ZEST BOLT Service Manual

Revotron 1.2T 114 iii. Fitment of Cylinder Block Sub-Assemblies Cylinder Block 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 surfaces just to clear unevenness. Measure across the length and breadth to specific mention value in table. Dimension (mm) Height of cylinder block (A & B) 265.8/265.6 Maximum permissible unevenness of cylinder block case mating surface with cylinder head 150 X 150 Cross wise (D) Length wise (C) 0.015 0.030 Maximum permissible out of parallelism between crank case top and bottom machined surface. 0.2 Maximum permissible shift in perpendicularity of cylinder bore from crank shaft axis when checked from crank shaft center line 0.25 Maximum permissible taper and sphericity of cylinder bore 0.007 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. Install thrust washers in crankcase at their respective locations on 4 th main bearing. 6. Place lower bearing shells and ensure the locking slot on bearing shells are properly fitted.