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
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