Nexon Service Manual

1.5L REVOTORQ ENGINE

1.7. ENGINE ON VEHICLE SERVICE PROCEDURE ................................................................ 96

A ENGINE REMOVAL............................................................................................................................ 96

B ENGINE INSTALLATION.................................................................................................................. 104

C EXHAUST SYSTEM ......................................................................................................................... 105

D COOLING SYSTEM.......................................................................................................................... 109

E FUEL SYSTEM ................................................................................................................................. 115

F TURBOCHARGER REMOVAL AND REFITMENT .......................................................................... 124

G TIMING BELT REMOVAL AND REFITMENT .................................................................................. 126

H STARTER MOTOR REMOVAL AND REFITMENT.......................................................................... 128

I ALTERNATOR MOTOR REMOVAL AND REFITMENT .................................................................. 130

J COMPRESSOR MOTOR REMOVAL AND REFITMENT................................................................. 131

K HIGH PRESSURE PUMP REMOVAL AND REFITMENT................................................................ 132

1.8. ENGINE OVEHAULING (ON OVERHAUL STAND) ......................................................... 135

A ENGINE DIS-ASSEMBLY

................................................................................................... 135

i ON OVERHAUL STAND.............................................................................................................. 135

ii REMOVAL OF INTAKE MANIFOLD............................................................................................ 139

iii REMOVAL OF EGR VALVE & OIL COOLER.............................................................................. 141

iv REMOVAL OF EXHAUST MANIFOLD........................................................................................ 142

v REMOVAL OF EVRV AND THERMOSTAT ................................................................................ 143

vi REMOVAL OF OIL SUMP ........................................................................................................... 145

vii REMOVAL OF TIMING BELT ...................................................................................................... 146

viii REMOVAL OF CYLINDER HEAD ............................................................................................... 151

ix REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES............................................................... 152

x REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES ............................................................ 155

xi PISTON CONNECTING ROD DIS-ASSEMBLY.......................................................................... 158