1.5L REVOTORQ ENGINE 7. ENGINE ON VEHICLE SERVICE PROCEDURE ...................................................................... 90 A FUSE BOX SHIFTING PROCEDURE .........................................................................................90 B ENGINE REMOVAL .................................................................................................................. 91 C ENGINE INSTALLATION ...........................................................................................................97 D EXHAUST SYSTEM .................................................................................................................. 98 E COOLING SYSTEM ................................................................................................................ 101 F FUEL SYSTEM ....................................................................................................................... 106 G TURBOCHARGER REMOVAL AND REFITMENT..................................................................... 113 H TIMING BELT REMOVAL AND REFITMENT ............................................................................ 115 I STARTER MOTOR REMOVAL AND REFITMENT .................................................................... 117 J ALTERNATOR MOTOR REMOVAL AND REFITMENT ............................................................. 118 K COMPRESSOR MOTOR REMOVAL AND REFITMENT............................................................ 119 L HIGH PRESSURE PUMP REMOVAL AND REFITMENT ........................................................... 120 M EGR VALVE REMOVAL AND REFITMENT .............................................................................. 122 8. ENGINE OVEHAULING (ON OVERHAUL STAND) ............................................................... 123 A ENGINE DIS-ASSEMBLY ....................................................................................................... 123 i ON OVERHAUL STAND ..................................................................................................... 123 ii REMOVAL OF EGR VALVE & OIL COOLER........................................................................ 127 iii REMOVAL OF INTAKE MANIFOLD ..................................................................................... 128 iv REMOVAL OF EXHAUST MANIFOLD ................................................................................. 130 v REMOVAL OF EVRV AND THERMOSTAT .......................................................................... 131 vi REMOVAL OF OIL SUMP ................................................................................................... 132 vii REMOVAL OF TIMING BELT .............................................................................................. 133 viii REMOVAL OF CYLINDER HEAD ........................................................................................ 138 ix REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES .......................................................... 139 x REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES ........................................................ 142 xi PISTON CONNECTING ROD DIS-ASSEMBLY .................................................................... 144 B ENGINE ASSEMBLY.............................................................................................................. 150
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