ZICA

3 CYL DIESEL ENGINE

3.7. ENGINE ON VEHICLE SERVICE PROCEDURE ................................................................ 89

A ENGINE REMOVAL....................................................................................................................... 89

B ENGINE INSTALLATION............................................................................................................... 93

C EXHAUST SYSTEM ...................................................................................................................... 94

D COOLING SYSTEM....................................................................................................................... 96

E FUEL SYSTEM.............................................................................................................................. 98

3.8. ENGINE OVEHAULING (ON OVERHAUL STAND) ......................................................... 105

A ENGINE DIS-ASSEMBLY

................................................................................................... 105

i ON OVERHAUL STAND ......................................................................................................... 105

ii REMOVAL OF INTAKE MANIFOLD........................................................................................ 108

iii REMOVAL OF EXHAUST MANIFOLD .................................................................................... 110

iv REMOVAL OF OIL SUMP....................................................................................................... 114

v REMOVAL OF TIMING BELT.................................................................................................. 115

vi REMOVAL OF CYLINDER HEAD ........................................................................................... 118

vii REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES ............................................................ 119

viii REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES.......................................................... 121

ix PISTON CONNECTING ROD DIS-ASSEMBLY....................................................................... 123

B ENGINE ASSEMBLY

......................................................................................................... 129

i FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES.............................................................. 129

ii FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES.................................... 130

iii FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES............................................................ 131

iv FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK........................................................ 132

v FITMENT OFTIMING BELT..................................................................................................... 133

vi FITMENT OF OIL SUMP......................................................................................................... 136

vii FITMENT OF EXHAUST MANIFOLD AND PERIPHERALS..................................................... 138

viii FITMENT OF INTAKE MANIFOLD AND PERIPHERALS ........................................................ 142

ix ON ENGINE SUPPORT STAND ............................................................................................. 144