ZEST BOLT Service Manual

Revotron 1.2T 90 29. Take out the engine and transaxle assembly along with support stand. 30. Remove the starter motor, alternator along with its mounting brackets. 31. Remove the engine wiring harness. 32. Remove the transaxle from the engine. 33. Fix the LH & RH mounting brackets to the engine. SPECIAL TOOL • LH Mounting Bracket -: 2702 5890 24 02 • RH Mounting Bracket -: 2702 5890 24 03 34. Safely lift the engine with the help of crane and fix it on overhaul stand. B. Engine Installation : 1. Engine installation is generally reverse of removal. Make certain all hardware is tightened to appropriate torque specification. 2. Prior to installing the engine, inspect the condition of the rubber on the engine mounts. Replace the engine mounts if the rubber is damaged. 3. Install the starter motor, AC Compressor, alternator along with its mounting brackets. 4. Mount the transaxle back onto the engine. Tighten the bolts with specified torque. 5. With the vehicle raised on the vehicle lift hoist, place the engine underneath the vehicle, aligned with the engine compartment. CAUTION • Use care when lowering the vehicle body to the engine and transaxle assembly. Verify all the engine and other components will not make direct contact or vehicle damage will occur. 6. Slowly and carefully lower the vehicle body over the engine. 7. Connect the lifting crane to the engine with a chain / belt. Raise the hoist slightly to apply lifting tension to the engine. 8. With the engine attached to the crane, remove the support stand. 9. Secure the engine in the vehicle by attaching the "C", "A" and "B" mounting brackets. Tighten the mounting bracket hardware at specified torque. 10. Remove the chain / belt after engine mounts are secure. 11. Install the left and right driveshaft assemblies. 12. Connect the gearshift linkage, clutch cable to the engine and transaxle. 13. Connect the engine wiring harness. 14. Connect the cooling system reservoir hoses. Verify the cooling system drain is closed on the radiator. Install the cooling system hoses to the engine, radiator and heater core. 15. To connect the exhaust front pipe tighten the flange near Catcon and connect at rear end. 16. Install the air filter assembly and intake system hoses to the engine. 17. Connect the vacuum hose connected between brake booster to vacuum pump.