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 A ND COMPONENTS...........................................................................30 J ENGINE SUSPENSION .............................................................................................................32 K EGR VALVE, THERMOSTA T 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 FILTE R CHANGE .....................................................................................44 ii ENGINE COOLANT REPLACEMENT ....................................................................................45 iii WIRING HARNESS CLIP REMOVAL .....................................................................................48
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