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1.5L REVOTORQ ENGINE
CONTENTS
1.1. GENERAL INFORMATION ................................................................................................... 1
A ENGINE INTRODUCTION.................................................................................................................... 1
B TECHNICAL SPECIFICATION ............................................................................................................. 2
C SPECIAL TOOLS.................................................................................................................................. 3
D ASSEMBLY CLEARANCES ................................................................................................................. 7
E LEAKAGE RATES ................................................................................................................................ 8
F RECOMMENDED LUBRICANTS AND COOLANTS............................................................................ 8
G SERVICE SCHEDULE.......................................................................................................................... 9
1.2. TROUBLESHOOTING ........................................................................................................ 10
1.3. CONSTRUCTIONAL AND SERVICE DETAILS.................................................................. 14
A ENGINE LIFTING HOOK.................................................................................................................... 14
B INTAKE MANIFOLD AND FUEL INJECTION SYSTEM..................................................................... 16
C LUBRICATION SYSTEM .................................................................................................................... 19
D AIR FILTER, SNORKEL, BLOW BY PIPE.......................................................................................... 22
E STARTER MOTOR, COMPRESSOR AND ALTERNATOR............................................................... 25
F TIMING BELT, AUTO TENSIONER, WATER PUMP......................................................................... 28
G EXHAUST MANIFOLD, CATCON, TURBOCHARGER ..................................................................... 31
H CYLINDER HEAD AND COMPONENTS ........................................................................................... 33
I PISTON, CRANKSHAFT AND COMPONENTS................................................................................. 36
J ENGINE SUSPENSION...................................................................................................................... 38
K EGR VALVE, THERMOSTAT AND COMPONENTS ......................................................................... 41
L CRANKCASE AND COMPONENTS .................................................................................................. 45
1.4. ENGINE TESTS AND MAINTENANCE............................................................................... 47
A PRELIMINARY INSPECTION............................................................................................................. 47
B ENGINE TESTS.................................................................................................................................. 47
C REGULAR MAINTENANCE ............................................................................................................... 52
i ENGINE OIL AND FILTER CHANGE ............................................................................................ 52
ii ENGINE COOLANT REPLACEMENT........................................................................................... 53