ZEST BOLT Service Manual

ENGINE 1.3 QUADRAJET (75PS) 1 CONTENTS SR. NO. DESCRIPTION PAGE NO. 3A.1.1. GENERAL INFORMATION 3A.1.1.1 TECHNICALSPECIFICATIONS 4 3A.1.1.2 TIGHTENINGTORQUES 5 3A.1.1.3 SPECIAL TOOLS 7 3A.1.1.4 MAINTENANCE, INSPECTIONAND TESTS 12 A. ENGINE OIL REPLACEMENT 12 B. ENGINE OIL FILTER CARTRIDGE REPLACEMENT. 13 C. AIR FILTER INSPECTIONAND CLEANING 14 D. AIR FILTER ASSEMBLY - REMOVAL 15 E. FUEL FILTER REPLACE 15 3A.1.2 ENGINE – MECHANICAL 17 3A.1.2.1 REMOVALOF ENGINE FROM VEHICLE 17 3A.1.2.2 CYLINDER HEADASSEMBLY 21 3A.1.2.2.1 EXPLODED VIEW 21 3A.1.2.2.2 REMOVAL OF CYLINDER HEADASSEMBLYAND OIL SUMP 21 3A.1.2.2.3 CYLINDER HEAD – OVERHAUL 29 3A.1.2.2.4 VALVE AND VALVE SPRING 32 A. EXPLODED VIEW 32 B. REMOVALAND OVERHAUL 33 C. INSTALLATION 35 3A.1.2.2.5 CYLINDER HEAD BLOCK 36 A. HEAD GASKET CORRECTION BASED ON CYLINDER HEAD BLOCK PLANARITY. 36 B. CAMSHAFTHOUSING INSPECTIONANDMEASUREMENT. 37 C. CYLIDER HEAD BLOCKASSEMBLY – REFITTING. 37 3A.1.2.2.6 SELECTION OF CYLINDER HEAD GASKET 39 3A.1.2.2.7 INSTALLATION OF CYLINDER HEADASSEMBLYAND OIL SUM P 40 3A.1.2.3 ENGINE BLOCK 45 3A.1.2.3.1 DISMANTLING 45 3A.1.2.3.2 PISTON - REMOVALAND FITMENT. 48 3A.1.2.3.3 ENGINE OIL PUMP - REMOVALAND FITMENT. 49 3A.1.2.3.4 ENGINE BLOCK – MEASUREMENT, INSPECTIONAND GRADEDETERMINATION 51 3A.1.2.3.5 ENGINE BLOCK –ASSEMBLING 57