ZEST BOLT Service Manual

ENGINE 1.3 QUADRAJET (75PS) 42 19. Refit the new injector dust seals into their seats in the camshaft housing. 20. Refit the injectors (1a) complete with bracket s (1b) in their seats. NOTE Q Before refitting, replace the copper seal on the injectors. 21. Refit the tapered washer (2a) and the washer (2b) in their seats. 22. Tighten the nut (3) securing the injector bracket to a torque of 1.8 ~ 2.2 Kg-m. 23. Use a suitable tool (e.g. vice) to set the chain tensioner and hold it fully back with a ret aining pin. 24. Place the chain tensioner (1a) in ist housing and secure it tightening the bolts (1b) to a torque 0.8 ~ 1.0 Kg-m . 25. Refit the exhaust side camshaf t toothed drive pulley together with chain and toothed drive pulley. NOTE Q Before refitting, replace the copper seal on the injectors Fit the exhaust side camshaft toothed drive pulley and the toothed drive pulley according to the position marked on disassembly. If the pulleys are replaced, fit with the wording facing outwards. 26. Place the timing chain moving p ad back in it s housing and secure it using the pin. 27. Place the timing chain fixed p ad back in it s housing and secure it using the bolts. 28. Tighten the bolt fixing the exhaust side camshaft toothed pulley to a torque. 13.5 ~ 16.5 Kg-m. 29. Remove the chain tensioner ret aining pin and check that the piston is in conat ct with the mobile pad. 30. Refit the support bracket complete with single fuel manifold pipe, fuel pressure regulator, fuel pressure sensor and secure using the bolts. 31. Connect the fuel return pipe to the single fuel manifold and tighten the band. 32. Fit new pipes from the fuel manifold to the injectors and secure with connectors without tightening. 33. Tighten the connectors for the pipes from the fuel manifold to the injector side injectors to a torque of 2.3 ~ 2.5 Kg-m using an appropriate commercial wrench. 34. Tighten the connectors for the pipes from the fuel manifold to the fuel manifold side injectors to a torque of 2.6 ~ 2.9 Kg-m using an appropriate commercial wrench. NOTE Q Clean the threaded pipe seats on the manifold and injectors with heptane. 35. Place a new pipe from the pressure pump to the single fuel manifold in its housing and secure it using the connectors without tightening them. 36. Tighten the M12 connector for the pipe from the pressure pump to the single fuel manifold, pump side, to a torque of 2.3 ~ 2.5 Kg-m using a spanner. 37. Tighten the M14 connector for the pipe from the pressure pump to the single fuel manifold, fuel manifold side, to a torque of 2.6 ~ 2.9 Kg-m using a spanner. 38. Connect the fuel outlet pipe from the injectors, injector side and push in until the clips click into place.