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1.2L REVOTRON ENGINE
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1.8 ENGINE OVERHAULING
(ON OVERHAUL STAND)
B. 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 70
0
to 80
0
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
surface 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. Fit the piston cooling nozzle to the crankcase.
Use new gasket when refitting the cooling
nozzle.
6. Match the lug of thrust washer with block.
7. Insert the thrust washers from 3
rd
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 into the crankcase.