Mitsubishi Renault F9Q1 F9Q2 engine factory workshop and repair manual download
Mitsubishi Renault F9Q1 F9Q2 engine factory workshop and repair manual
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Manual Contents
GENERAL INFORMATION
1. SPECIFICATIONS
SERVICE SPECIFICATIONS
TORQUE SPECIFICATIONS
2. SPECIAL TOOLS
3. CRANKSHAFT PULLEY
4. TIMING BELT
5. OIL SEPARATOR AND OIL RETURN PIPE
6. INJECTION PUMP AND FUEL INJECTOR
7. VACUUM HOSE
8. INTAKE AND EXHAUST
9. WATER PUMP AND WATER PIPE
10. CAMSHAFT AND VACUUM PUMP
11. CYLINDER HEAD
12. OIL PAN AND OIL PUMP
13. PISTON
14. CYLINDER BLOCK
About the F9Q1 F9Q2 engine
The F9x is the direct injected Diesel version and also features an 8-valve SOHC configuration, it has swirl generating intake ports to create swirling (vortex) of the aspirated air, and either a torodial- or an elsbett- piston bowl to twist the injected fuel vapour, also to achieve the required air/fuel mixing. The diesel-fuel is delivered either by a mechanical injection pump or a common rail fuel injection installation.
Applications:
F9Q 1.9 L (1,870 cc or 114 in3), B x S: 80.0 by 93.0 millimetres (3.15 in × 3.66 in).
1995–2002 Renault Mégane
1996–2002 Renault Espace
1996–2003 Renault Scenic I
1997–2010 Renault Master
1997–2001 Renault Laguna I
1998–2004 Mitsubishi Carisma
1998–2004 Mitsubishi Spacestar
1998–2004 Volvo S40
2001–2005 Renault Laguna II
2001–2012 Renault Clio
2001–2006 Renault Trafic II
2001–2006 Vauxhall Vivaro
2001–2006 Opel Vivaro
2002–2005 Nissan Interstar X70
2002–2006 Nissan Primastar
2003–2009 Renault Scenic II
2005–2015 Suzuki Grand Vitara
2009–2011 Renault Scenic III
Mitsubishi Renault F9Q1 F9Q2 engine factory workshop and repair manual Download
- Purpose and quick overview
- Change the engine oil and oil filter (oil_filter) on a Mitsubishi vehicle fitted with the Renault F9Q1 / F9Q2 diesel engine: drain old oil, replace the filter element and seals, reinstall drain plug, refill with correct oil, run and check for leaks.
- Required consumable parts every oil change: engine oil (correct grade/spec — check your owner’s manual), oil filter element (cartridge) and its O‑ring/seal, and a new drain‑plug crush washer. Replace the drain‑plug and filter housing O‑ring if damaged or brittle.
- Safety first
- Work on level ground, parking brake on, chock wheels to stop rolling.
- Let the engine cool 10–20 minutes if it was very hot (warm oil drains faster but don’t work on scalding oil).
- Use jack stands or ramps; never rely on a jack alone.
- Wear nitrile or mechanic gloves, eye protection, and keep rags and a fire extinguisher nearby.
- Dispose of used oil and filter at a recycling center — do not pour down drains.
- Tools you will need (description + how to use each)
- Socket set (metric: 8–19 mm common sizes) with ratchet and extensions
- Description: sockets fit over bolt heads; ratchet lets you turn fasteners quickly.
- How to use: pick correct socket, push onto ratchet, place on bolt, pull handle to break loose and spin. Use extensions to reach recessed bolts.
- Oil drain pan
- Description: low shallow container to catch used oil.
- How to use: slide under oil pan/drain plug before loosening plug. Keep clear of spilled oil.
- Wrench or socket for oil drain plug (size varies by model)
- Description: typically a single socket or spanner that fits the drain plug head.
- How to use: break plug loose while pan is in place, then remove by hand. Turn slowly — oil will gush.
- Oil filter wrench or cap socket (strap wrench or specific cap size)
- Description: strap wrench grips canisters; cap-type fits over cartridge housing cap; some Renault/PSA engines use a deep socket or special hex.
- How to use: engage wrench on the filter housing cap and turn counterclockwise to loosen. If cap is plastic, use care not to round it off; use correct size cap socket where possible.
- Funnel
- Description: plastic or metal cone to pour oil without spilling.
- How to use: insert in filler neck, pour slowly to avoid overflow.
- New oil filter element and replacement O‑ring(s)
- Description: filter cartridge that fits inside the housing; O‑ring seals the cap to the housing.
- How to use: remove old cartridge, clean housing, install new cartridge and lubricate O‑ring with clean oil before seating to ensure seal.
- New crush washer (drain plug gasket)
- Description: thin metal (often copper) washer that seals drain plug to oil pan.
- How to use: remove old washer, place new washer on drain plug before reinstallation; torque plug to spec or snugly as described below.
- Torque wrench (recommended)
- Description: wrench that applies a controlled tightening torque.
- How to use: set to specified torque for drain plug and filter cap (check manual). If you don’t have one, tighten to snug + a small quarter turn; don’t overtighten to avoid stripping threads.
- Jack and jack stands or ramps
- Description: hydraulic jack lifts vehicle; stands support it safely.
- How to use: lift at manufacturer jacking points, place stands, slowly lower onto stands. If using ramps, drive up slowly and set parking brake.
- Breaker bar (optional)
- Description: long non‑ratcheting bar for extra leverage on stuck fasteners.
- How to use: attach socket and apply steady force to break free corroded bolts.
- Gloves, shop rags, cleaning solvent (degreaser)
- Description: protect hands and clean parts.
- How to use: wipe leaks, clean mating surfaces, remove old oil and grime before installing new seals.
- Extra tools you might need and why
- Specific oil filter cap socket (if the housing cap is a specific size) — prevents rounding the cap and makes removal easier.
- Impact wrench (not necessary but can loosen stubborn bolts) — use with care to avoid overtightening on reassembly.
- Magnetic drain plug or thread chaser (if metal debris suspected) — helps detect metal shavings or clean threads.
- Flashlight or inspection lamp — improves visibility under car and around filter housing.
- Service manual or repair data sheet — gives exact torque specs, oil capacity, filter part numbers and any vehicle‑specific procedures.
- Parts replacement details (what to replace, why, what to buy)
- Oil filter element (replace every oil change)
- Why: removes contaminants; reused filter will clog and reduce engine protection.
- What to buy: filter cartridge specific to F9Q1/F9Q2 and your vehicle year — buy OEM or high‑quality equivalent. Often sold as “filter cartridge + O‑ring” kit.
- O‑ring/seal for filter housing (always replace)
- Why: sealing ring compresses and can harden; reuse risks leaks.
- What to buy: the O‑ring that fits the filter housing cap — included with most filter kits.
- Drain plug crush washer (replace every time)
- Why: crush washers seal between plug and pan; they deform and lose sealing ability after removal.
- What to buy: copper or aluminum washer sized for your drain plug (usually inexpensive and sold per piece or in packs).
- Engine oil (full oil change)
- Why: oil degrades and becomes contaminated, losing lubrication and engine protection.
- What to buy: oil that meets the manufacturer’s specifications (check owner’s manual or service sticker). Choose correct viscosity and specification for diesel engines (ACEA/Manufacturer spec). Buy enough volume for a full change (including filter) — check manual for capacity.
- Drain plug (only if damaged)
- Why: stripped threads or rounded head will not seal or allow proper torque.
- What to buy: OEM replacement plug or correct‑thread aftermarket plug.
- Step‑by‑step procedure (bullets for each major action)
- Prepare: gather tools, new oil, filter kit, crush washer, rags, drain pan, funnel, and jack/stands.
- Warm the engine briefly (2–5 minutes) so oil is warm but not scalding — warm oil drains faster and carries more contaminants. Turn off engine.
- Position vehicle: park on level ground, chock rear wheels, lift front with jack at jacking points and support securely on jack stands or drive up ramps.
- Locate drain plug and filter housing: drain plug on oil pan underneath; filter housing usually on top of engine or lower front — consult manual if unsure.
- Place drain pan: slide pan under drain plug and under filter housing if removing lower parts.
- Remove drain plug: loosen with correct socket/wrench, back out by hand, let oil drain into pan. Be prepared for a stream — remove slowly once loosened to control flow.
- Remove oil filter cartridge:
- If housing cap on top: use correct cap socket or strap wrench to turn cap counterclockwise and remove.
- Pull out the old cartridge and the old O‑ring(s).
- Clean inside housing and cap with a lint‑free rag.
- Replace O‑ring(s) and filter cartridge:
- Fit new O‑ring(s) into cap groove; coat lightly with new engine oil to help seal and prevent pinching.
- Insert new cartridge into housing, ensure correct orientation.
- Refit cap and hand‑thread; tighten with wrench to specified torque or snug plus a small fraction of a turn (if no torque wrench).
- Refit drain plug:
- Clean mating surface, install new crush washer on plug, thread by hand to avoid cross‑threading.
- Tighten to specified torque if available; if not, tighten until snug then a small extra turn — don’t overtighten.
- Refill with new oil:
- Remove oil filler cap on top of engine, insert funnel, pour correct oil quantity slowly.
- Leave a little under full; you’ll top up after running engine.
- Start engine and check for leaks:
- Run for 1–2 minutes at idle, watch under car and around filter housing and drain plug for leaks.
- Turn off engine and wait 2–5 minutes for oil to settle.
- Check oil level:
- Use dipstick to check level and add small amounts until within the safe range. Do not overfill.
- Final check and cleanup:
- Re‑check filter cap and drain plug for tightness.
- Clean spilled oil, dispose of used oil and filter properly, reset service indicator if applicable.
- Common pitfalls and how to avoid them
- Rounded filter cap: use correct cap socket or strap wrench and avoid cheater bars; don’t use pliers on plastic caps.
- Cross‑threaded drain plug: always start threads by hand; don’t force if it feels wrong.
- Forgetting to replace O‑ring or crush washer: always replace to avoid leaks.
- Overfilling oil: causes foaming and possible engine damage — add slowly and check level after running.
- Working without supports: always use jack stands; jacks can fail.
- When to get professional help / additional recommended checks
- If filter cap or drain plug is seized or rounded, seek a shop to remove without damage.
- If you find metal shavings in the oil, get a mechanic to inspect — could indicate internal wear.
- If you’re unsure about torque specs, filter orientation, or exact parts, consult the vehicle’s service manual or a dealer and consider having a shop do the job.
- Quick checklist to buy before you start
- Correct engine oil (type/quantity per manual), oil filter cartridge kit (element + O‑ring), drain plug crush washer, and basic tool set (socket set, oil filter cap/strap wrench, drain pan, funnel, jack stands). rteeqp73
Надежный или неудачный? Разбираем все проблемы дизел... Двигатель F9Q, появившийся в 1997 году на Renault Megane, стал первым французским дизелем с непосредственным ...
Надежный или неудачный? Разбираем все проблемы дизел... Двигатель F9Q, появившийся в 1997 году на Renault Megane, стал первым французским дизелем с непосредственным ...
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Summary (one line)
- This is a complete beginner-friendly guide to diagnosing, removing, inspecting, and replacing an automatic/automated clutch system on Renault F9Q1/F9Q2 diesel applications (the “F9Q” engines), with theory, components, common faults, required tools, safety, and step-by-step procedures. Always cross-check vehicle‑specific values and procedures in the official service manual.
Safety first
- Work on a cool engine in a well‑ventilated, flat area. Use rated jack stands, wheel chocks, and a transmission jack or engine support. Disconnect the negative battery terminal before electrical/hydraulic work. Wear eye protection and gloves. If you are unsure at any step, stop and consult a professional.
Why this repair is needed (theory and symptoms)
- What the clutch does: The clutch is the mechanical interface that connects (and disconnects) engine torque to the gearbox. Think of it as a controlled handshake between engine and transmission. An “automatic” or automated clutch system still uses a conventional clutch disc/pressure plate assembly, but engagement/disengagement is handled by hydraulic and/or electro‑hydraulic actuators plus an electronic control module instead of only by a driver pressing a pedal.
- Why it fails: Wear (friction disc thinning), heat damage, contamination (oil on the friction surface), failing hydraulic seals/concentric slave, failed actuator motor/solenoid/sensors, dual‑mass flywheel failure, warped flywheel, release bearing failure, or electrical faults can cause slip, chatter, inability to engage/shift, clutch drag, or slow/failed engagement.
- Symptoms that point to clutch/actuator problems:
- Engine revs rise but vehicle acceleration is poor (slipping).
- Clutch engagement is jerky (judder) or harsh.
- Transmission cannot be engaged/gets stuck between gears.
- Strange noises when releasing or engaging (growl, rattles).
- Leaking hydraulic fluid under bellhousing or around concentric slave.
- Diagnostic trouble codes (DTCs) from the transmission/clutch ECU.
- Pedal/actuator does not move or moves slowly (on semi‑automatic systems).
Key components — what they are and what they do
- Flywheel (single‑mass or dual‑mass/DMF): Bolts to the crank; provides a friction surface and smooths engine vibrations. DMFs have internal springs/damping. A worn/failed DMF causes vibration, noise, and clutch life reduction.
- Clutch friction disc (driven disc): Spline in the center fits the transmission input shaft; friction material on both sides engages the flywheel/pressure plate. Wears by friction; contamination ruins it.
- Pressure plate (cover assembly): Bolts to the flywheel; spring(s) press the disc against the flywheel. Diaphragm spring type is common. Pressure plate clamps the disc; when released the clamp is removed.
- Release mechanism:
- Conventional systems: release/throw‑out bearing + release fork or hydraulic concentric slave.
- Concentric slave (CSC): hydraulic cylinder around the input shaft inside the bellhousing; actuates the pressure plate collar directly. Common on modern F9Q installs.
- Release (throw‑out) bearing: Slides on the input shaft and presses the pressure plate fingers.
- Actuator (automatic system): Motor, solenoid, and/or hydraulic valve and position sensors that operate the clutch instead of (or in addition to) a pedal. It is controlled by an ECU and reads vehicle speed, engine torque, RPM, gear selection, etc.
- Hydraulic lines and master cylinder (if present): Provide hydraulic pressure to the concentric slave; leaks here cause loss of actuation.
- Transmission input shaft: Splined shaft that carries torque into the gearbox; clutch disc inner splines must be lubricated and free to slide.
- Sensors and ECU: Clutch position sensors, pedal position switch (on some systems), temperature sensors, and a transmission/clutch control module that commands the actuator and reads DTCs.
- Bellhousing: The casing that connects engine to gearbox and houses the clutch components.
- Bolts/fasteners, dowel pins, seals, gaskets: Correct hardware and sealing are essential.
Tools and supplies (minimum)
- Full metric socket/ratchet set and extensions, torque wrench (range covering small bolts to flywheel bolts).
- Transmission jack and engine support or hoist if needed.
- Jack stands and wheel chocks.
- Clutch alignment tool (appropriate spline size).
- Screwdrivers, pry bars (plastic prying tools preferred), snap ring pliers.
- Brake cleaner, lint‑free rags, wire brush.
- New clutch kit: pressure plate, friction disc, release bearing (or concentric slave), pilot bearing if present, new bolts for pressure plate/flywheel if specified.
- Replacement DMF or resurfacing service if required.
- Hydraulic fluid (DOT or mineral oil as specified), bleed kit or vacuum pump.
- Diagnostic tool that can read transmission/clutch codes and perform relearn/calibration (highly recommended).
- Anti‑seize/Loctite as specified by manual, splines grease (high‑temp moly grease), new crush washer for hydraulic lines if applicable.
- Service manual for exact torque specs and special instructions.
Diagnosis — don’t replace parts blind
- Read DTCs with a capable OBD II/diagnostic tool that supports the transmission/clutch module. Note stored freeze frames/symptoms.
- Visual inspection: Look for hydraulic leaks at the bellhousing, damaged wiring to actuator, burnt smell, oil on bellhousing, or damaged clutch pedal assembly.
- Mechanical tests:
- Check clutch pedal/actuator movement and whether the actuator responds when commanded by the diagnostic tool.
- With the engine off and vehicle raised, attempt to rotate the transmission input shaft by hand while engaging/disengaging the clutch via actuator command or manual lever — see if engagement/disengagement changes.
- Measure wear: Remove gearbox and visually measure friction disc thickness relative to new spec; inspect friction surface for glazing, heat spots, contamination.
- If the actuator motor is electrically dead: verify supply and ground with a multimeter and check for DTCs.
- If hydraulic failure suspected: check pressure or see if the concentric slave is seizing or leaking.
General disassembly/repair workflow (step-by-step)
Note: This is a general step flow for an automated clutch replacement that requires gearbox separation. Specifics (torque, bolt sequences, removal of ancillaries) vary by vehicle — consult the Renault/Mitsubishi service manual for exact steps and values.
1) Preparation
- Gather parts and tools. Have new clutch kit and any replacement hydraulic/concentric slave components ready.
- Park on flat surface, chock rear wheels, disconnect negative battery.
- Drain gearbox fluid if recommended by manual to avoid spillage on clutch parts.
- Remove engine covers, airbox, intake plumbing obstructing transmission removal.
2) Support engine and transmission
- Support the engine from above if necessary (engine support bar or hoist).
- Place a transmission jack under the gearbox; support securely.
- Remove driveshaft/axles as required (CV joints, halfshafts). Label and mark as needed.
3) Disconnect electrical/hydraulic
- Unplug electrical connectors to actuator and sensors; label wires.
- Disconnect hydraulic lines to concentric slave (have catch pan for fluid). Cap lines to prevent contamination.
- Remove shift linkage and any brackets attached to the gearbox.
4) Unbolt and separate transmission from engine
- Remove gearbox-to-engine bolts in a specified pattern; keep track of bolt lengths and positions.
- Once all bolts removed, slide transmission back off the engine dowels. Lower slowly with transmission jack — ensure nothing is still connected.
- When bellhousing is open you will see the clutch assembly and flywheel.
5) Inspect and remove clutch assembly
- Note orientation of the clutch and any dowel pins. If the flywheel has marks, preserve orientation.
- If replacing the clutch, remove pressure plate bolts in a star pattern gradually to relieve diaphragm spring evenly.
- Withdraw friction disc and pressure plate. Inspect for oil contamination or abnormal wear.
- Inspect flywheel: if DMF, check for excessive play in the DMF (axial or rotational play). Look for scoring, heat spots, cracked rivets. If single mass, check for warpage; if resurfacing, send to machine shop or replace. DMFs are usually replaced, not resurfaced.
- Inspect splines on input shaft for wear; clean but do not file.
6) Replace concentric slave or release bearing
- If using a concentric slave, remove and install the new unit. Replace hydraulic seals/hoses where required. It’s common to replace the concentric slave with the clutch.
- If using a separate release bearing, replace bearing and check fork/sliding surfaces.
7) Fit new clutch components
- Clean flywheel mating surface with brake cleaner and a lint‑free cloth.
- If flywheel replaced or resurfaced, follow alignment and bolt torque instructions from the manual.
- Use the clutch alignment tool to position the friction disc centered on the flywheel.
- Fit the pressure plate over the disc and hand‑tighten bolts. Tighten bolts in a star pattern to the specified torque (consult manual). DO NOT re-use single‑use bolts unless manual allows.
- Apply high‑temp spline grease sparingly on the disc splines (do not get grease on friction surfaces).
8) Reinstall transmission
- Ensure dowel pins and mating faces are clean.
- Raise the gearbox and carefully align input shaft with disc splines using the alignment tool; slide forward until bellhousing mates evenly.
- Tighten gearbox‑to‑engine bolts to specified torque and sequence.
- Reconnect hydraulic lines (new crush washers if required), electrical connectors, shift linkage, and driveshafts.
9) Refill fluids and bleed hydraulic system
- Refill gearbox fluid to recommended level and type.
- Bleed the clutch hydraulic circuit thoroughly. Use the recommended fluid type. Many concentric slaves must be bled with the hydraulic actuator in a specific position — follow vehicle procedure.
- When bleeding, ensure no air remains (air causes soft or non‑functional actuation).
- Check for leaks.
10) Electrical/ECU calibration and relearn
- Many automated clutches require a relearn/calibration using a diagnostic tool after replacement to set actuator zero position and to clear adaptation values.
- Perform any actuator calibration, clutch adaptation, or automatic bite point learning as per the diagnostic tool instructions or workshop manual.
- Clear fault codes and re-scan.
11) Test and break‑in
- Start engine and allow to warm. With vehicle on stands, test engagement/disengagement via gear selection and actuator commands.
- Carefully road test: avoid heavy loads/lugging for the first 200–500 km to allow friction material bedding in. Follow break‑in procedure from clutch manufacturer.
What can go wrong and how to avoid it
- Incorrect torques or loose bolts: result in clutch vibration, bolt breakage, or flywheel movement. Always use specified torque values and sequences.
- Contaminating friction surfaces with grease/oil: causes slipping and premature wear. Never touch friction material with greasy hands; avoid using brake cleaner directly on friction surfaces.
- Reusing worn flywheel: causes hot spots and clutch chatter; replace or resurface if out of spec.
- Air in hydraulic circuit: causes engagement failure. Proper bleeding and checking for leaks is vital.
- Wrong alignment: misalignment causes grinding when installing gearbox and bearing wear. Use alignment tool.
- Using wrong parts: some cars use specific DMF/clutch kits and special concentric slaves — match part numbers.
- Damaged splines: if input shaft splines are damaged the disc will not slide properly — replace or repair.
- Electrical faults: loose connectors, damaged wiring to actuator or sensor give intermittent faults. Inspect wiring harnesses carefully.
- Not performing ECU relearn: can make actuator zero point wrong; clutch will engage at incorrect point or have erratic behavior.
Analogy wrap‑up
- Think of the clutch as a coupling handshake and the actuator as a robotic hand that closes and opens the handshake. The friction disc is the palm that wears down; the flywheel is the firm hand on the engine side; the pressure plate is the robotic fingers that clamp. If the palm gets thin, oily, or the robotic fingers lose calibration or strength, the handshake slips or is jerky. Replacing both the worn parts and ensuring the robotic hand is calibrated gives a smooth reconnection.
Final notes and cautions
- Exact bolt torques, tightening sequences, hydraulic fluid type (some Renault systems use specific oils), and ECU relearn steps are vehicle‑ and year‑specific. Use the factory workshop manual or an OEM diagnostic tool for those values and procedures.
- If the vehicle has a DMF, consider replacing it with the new clutch unless you are certain it’s within spec — DMF failures commonly ruin new clutches quickly.
- If you lack a diagnostic tool capable of clutch actuator relearn, a professional shop should perform the final calibration.
- If you are a beginner, consider having an experienced mechanic supervise your first clutch removal and installation.
This guide covers the full theory, components, common faults, diagnostic checkpoints, tools, and a safe stepwise repair flow for an automated clutch on F9Q1/F9Q2 applications. Follow the vehicle’s service manual for exact specifications and safety steps. rteeqp73