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1.2L REVOTRON ENGINE
123
2.8 ENGINE OVERHAULING:
(ON OVERHAUL STAND)
A. Engine Assembly :
I. Assembly of Cylinder Block Sub-
Assemblies
1. Check cylinder block for cracks by pressure
testing method. Clean cylinder bores, bearing
surfaces, oil passages in crank case
thoroughly. Check water jackets for leakages
by blowing air at a pressure of 5 bar & then
dipping the cylinder block in the hot water.
(Temp of water 700 to 800 C)
NOTE
 The block with any leakages / cracks
should be discarded.
2. Check crankcase mating surfaces with
cylinder head for unevenness with the help of
straight edge and feeler gauge. If necessary
grind this surfaces just to clear unevenness.
Measure across the length and breadth to
specific mention value in table.
3. Ensure main bearing parent bore dimensions
are within specified limits. (For specified limit
and procedure refer cylinder block inspection
chapter.)
4. Ensure that the minimum height of crank case
is not less than the specified minimum height.
NOTE
 Apply light coat of grease to the fourth
main bearing cap.
 Ensure the slot on thrust washers are
facing on outer side.
5. Tighten the hex socket counter sunk screw to
join the crank sensor target wheel to
crankshaft.
NOTE
 Ensure the dowel pin.
 While replacing target wheel or ECU we
have to do flywheel learning (for procedure
refer page no 147 of petrol Engine.)
6. Match the lug of thrust washer with block.
7. Insert the thrust washers from 3rd bearing
from cylinder block and place the upper
bearing shell. (Apply the coat of engine oil.)
NOTE
 Apply light coat of engine oil to all main
bearing shells and crankshaft journals.
 Ensure crankshaft holes are properly
cleaned and free from any blockages.
8. Place the crankshaft.
9. Spread the liquid red sealant on crankcase
without spilling the sealant in oil paths / inside
the block.