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 AND COMPONENTS................................................................................. 30 J ENGINE SUSPENSION...................................................................................................................... 32 K EGR VALVE, THERMOSTAT 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 FILTER CHANGE ............................................................................................ 44 ii ENGINE COOLANT REPLACEMENT ........................................................................................... 45 iii AIR FILTER ELEMENT REPLACEMENT...................................................................................... 49
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