ZEST/BOLT

ENGINE 1.3L QUADRAJET (90PS)

15.Check that the diameter of the main journal seats

is within specified limits (without fitting the half-

bearings).

3A.1.2.3.4 ENGINE BLOCK -

MEASUREMENT, INSPECTION & GRADE

DETERMINATION

1. Clean sealant residues off the mating surfaces

between: cylinder head extension/lower cylinder

head, upper crankcase/lower crankcase and lower

crankcase/crankcase sump.

2. Clean the parts removed thoroughly and check their

condition visually.

3. Fit the water/oil sealing plugs in the crankcase

using suitable fitting tools.

4. Lubricate all the mechanical components with

engine oil.

5. Measure the cylinder bore diameter using the

diagram illustrated.

6. Check for the values to be within the recommended

values for the respective grades as shown below.

1 Cylinder liner diameter -

69.600 ~ 69.610

GradeA (mm)

1 Cylinder liner diameter -

69.610 ~ 69.620

Grade B (mm)

1 Cylinder liner diameter -

69.620 ~ 69.630

Grade C (mm)

7. Check that the taper of the cylinder liners/bores is

within the recommended limits of lesser than

0.010mm

Cylinder liner taper (mm)

< 0.010

8. Check that the ovality of the cylinder liners is within

the recommended limits.

Cylinder liner ovality (mm)

+/- 0.005

9. If the cylinder bore measurements are not within

the recommended limits, ream the cylinder bores

following the recommended oversize of 0.1mm.

Cylinder liner diameter oversize (mm)

0.1

NOTE :

If reaming is undertaken, ensure that all the bores

have the same oversize.

10 Use an appropriate support tool to replace the upper

crankcase on the overhaul stand.

11 Refit the lower crankcase locating bushes in their

seats.

12 Provisionally fit the lower engine block on the upper

engine block to measure the main journal seats

and then remove it.

13.Loosen the central M10 bolts (1a) securing the

lower crankcase to a torque of 1.9 ~ 2.1Kg-m +/-

, following the order shown in the figure. Use the

angular tightening tool (1b).

14.Tighten the lower crankcase side M8 bolts to a

torque of 2.9 ~ 3.2 Kg-m, following the order shown

in the figure.