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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 ................................................................................................................................ 7
1.2. TROUBLESHOOTING .......................................................................................................... 8
1.3. CONSTRUCTIONAL AND SERVICE DETAILS.................................................................. 12
A ENGINE LIFTING HOOK.................................................................................................................... 12
B INTAKE MANIFOLD AND FUEL INJECTION SYSTEM..................................................................... 14
C LUBRICATION SYSTEM .................................................................................................................... 16
D AIR FILTER, SNORKEL, BLOW BY PIPE.......................................................................................... 19
E STARTER MOTOR, COMPRESSOR AND ALTERNATOR............................................................... 22
F TIMING BELT, AUTO TENSIONER, WATER PUMP......................................................................... 25
G EXHAUST MANIFOLD, CATCON, TURBOCHARGER ..................................................................... 28
H CYLINDER HEAD AND COMPONENTS ........................................................................................... 31
I PISTON, CRANKSHAFT AND COMPONENTS................................................................................. 34
J ENGINE SUSPENSION...................................................................................................................... 36
K INTERCOOLER, THERMOSTAT AND COMPONENTS.................................................................... 39
L CRANKCASE AND COMPONENTS .................................................................................................. 42
1.4. ENGINE TESTS AND MAINTENANCE............................................................................... 44
A PRELIMINARY INSPECTION............................................................................................................. 44
B ENGINE TESTS.................................................................................................................................. 44
C REGULAR MAINTENANCE ............................................................................................................... 49
i ENGINE OIL AND FILTER CHANGE ............................................................................................ 49
ii ENGINE COOLANT REPLACEMENT........................................................................................... 50
iii COOLANT FILLING (DE – AREATION PROCEDURE) ................................................................ 51