzle tester . Maintain the pressure for 10 seconds. No fuel must dribble o ut of t he nozzle during this test. (2) If dribbling starts within this 10 second period, disassemble and clean the injection nozzle 3 and repeat t[...]

F8QT ENGINE - Fuel Injection Nozzle 1 1A-18-4 (c) Clean the seating E of the nozzle tip 11 with t he special scraper tool F . Caution D T ake care not to damage the seating face. (d) Use Fuso carbon deposit cleaning agent to remove encrusted carbon deposits. (e) Remove the carbon deposits in the injection hole of the nozzle tip 11 by rotating the n[...]

F8QT ENGINE - Fuel Injection Pump 1 1A-19-1 19. FUEL INJECTION PUMP REN0101 22.5 Nm 22.5 Nm 70 Nm 20 Nm 1 90 Nm Removal steps 1. Screwed sleeve/nut assembly 2. Flange 3. Nut 4. W asher A A "" A A 5. Sprocket 6. Injection pipe 7. Throttle cable 8. Fuel return pipe 9. Fuel supply pipe 10. V acuum hose 1 1. V acuum hose 12. Wiring harness co[...]

F8QT ENGINE - Fuel Injection Pump 1 1A-19-2 REMOV AL SERVICE POINTS A A " SPROCKET REMOV AL (1) Locate the sprocket stopper MB996043 between the pump bracket a nd the sprocket. Fasten the tool with the bolts supplied with th e set. (2) Remove t he screwed sleeve and nu t assembly with hexagon socket spanner MB996036 (release by turning clockwi[...]

F8QT ENGINE - Fuel Injection Pump 1 1A-19-3 FUEL INJECTION TIMING CHECK MEASURING T OOL INST ALLA TION (1) T urn 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: D flywheel/clutch housing D timing belt cover/camshaft sprocket. (2) T urn the crankshaft (clockwis[...]

F8QT ENGINE - Fuel Injection Pump 1 1A-19-4 FUEL INJECTION PUMP ADJUSTMENT MEASURING T OOL INST ALLA TION (1) T urn 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: D flywheel/clutch housing D timing belt cover/camshaft sprocket. (2) Remove cover 1 a nd th e bo[...]

F8QT ENGINE - Fuel Injection Pump 1 1A-19-5 (5) T urn the crankshaft (clockwise) 1 3/4 revolutions. (6) Remove the plug A . (7) Fit measuring device adaptor MB996030. D Locate the guide bush B in the pump. D Slide th e measuring pin C , which is part of t he measuring tool, into the guideway of the pump. D Locate and secure the holder D . (8) Posit[...]

F8QT ENGINE - Fuel Injection Pump 1 1A-19-6 (1 1) 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 in the n[...]

F8QT ENGINE - Pistons and Connecting Rods 1 1A-20-1 20. PISTONS A ND CONNECTING RODS REMOV AL AND INST ALLA TION REN01 10 45 Nm Lubricate all internal parts with engine oil during reassembly . Removal steps 1. Bolt 2. Connecting r od cap " A A 3. Connecting r od lower bearing (big-end bearing) " A A 4. Connecting rod upper bearing (big-en[...]

F8QT ENGINE - Pistons and Connecting Rods 1 1A-20-2 CONNECTING ROD BEARINGS Caution D Do not fit old connecting rod bearings 3, 4 if they are badly worn. D If any one of the connecting rod bearings 3, 4 is defective, the bearings should be replaced as a set. Clearance between connecting rod and crankshaft (1) Replace the part in question if the cle[...]

F8QT ENGINE - Pistons and Connecting Rods 1 1A-20-3 " B A PISTON AND CONNECTING ROD INST ALLA TION Caution D Ensure that the piston ring gaps A are correctly positioned. D T ake care not to damage the piston crown (combustion chamber) B. D T ake care not to strike the connecting rod against the oil jet. (1) Lightly coat the big-end journal, cy[...]

F8QT ENGINE - Pistons and Piston Pins 1 1A-21-1 21. PISTONS AN D PISTON PINS REMOV AL AND INST ALLA TION REN01 15 Lubricate all internal parts with engine oil during reassembly . Removal steps 1. Circlip A A "" B A 2. Piston pin 3. Connecting r od A B "" A A 4. Piston ring No. 1 A B "" A A 5. Piston ring No. 2 A B &quo[...]

F8QT ENGINE - Pistons and Piston Pins 1 1A-21-2 A B " PISTON RING REMOV AL 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 t he limit value. PISTON RING GAP (1) Insert the piston rings 4, 5, 6 in t he cylinder bore of the cyl[...]

F8QT ENGINE - Pistons and Piston Pins 1 1A-21-3 CUR V A TURE AND TWIST OF CONNECTING ROD (1) Measure th e curvature and t he twist of the connecting rod 3 . Replace the connecting rod if the limit values are exceeded. Caution D Installed connecting rod 3, with upper and lower connecting rod bearings in place, in the connecting rod alignment tool. D[...]

F8QT ENGINE - Flywheel 1 1A-22-1 22. FL YWHEEL REMOV AL AND INST ALLA TION REN0120 53 Nm Removal steps A A "" B A 1. Bolt A B "" A A 2. Flywheel ring gear 3. Flywheel REMOV AL SERVICE POINTS A A " FL YWHEEL REMOV AL Use flywheel stopper MB996015 to hold the flywheel during removal. A B " FL YWHEEL RING GEAR REMOV AL (1[...]

F8QT ENGINE - Flywheel 1 1A-22-2 INSPECTION FL YWHEEL 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 th e flywheel 3 . NOTE A new flywheel is always suppl[...]

F8QT ENGINE - Crankshaft and Cylinder Block 1 1A-23-1 23. CRANKSHAFT AND CYLINDER BLOCK REMOV AL AND INST ALLA TION REN0124 65 Nm 12.5 Nm Lubricate all internal parts with engine oil during reassembly . Removal steps 1. Bolt " C A 2. Front plate " D A 3. Oil seal 4. Bolt A A "" B A 5. Main bearing cap 6. Crankshaft " A A 7.[...]

F8QT ENGINE - Crankshaft and Cylinder Block 1 1A-23-2 REMOV AL SERVICE POINTS A A " MAIN BEARING CAP REMOV AL (1) Remove t he retaining bolts. NOTE T o remove No. 1 bearing cap (flywheel end) with screwdrivers, two M7 bolts must be fitted in t he bearing cap an d two M7 bolts in the cylinder block. INSPECTION CRANKSHAFT Ovality and taper of ma[...]

F8QT ENGINE - Crankshaft and Cylinder Block 1 1A-23-3 INST ALLA TION SERVICE POINTS " A A THRUST W ASHER INST ALLA TION (1) Fit t he thrust washers 7 at No. 2 journal on th e crankshaft 6 . Caution D Fit the thrust washers 7 with the oil grooves A facing outwards. " B A CRANKSHAFT MAIN BEARING / MAIN BEARING CAPS INST ALLA TION Caution D [...]

F8QT ENGINE - Crankshaft and Cylinder Block 1 1A-23-4 " D A CRANKSHAFT FRONT OIL SEAL INST ALLA TION (1) Coat the lip 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. (4) Fit the oil seal with oil seal installer MB99[...]

NOTES[...]