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.................................................................................................................8 F. SEALANTS ...........................................................................................................................................8 G. LEAKAGE RATES................................................................................................................................8 2. TROUBLE SHOOTING...............................................................................................................................9 3. CONSTRUCTIONAL AND SERVICE DETAILS.......................................................................................17 A. ENGINE LIFTING HOOKS.................................................................................................................17 B. INTAKE MANIFOLD...........................................................................................................................18 C. CYLINDER HEAD COVER.................................................................................................................20 D. CYLINDER HEAD-A...........................................................................................................................22 E. CYLINDER HEAD-B...........................................................................................................................24 F. CYLINDER BLOCK............................................................................................................................26 G. LUBRICATION PUMP AND COMPONENTS.....................................................................................28 H. PISTON, CRANKSHAFT AND COMPONENTS.................................................................................31 ENGINE TIMING................................................................................................................................33 I. J. TURBOCHARGER, CATCON AND COMPONENTS.........................................................................35 K. FUEL INJECTION EQUIPMENT........................................................................................................38 L. AIR FILTER, SNORKEL AND BLOW-BY PIPE ..................................................................................40 M. WATER PUMP, THERMOSTAT AND COMPONENTS.......................................................................43 N. STARTER MOTOR AND ALTERNATOR............................................................................................45 O. COMPRESSOR, AUTO-TENSIONER AND BELT..............................................................................46 P. ENGINE SUSPENSION.....................................................................................................................47 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)_DCT
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