ZEST/BOLT

ENGINE 1.3 QUADRAJET (75PS)

28.Refit the lower crankcase (1) with lower main

bearing halves in its seat.

29.Tighten the M10 central bolt s (2a) securing the

lower crankcase to the specified torque of 1.9 ~

2.1Kg-m + 80

+/- 3

, following the order shown in

the figure. Use the angular tightening tool (2b).

30 Tighten the lower M8 crankcase side bolt s to a

specified torque of 2.9 ~ 3.2Kg-m, following the

order shown in the figure.

31.Remove the lower crankcase with main bearing

halves fitted previously and, using a suit able

graduated measuring instrument (1a), measure

the clearance shown by the calibrated wire (1b).

Clearance between main bearings -

crankshaft main journals (mm)

0.028 ~ 0.048

NOTE:

If the figure measured is outside of the

tolerance, replace the half-bearings with ones of the

correct size nd category.

32.After checking all the main journals, apply a strip

of specified silicon sealant to the contact surfaces

between the lower crankcase and the upper

crankcase as shown in the figure above.

NOTE :

The sealant strip must be unbroken. The

sealant strip diameter must be 2.5 - 3.5 mm.

33.After applying the sealant clean the crankshaft

lower oil seal seat.

34.Fit the lower crankcase to the upper crankcase

permanently by tightening the bolt s as shown

previously.

35.Check that the small end bush bore (inner

diameter) diameter is within the recommended

limits of 23.006 mm ~ 23.012 mm; if not, replace

the connecting rod assemblies.

36.Check that the diameter of the gudgeon pin

housing in the piston is within the recommended

values of 22.990 mm ~ 22.996 mm.

37.If

the piston pin bore diameter is not within

specified values, replace the piston complete with

its piston pin and rings.

38.Check that the outer diameter of the piston pins is

within the recommended limit s of 22.982 mm ~

22.987 mm; if not, replace the worn piston pins.

39.Fit the piston rings in the cylinder bore and check

that the opening between the ends is within the

recommended values; if this is not the case,

replace the circlips.

Cylinder compression 1st sealing

ring gap (mm)

0.20 ~ 0.30

Cylinder compression 2nd sealing

ring gap (mm)

1.0 ~ 1.5

Piston oil scraper ring gap (mm)

0.25 ~ 0.50