TABLE OF CONTENTS 1. GENERAL INFORMATION ........................................................................................................................1 A. ENGINE INTRODUCTION...................................................................................................................1 B. ELECTRONIC CONTROL UNIT...........................................................................................................2 C. TECHNICAL SPECIFICATION.............................................................................................................3 D. SPECIAL TOOLS..................................................................................................................................4 E. ASSEMBLY CLEARANCES.................................................................................................................7 F. SEALANTS ...........................................................................................................................................7 G. LEAKAGE RATES................................................................................................................................7 2. TROUBLE SHOOTING...............................................................................................................................8 3. CONSTRUCTIONAL AND SERVICE DETAILS.......................................................................................16 A. ENGINE LIFTING HOOKS.................................................................................................................16 B. INTAKE MANIFOLD...........................................................................................................................17 C. CYLINDER HEAD COVER.................................................................................................................19 D. CYLINDER HEAD-A...........................................................................................................................21 E. CYLINDER HEAD-B...........................................................................................................................23 F. CYLINDER BLOCK............................................................................................................................25 G. LUBRICATION PUMP AND COMPONENTS.....................................................................................27 H. PISTON, CRANKSHAFT AND COMPONENTS.................................................................................30 ENGINE TIMING................................................................................................................................32 I. J. TURBOCHARGER, CATCON AND COMPONENTS.........................................................................34 K. FUEL INJECTION EQUIPMENT........................................................................................................37 L. AIR FILTER, SNORKEL AND BLOW-BY PIPE ..................................................................................39 M. WATER PUMP, THERMOSTAT AND COMPONENTS.......................................................................42 N. STARTER MOTOR AND ALTERNATOR............................................................................................44 O. COMPRESSOR, AUTO-TENSIONER AND BELT..............................................................................45 P. ENGINE SUSPENSION.....................................................................................................................46 Q. INTERCOOLER AND HOSES............................................................................................................49 4. ENGINE TESTS AND MAINTENANCE ...................................................................................................52 A. PRELIMINARY INSPECTION............................................................................................................52 B. ENGINE TESTS.................................................................................................................................53 C. REGULAR MAINTENANCE...............................................................................................................56 ENGINE OIL AND FILTER CHANGE...........................................................................................56 I. ENGINE COOLANT REPLACEMENT.........................................................................................58 II. Petrol Engine Ph-2 (CAFÉ)
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