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ENGINE
F9Q SERIES
CONTENTS
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
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Description Specification
Compression ratio 19
Exhaust 4
Fuel injection system Direct injection system (common rail fuel injection)
Timing belt
Cylinder head
Exhaust 0.40 –
Piston
TORQUE SPECIFICATIONS
Item Nm
Crankshaft pulley
Bracket bolt 44 ± 4
Timing belt
Turbo nipple 26 ± 2
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Pressure regulator 35 ± 5
Turbocharger nut 24 ± 10
Manifold nut 28 ± 2
Item Nm
Glow plug 15 ± 1
Piston
Cylinder block
Flywheel bolt 55 ± 5
MD998715 Pulley holder pin Retaining the camshaft sprocket (use together
with MB990767)
MB996038 Oil seal installer Installation of crankshaft oil seal (flywheel end)
MB996040 Oil seal installer Installation of crankshaft oil seal (timing gear
end)
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MB991668 Belt tension meter Timing belt tension measurements (Use with
set MUT-II)
MB991802 Pin B
20 ± 2 Nm
) 115_ ± 15_
2
4
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44 ± 4 Nm
Removal steps
1. Alternator
2. Bracket
AA" "AA 3. Crankshaft pulley
4. Idler pulley
5. Auto tensioner
MB991802
(4) Tighten the bolt further 115_ ± 15_ using an angle gauge.
9 ± 0.9 Nm
60 ± 6 Nm 2
50 ± 5 Nm
4
1 3
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5
8
10 ± 1 Nm
REN0166
Removal steps
1. Timing belt cover, front
AA" "BA 2. Timing belt
3. Tensioner pulley
4. Crankshaft sprocket
5. Tensioner plate
AB" "AA 6. Camshaft sprocket
7. Engine cover bracket
8. Timing belt cover, rear
MB990767 REN0212
C
B
REN0168
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REN0169
MB996048
REN0170
MB996048
REN0170
MB991668
(Microphone)
10 – 20 mm
Y6035AJ
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REN0169
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.
REN0172
24 ± 10 Nm
12
26 ± 2 Nm
14
13 13
15
1
2
3
10
8
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12 ± 1 Nm
5
7
9
6
11
4
16
REN0173
1 2
25 ± 2 Nm
15 ± 1 Nm 4 3
) 60_ ± 10_
25 ± 0.2 Nm
12
7 5
62 ± 6 Nm 6
13
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10
35 ± 5 Nm 9
11
14
25 ± 2 Nm
16
8
15
25 ± 2 Nm
REN0174
Removal steps
1. Clip AA" "AA 12. Injection pump sprocket
2. Fuel return ramp 13. Engine hanger
"BA 3. High pressure pipe 14. Pressure regulator
4. Fuel injector flange 15. Injection pump
5. Fuel injector 16. Injection pump bracket
6. Adjusting washer NOTE
7. Pressure sensor When the fuel injectors and fuel injection rail are
"BA 8. High pressure pipe removed, put caps on their high pressure pipe
9. Pressure limiter connecting ports to prevent dust from entering the
10. Pressure limiter nipple fuel line. Leave the caps installed until the injectors
"BA 11. Fuel injection rail and fuel injection rail are reinstalled.
(2) For preparatory work, replace the center bolt of the special
tool MH062464 with a sufficiently longer bolt.
MH062464
(3) Remove the injection pump sprocket using the special
tool.
Bolt
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High pressure pipe "BA HIGH PRESSURE PIPE / FUEL INJECTION RAIL
B INSTALLATION
A (1) Position the fuel injection rail and finger tighten the
mounting bolts (the rail should be floating).
(2) Position all the high pressure pipes and finger tighten
then.
Tighten all the high pressure injection pipe connection
C (on the injector side A then on the fuel injection rail side
High pressure D B).
pipe Fuel injection
rail (3) Tighten the high pressure pipe C.
REN0178
(4) Tighten the fuel injection rail bolts D.
3
2
1
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REN0179
Removal steps
1. Solenoid valve
2. Vacuum hose
3. Vacuum tank
1
20 ± 2 Nm
28 ± 2 Nm 6
9
5
6
24 ± 10 Nm
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2
8 ± 0.8 Nm
3
10
8
7
4
8 ± 0.8 Nm
Removal steps
1. Engine hanger
2. Flap box
3. EGR valve
4. EGR valve gasket
5. EGR hose
6. EGR hose clamp
7. Turbocharger
8. Intake manifold
9. Exhaust manifold
10. Manifold gasket
2
9 3 1
6
5
4
14
8
15
7
10 ± 1 Nm
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13
12
11
10
39 ± 3 Nm
REN0181
Removal steps
1. Clip 9. Thermostat case gasket
2. Engine coolant temperature sensor 10. Cooling water line pipe
3. Gasket 11. O-ring
4. Thermostat case cover 12. Cooling water line pipe
5. Reinforcement 13. O-ring
6. Thermostat case cover gasket 14. Water pump
7. Thermostat 15. Water pump gasket
8. Thermostat case
12 ± 1 Nm
20 ± 2 Nm
3
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8
10
8.8 ± 1.5 Nm
15 ± 1 Nm
13 ± 1 Nm 5
1
4
REN0182
Removal steps
1. Engine hanger 6. Cylinder head cover
2. Glow plug 7. Cylinder head cover gasket
3. Camshaft position sensor "BA 8. Oil seal
"CA 4. Vacuum pump AA" "AA 9. Bearing cap
5. Vacuum pump gasket 10. Camshaft
REN0183
REN0184
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1
10
30 Nm + 50_ ± 4_
®Fully loosen 11
®25 Nm + 213_ ± 7_
4
5
6
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7
2
8
12
9
REN0185
Removal steps
"EA 1. Cylinder head bolt 7. Valve spring seat
"DA 2. Cylinder head gasket 8. Intake valve
3. Tappet 9. Exhaust valve
AA" "CA 4. Retainer locks AB" "BA 10. Valve stem seal
5. Valve spring retainer AC" "AA 11. Valve guide
AA" "CA 6. Valve spring 12. Cylinder head
REN0049
REN0050
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REN0051
REN0070
MB996029 (4) Locate the valve guides with the taper pointing down,
9,000 N on valve guide installer MB996029.
(5) Press in the valve guides until the installer abuts the
cylinder head.
Caution
D 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.
REN0071
(6) Clean the valve guide inner bores with reamer MB996024.
MB996024
REN0072
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REN0074
4ME0122
(2) Measure the valve seat angle and correct if it does not
meet the standard value.
Standard value: 45_
45_
REN0186
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(3) Insert the valve in the cylinder head and measure the
valve projection from the cylinder head bottom surface.
Replace the valve if the measurement does not meet
the standard value.
Standard value: –0.03 – 0.21 mm
REN0187
CYLINDER HEAD
(1) Check the cylinder head bottom surface for distortion.
Replace the cylinder head if the measurement does not
meet the standard value.
Standard value: 0.05 mm
Caution
D The cylinder head may not be reground.
VALVE SPRING
Out of square
(1) Measure the valve spring free height. If the measurement
does not meet the standard value, replace the valve
spring.
Standard value: 45.8 mm
Free height
1EN0264
VALVE GUIDE
(1) Measure the inner and outer diameters of the valve guide
to confirm that they are within the standard value range.
Standard value:
Inner diameter 7.00 – 7.02 mm
Outer diameter 12.03 – 12.05 mm
(2) Check that the dimension shown in the illustration meets
the standard value when the valve guide is installed in
the cylinder head.
REN0189
Standard value: 80.7 – 81.4 mm
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VALVE SEAT
90_
Measure at the positions shown in the illustration.
Standard value:
Seat angle 90_
Seat width 1.8 mm
Exterior diameter intake:
Intake 36.9 mm
1.8 mm
Exhaust 33.6 mm
Exterior diameter
TAPPET
Measure the tappet height to check that it meets the standard
value.
Standard value: 34.97 – 34.99 mm
REN0190
VALVE CLEARANCE CHECK AND ADJUSTMENT
(1) The valve clearances have to be checked/adjusted in
the following sequence.
14
12
13
15 ± 1.5 Nm
2
15
1 16
17
11
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5 15 ± 1 Nm
4
3 25 ± 2 Nm
10
14 ± 1 Nm
7
6
Removal steps
1. Oil pressure switch AA" 10. Oil plate
2. Gasket 11. Oil pump
3. Oil filter AB" "AA 12. Cylinder block plate, front
4. Oil cooler adaptor 13. Gasket
5. Oil cooler "BA 14. Oil seal
6. Drain plug "AA 15. Chain pad
7. Drain plug gasket 16. Gear
"CA 8. Oil pan 17. Chain
9. Oil pan gasket
REN0192
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REN0192
MB996040
REN0135
REN0194
Timing belt side (2) Tighten the oil pan bolts to 8 ± 0.8 Nm in the order shown
1 4 8 12 in the illustration.
13 9 5
(3) Then tighten them to 14 ± 1 Nm in the same order.
16
17
20
21
19
18 15
14 3 7 11
10 6 2
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10
8
9
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11
50 ± 5 Nm
1
4
3
REN0195
Removal steps
1. Connecting rod bolt 7. Oil ring
AA" 2. Connecting rod cap AB" "AA 8. Snap ring
"CA 3. Connecting rod lower bearing AB" "AA 9. Piston pin
"CA 4. Connecting rod upper bearing "DA 10. Piston
"BA 5. Piston ring No. 1 "DA 11. Connecting rod
"BA 6. Piston ring No. 2
REN0196
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Mark
REN0198
Base Support
REN0232
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Bearing (2) Set a bearing on the guide and slide the guide in the
direction of arrow.
MB996050
REN0233
(3) Firmly press the guide against the connecting rod to install
the bearing in position in the connecting rod.
(4) Slide back the guide and remove the connecting rod.
(5) Repeat the above procedure for all the remaining
connecting rods.
MB996050
REN0234
MB996050
REN0238
(7) Slide the support until the bearing cap comes in contact
with the guide pins on the base.
MB996050
Bearing cap
REN0235
MB996050
REN0236
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(9) Firmly press the guide against the bearing cap to install
the bearing in position in the bearing cap.
(10)Slide back the guide and remove the bearing cap.
(11)Repeat the above procedure for all the remaining bearing
caps.
MB996050
REN0237
50 Nm
REN0114
REN0199
PISTON RING
(1) Measure the thickness of the piston rings to check for
wear.
Standard value
Piston ring No. 1: 2.5 mm
Piston ring No. 2: 2.0 mm
Oil ring: 3.0 mm
REN0200
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PISTON PROTRUSION
(1) Clean the piston crown to remove deposits.
(2) Turn the crankshaft in the direction of operation to bring
No. 1 piston to TDC.
(3) Measure the protrusion of No. 1 piston using a dial gauge.
If the measurement is out of specification, replace the
Protrusion piston with a new one.
If the protrusion is still out of specification, replace the
cylinder block.
DEN0798 Standard value: 0.50 – 0.62 mm
NOTE
Do not take measurement at valve recess.
(4) Measure the piston protrusion on the remaining cylinders
by following the same procedure.
11
10
7
8 9
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6
1
55 ± 5 Nm
3
65 ± 6 Nm 4 REN0202
MB996015
REN0147
REN0211
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REN0203
REN0205
REN0207
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REN0209
REN0210
REN0136
MB996015
REN0147
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ENGINE F9Q
WORKSHOP MANUAL
FOREWORD
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.
Indicates the Indicates the Indicates the Indicates the Indicates the
group title. section title. group number. section number. page number.
Denotes tightening
torque.