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1.5L REVOTORQ ENGINE
CONTENTS
1. GENERAL INFORMATION ...................................................................................................... 1
A ENGINE INTRODUCTION.................................................................................................................... 1
B TECHNICAL SPECIFICATION ............................................................................................................. 2
C SPECIAL TOOLS.................................................................................................................................. 3
D ASSEMBLY CLEARANCES ................................................................................................................. 7
E LEAKAGE RATES ................................................................................................................................ 7
2. TROUBLESHOOTING.............................................................................................................. 8
3. CONSTRUCTIONAL AND SERVICE DETAILS ..................................................................... 12
A ENGINE LIFTING HOOK.................................................................................................................... 12
B INTAKE MANIFOLD AND FUEL INJECTION SYSTEM..................................................................... 13
C LUBRICATION SYSTEM .................................................................................................................... 15
D AIR FILTER, SNORKEL, BLOW BY PIPE.......................................................................................... 18
E STARTER MOTOR, COMPRESSOR AND ALTERNATOR............................................................... 20
F TIMING BELT, AUTO TENSIONER, WATER PUMP......................................................................... 22
G EXHAUST MANIFOLD, CATCON, TURBOCHARGER ..................................................................... 24
H CYLINDER HEAD AND COMPONENTS ........................................................................................... 27
I PISTON, CRANKSHAFT AND COMPONENTS................................................................................. 30
J ENGINE SUSPENSION...................................................................................................................... 32
K EGR VALVE, THERMOSTAT AND COMPONENTS ......................................................................... 34
L CRANKCASE AND COMPONENTS .................................................................................................. 37
4. ENGINE TESTS AND MAINTENANCE .................................................................................. 39
A PRELIMINARY INSPECTION............................................................................................................. 39
B ENGINE TESTS.................................................................................................................................. 39
C REGULAR MAINTENANCE ............................................................................................................... 44
i ENGINE OIL AND FILTER CHANGE ............................................................................................ 44
ii ENGINE COOLANT REPLACEMENT........................................................................................... 45
iii AIR FILTER ELEMENT REPLACEMENT...................................................................................... 49